Controlled Cellular Material Formation via Stretching Apertures
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Solution Overview
Problem
Existing methods for forming cellular materials, such as foamed plastics, struggle to control the size, shape, distribution, and position of gas cells, resulting in randomly sized and shaped cells that are not optimally suited for various industrial applications.
Innovation Solution
A method involving a stretching apparatus with apertures that allows a fluid to enter the material through these apertures as it is stretched, defining voids at controlled locations, thereby creating a cellular structure with predetermined cell size, shape, and distribution within a polymeric slab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional foaming techniques are used to create gas cells in plastic material, then cellular material is formed, but the cells are randomly sized, shaped, distributed and positioned
Solution Approach 1:
The stretching surfaces are prepared with apertures in advance before the forming process. These apertures are strategically positioned to control where gas cells will form in the plastic material during stretching, eliminating the randomness of conventional foaming while maintaining process simplicity
Solution Approach 2:
Gas is introduced through the aperture array in the stretching surfaces as an intermediary mechanism. The gas flows through the apertures and forms cells at controlled locations within the plastic material during stretching, providing precise spatial control over cell formation without complex additional equipment
2Manufacturing precision
If blowing agents are used to create gas cells during material manufacture, then cellular structure is formed, but control over cell location and distribution is limited
Solution Approach 1:
The conventional chemical blowing agent approach is replaced with a mechanical gas introduction system. Gas is delivered through the aperture array in the stretching surfaces, providing mechanical control over cell location and distribution while simplifying the manufacturing process by eliminating chemical agents
Solution Approach 2:
The aperture array provides local control over gas introduction at specific positions in the stretching surfaces. This creates localized gas cell formation at predetermined locations in the final product, enabling spatial variation in cell distribution according to design requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the formation of cellular slabs with regularly spaced, controlled-sized voids, enhancing the material's structural characteristics and porosity, allowing for tailored properties suitable for aerospace, automotive, and other industries.
Implementation Method 1
a fluid is allowed to enter the material through these apertures as it is stretched, defining voids at controlled locations
Implementation Method 2
The stretchable material is then hardened with voids at locations controlled/defined by the apertures
Implementation Method 3
The stretchable material is then hardened
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
A hardened cellular material formed by stretching a stretchable material is disclosed. Fluid is allowed to enter softened stretchable material through apertures in a stretching surface to define voids at locations in the stretchable material at locations defined by the apertures. The stretchable material is then hardened with voids at locations controlled/defined by the apertures.