Co-molded Polymer Link Material for Conformable Shapes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing materials, such as solid leather, lack conformability and flexibility to accommodate complex shapes, and traditional methods like weaving or threading individual elements are labor-intensive and costly for producing flexible, conformable materials.
Innovation Solution
A multi-polymer material is created using incompatible chemistries of two injected polymers to form a frame and links, allowing the links to pivot and slide independently, eliminating the need for threading or weaving, and enabling the material to conform to complex shapes without bonding, thus reducing manufacturing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional weaving or threading methods are used to create flexible materials, then conformability and flexibility are achieved, but labor intensity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (frame and links made from different polymers) into a single integrated structure through co-molding. This merging eliminates the need for separate threading or weaving operations, achieving both conformability and manufacturing efficiency simultaneously.
Solution Approach 2:
The invention uses composite materials by co-molding two different polymers (first polymer for frame, second polymer for links) in a single process. This creates a multi-material structure that provides both structural support and flexibility without requiring manual assembly, resolving the contradiction between conformability and productivity.
2Ease of operation
If individual links are threaded onto a frame matrix, then flexibility and conformability are achieved, but manufacturing time and labor cost increase
Solution Approach 1:
The frame and links are pre-formed as separate components using injection molding, and then assembled together in a single co-molding operation. This preliminary preparation eliminates time-consuming manual threading operations while maintaining the flexibility provided by individual links.
Solution Approach 2:
The patent replaces the mechanical threading process with a co-molding process where the frame and links are formed and joined in a single manufacturing step. This substitution eliminates manual labor and significantly reduces manufacturing time while preserving the flexible link structure.
3Strength
If solid materials like leather are used, then structural strength is maintained, but conformability and flexibility are lost
Solution Approach 1:
The patent segments the material structure into a frame component (first polymer) and link components (second polymer). This segmentation allows each component to be optimized for its specific function: the frame provides structural strength while the links provide flexibility and conformability, resolving the contradiction between strength and conformability.
Solution Approach 2:
By using composite materials with different polymer properties, the invention achieves both structural strength (from the frame polymer) and conformability (from the link polymer). The incompatible chemistries of the two polymers allow them to be co-molded without bonding, creating a structure that combines the advantages of both materials.
4Ease of operation
If woven materials are used to accommodate complex shapes, then conformability is achieved, but edge un-raveling issues and manufacturing complexity increase
Solution Approach 1:
The patent applies local quality by using different polymer materials in different locations: a rigid or semi-rigid polymer for the frame structure and a flexible polymer for the links. This localized material selection provides conformability where needed while maintaining structural integrity, reducing manufacturing complexity compared to uniform woven materials.
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
The material is ventilated, flexible, and conformable, offering manufacturing cost reductions and mold cost savings, while providing adjustable attributes to fit dynamic shapes without the labor and cost of traditional methods.
Implementation Method 1
incompatible chemistries of two injected polymers to form a frame and links to produce a piece of material formed of the frame and links in a non-bonded state
Implementation Method 2
This bonding incompatibility allows a series of links to rotationally pivot, shift and slide independently of one another along the frame
Data Source
AI summary
A material includes a frame having at least one elongate member formed of a first polymer. At least one link is formed of a second polymer, with a portion of each link co-molded about a portion of at least one elongate member, and at least one link movable with respect to a corresponding elongate member.