Adjustable Woven Sleeve for Bulk Containers
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Solution Overview
Problem
The existing bulk material containers face challenges in ensuring a snug fit between the outer tubular sleeve and the forming member due to manufacturing tolerance mismatches, leading to potential rupture of the forming member under applied forces, which requires labor-intensive sorting and matching processes, making automation difficult.
Innovation Solution
A method of manufacturing the outer sleeve with a continuously woven tubular configuration and adjustable circumference, using bonding strips to adjust the inner circumference to match the forming member's nominal dimensions, ensuring a precise fit and eliminating the need for pre-sorting and manual matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer sleeve is manufactured to its maximum inside circumferential tolerance and the forming member to its minimum outer circumferential tolerance, then the manufacturing cost is reduced, but the sleeve does not snugly engage the forming member, leading to potential rupture
Solution Approach 1:
The sleeve is designed with dynamic adjustability through circumference adjustment tails that can be modified during assembly. This allows the sleeve to adapt its inner circumference to match the actual outer circumference of the forming member, ensuring a reliable snug fit while maintaining manufacturing efficiency.
Solution Approach 2:
The sleeve's circumferential dimension is made variable through the adjustment tails. By changing the parameter of the sleeve's inner circumference to match the forming member's actual dimension, the system achieves both manufacturing precision and reliable engagement without requiring tight tolerances on both components.
2Ease of manufacture
If random matching of forming members with sleeves is used during assembly, then the assembly process is simplified, but the tolerance mismatch causes forming member rupture under applied forces
Solution Approach 1:
The sleeve is pre-equipped with circumference adjustment tails during manufacturing. This preliminary preparation allows the sleeve to be adjusted during assembly to match the forming member's actual dimensions, ensuring reliable engagement while maintaining simple random matching procedures.
Solution Approach 2:
The adjustment tails enable the sleeve to self-adjust to the forming member's actual circumference during assembly. This self-service mechanism eliminates the need for complex sorting and matching processes while ensuring the forming member remains reliably engaged and does not rupture under applied forces.
3Reliability
If labor-intensive sorting and matching of sleeves with forming members is performed, then the snug fit is ensured, but the assembly cost and time increase significantly
Solution Approach 1:
The sleeve incorporates dynamic adjustment capabilities through circumference adjustment tails that can be modified during assembly. This allows the system to achieve reliable snug fits without requiring labor-intensive sorting and matching, as the sleeve can adapt to the forming member's actual dimensions during the assembly process.
Solution Approach 2:
The sleeve's inner circumference parameter is made adjustable through the adjustment tails. By allowing this parameter to be changed during assembly to match the forming member's actual dimension, the system achieves reliable engagement while maintaining high productivity and low assembly costs through simple random matching.
4Weight of moving object
If the forming member is made from lightweight corrugated material, then the container cost is reduced, but the forming member requires precise engagement with the sleeve to prevent rupture
Solution Approach 1:
The sleeve is designed with dynamic adjustment through circumference adjustment tails, allowing it to adapt to the actual dimensions of the lightweight corrugated forming member. This ensures precise engagement and prevents rupture while maintaining the forming member's lightweight construction and cost-effectiveness.
Solution Approach 2:
The sleeve's inner circumference parameter is made variable through adjustment tails, enabling it to match the actual dimensions of the lightweight forming member. This allows the system to use cost-effective lightweight materials while achieving the precise engagement needed to prevent rupture under applied forces.
Data Source
AI summary
A collapsible bulk material container with a unique outer support sleeve and method of manufacture thereof are disclosed. The initial inner circumference of an oversized continuous woven tubular support sleeve is adjustably sized to mattingly match the outer peripheral circumference of a bulk material container forming member which it is designed to support. One or more adjustment tails are formed from the continuous sleeve material to accurately reduce the initial inner sleeve circumference to an adjusted inner circumference. The sizing operation can be performed during initial manufacture of the sleeve or prior to assembly of the sleeve to the forming member.