Manufacturing method and manufacturing equipment for corrugated net
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Solution Overview
Problem
Conventional methods for manufacturing corrugated nets face inefficiencies due to uneven heat conduction, high electricity costs, and lengthy processing times, requiring additional heating steps and resulting in defective products.
Innovation Solution
A manufacturing method and equipment that directly form corrugated nets by injecting thermoplastic mesh material, cooling it to a moldable temperature using a liquid medium, and then pressing it to create creases, eliminating the need for additional heating equipment and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air heating module is used to heat the net, then the net can reach moldable temperature, but heat conduction efficiency is poor and heating effect is uneven
Solution Approach 1:
A water tank filled with water serves as an intermediary heat transfer medium. The heating module heats the water, and the water then uniformly heats the net through conduction when the net is immersed or contacted with the water, eliminating the poor heat conduction and uneven heating effects of direct air heating.
2Temperature
If heating module is used to heat the net to moldable temperature, then the net can be deformed, but electricity consumption cost increases
Solution Approach 1:
The system utilizes the injection molding machine's own heating capability to heat the water in the water tank, rather than requiring a separate heating module. This self-service approach reduces additional electricity consumption while still achieving the necessary moldable temperature for net deformation.
Solution Approach 2:
The patent employs hydraulic or pneumatic pressing mechanisms integrated with the injection molding machine to deform the net after heating. This combines the heating and deformation functions into one system, reducing energy consumption compared to separate heating and forming operations.
3Temperature
If heating module heats the net to predetermined temperature, then the net becomes moldable, but heating time increases and productivity is limited
Solution Approach 1:
The heating process occurs continuously during the injection molding cycle. The injection molding machine heats the water and the net is heated simultaneously during material injection and cooling phases, eliminating separate heating steps and reducing total processing time to increase productivity.
4Ease of operation
If cooling and winding operation is performed before processing, then the net can be handled, but additional time is required and manufacturing process becomes lengthy
Solution Approach 1:
The cooling, winding, and heating operations are merged into a single integrated process. The net is cooled during injection molding, then directly immersed in the water tank for heating without intermediate winding or handling steps. This combination eliminates unnecessary time losses while maintaining ease of operation through the water-based handling system.
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 method reduces processing time and costs, ensures uniform crease formation, and improves product yield by maintaining consistent moldable temperatures throughout the mesh material, resulting in higher quality corrugated nets.
Implementation Method 1
cooling the plastic mesh material down to a moldable temperature by the liquid holding temperature medium
Implementation Method 2
pressing the plastic mesh material with the moldable temperature to cause the plastic mesh material with the moldable temperature to form creases during the pressing process
Data Source
AI summary
The invention relates to a manufacturing method and a manufacturing equipment for a corrugated net. The manufacturing method comprises steps of: injecting a thermoplastic plastic mesh material, the plastic mesh material having an injection temperature; directly reducing a temperature of the plastic mesh material from the injection temperature to a moldable temperature; and pressing the plastic mesh material with the moldable temperature to cause the plastic mesh material with the moldable temperature to form creases. The invention is capable of reducing manufacturing procedures and time by directly adjusting the injected plastic mesh material to the moldable temperature and pressing to form creases without requiring heating equipment, and the moldable temperature of the overall plastic mesh material is uniformly set to be capable of improving an effect of forming corrugated structure for the mesh material.