Load-Bearing Fabric Frame Molding Without Carrier or Trimming
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Solution Overview
Problem
Manufacturing load bearing fabric structures by directly molding the frame onto the fabric is challenging due to material incompatibility, leading to increased costs and waste from excess fabric trimming.
Innovation Solution
An apparatus comprising a mold, stretching assembly, and fabric retaining assembly that stretches and holds the fabric in place during molding, allowing the frame to be molded directly onto the fabric without a separate carrier, eliminating the need for excess fabric trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate carrier is used to mount the load bearing fabric to the support frame, then the manufacturing process can accommodate material incompatibility between frame materials and fabric, but the manufacturing cost and assembly complexity increase due to additional components and steps
Solution Approach 1:
The patent removes the intermediate carrier component from the assembly, allowing the frame to be molded directly onto the fabric. This extraction of the unnecessary intermediary element simplifies the overall structure while maintaining manufacturing feasibility through direct molding processes.
Solution Approach 2:
The patent combines the frame and fabric into a single integrated molded structure, eliminating the separate carrier component. This merging of components reduces assembly steps and structural complexity while maintaining the necessary material compatibility through direct molding.
2Ease of manufacture
If the load bearing fabric extends fully through the mold cavity with peripheral edge held outside, then the fabric can be molded in place directly on the support frame, but excess fabric must be trimmed resulting in material waste and visible trim lines
Solution Approach 1:
The patent applies preliminary stretching to the fabric before the molding process, pre-positioning it within the mold cavity in the correct configuration. This preliminary action eliminates the need for excess fabric extensions and subsequent trimming, as the fabric is already sized and positioned correctly from the start.
Solution Approach 2:
The patent changes the physical state and dimensions of the fabric through stretching, transforming it from its original unstretched state to a stretched configuration that fits precisely within the mold cavity. This parameter change (stretching) allows the fabric to be molded directly without requiring excess material for trimming.
3Manufacturing precision
If conventional stretching assemblies are used to stretch the fabric, then the fabric can be stretched during molding, but the stretching assembly interferes with the mold closing process
Solution Approach 1:
The patent divides the stretching function into a separate preliminary step from the molding process. The stretching assembly operates independently before molding begins, allowing the fabric to be stretched and positioned without interfering with the subsequent mold closing and injection processes.
Solution Approach 2:
The patent performs the fabric stretching operation as a preliminary action before the molding process begins. This sequencing ensures that the stretching assembly is no longer needed during mold closing, eliminating interference while maintaining consistent fabric stretch through controlled pre-positioning.
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 provides an efficient, cost-effective, and uniform manufacturing process with consistent fabric stretch and integration of the frame with the fabric, reducing waste and assembly time.
Implementation Method 1
a stretching assembly for stretching the load bearing fabric
Implementation Method 2
a fabric retaining assembly for holding the fabric in the stretched condition during molding
Implementation Method 3
a mold for forming the support frame
Data Source
AI summary
A method and apparatus for manufacturing load bearing fabric structures in which the peripheral edge of the load bearing fabric terminates with the mold cavity. The apparatus includes a stretching assembly for stretching the fabric, a fabric retaining assembly for holding the fabric in the stretched condition and a mold assembly for molding the frame about the periphery of the fabric. The method includes the steps of gripping the peripheral edge of the fabric in a stretching assembly, activating the stretching assembly to stretch the fabric in a location adjacent to the mold assembly, clamping the stretched fabric against a face of the mold assembly, releasing the peripheral edge of the fabric from the stretching assembly, moving the stretching assembly from the path of the mold assembly, closing the mold assembly on the fabric with the peripheral edge of the fabric terminating in the mold cavity and injecting molten material into the mold cavity to form the frame directly on the peripheral edge of the fabric.