Load-Bearing Fabric Assembly With Inspectable Molded Carrier Bond
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for attaching load bearing fabrics to support structures often result in improper bonding, leading to potential separation or unraveling of the fabric, and there is a need to vary the stiffness of the carrier while maintaining the same fabric, as well as a means to detect attachment defects post-assembly.
Innovation Solution
The load bearing fabric assembly features multiple view ports for visual inspection of the junction between the fabric and carrier, and a molding process using a mold with coolant tubes to inject molten thermoplastic, allowing for a higher melt point carrier material and improved bonding by maintaining the fabric at a lower temperature than the molten thermoplastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the carrier is molded directly onto the fabric using conventional TPE, then the fabric is properly encapsulated, but the carrier stiffness is limited because the TPE melt temperature must be at or below the fabric monofilament melt temperature
Solution Approach 1:
A release fabric is introduced as an intermediary layer between the load bearing fabric and the molten TPE carrier material. The release fabric has a higher melt temperature than the load bearing fabric, allowing the carrier TPE to be molded at temperatures above the load bearing fabric's melt point without directly contacting and damaging the fabric. The release fabric protects the load bearing fabric from direct thermal contact while still allowing the carrier to bond to the fabric through the release fabric medium.
2Reliability
If the carrier is installed within the frame and the fabric is stretched, then the fabric is secured to the support structure, but attachment defects such as fabric separation or unraveling may occur that are difficult to detect
Solution Approach 1:
The release fabric is provided in different colors than the load bearing fabric, creating a visible color contrast at the interface between the carrier and the load bearing fabric. This color difference allows visual inspection to easily detect attachment defects such as fabric separation, unraveling, or improper encapsulation, as any defects will be clearly visible where the colored release fabric meets the load bearing fabric.
3Strength
If molten TPE at high temperature is used to mold the carrier, then the carrier can be made more rigid, but the fabric may deteriorate or decay due to heat exposure
Solution Approach 1:
The release fabric serves as a thermal barrier intermediary that protects the load bearing fabric from direct contact with molten TPE at temperatures exceeding the fabric's melt point. This allows the carrier to be molded with rigid, high-melt-temperature TPE materials while the release fabric absorbs and blocks the harmful thermal effects, preventing fabric deterioration.
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 solution enables easy detection of attachment defects and allows for the use of more rigid thermoplastics for the carrier, enhancing the strength and durability of the assembly while ensuring proper bonding and preventing fabric deterioration.
Implementation Method 1
a mold with coolant tubes to inject molten thermoplastic, allowing for a higher melt point carrier material and improved bonding by maintaining the fabric at a lower temperature than the molten thermoplastic
Data Source
AI summary
A load bearing fabric assembly having a frame, a carrier and a load bearing fabric. The load bearing fabric is attached directly to the carrier. The frame defines view ports to enable visual inspection of the junction between the carrier and the load bearing fabric after the carrier and fabric have been mounted to the frame. A method of manufacturing the carrier for such a load bearing fabric assembly includes the steps of: (a) placing the fabric inside a mold with at least a portion of the fabric directly engaging the surface of the mold; (b) injecting a molten thermoplastic into the mold to form the carrier, the molten thermoplastic having a melt point greater than that of the fabric; and (c) permitting the molten thermoplastic to cure to form a carrier directly on the fabric. In one embodiment, the fabric is positioned so that the entry of molten thermoplastic urges the fabric against a surface of the mold cavity.