Plastic-Bound Fiber Mat Blank Separation via Strip Extraction
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Solution Overview
Problem
Producing blanks from plastic-bonded fiber structures is challenging due to the high forces required to lift them out of the remaining fabric, entanglement of cut fiber ends, and the formation of adhesive bridges when using conventional cutting methods, making manual labor necessary for detachment and handling.
Innovation Solution
Widening the parting line between the blank and the remaining scrim by removing a scrim strip using a tool, such as a milling head or a graver, to prevent non-positive and positive locking, allowing easy lifting with conventional gripping or suction devices, and potentially recutting the outline for improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cutting methods are used to produce blanks from plastic-bonded fiber structures, then the cutting process is simple, but high forces are required to lift the blanks out of the remaining fabric and manual labor is necessary for detachment
Solution Approach 1:
The cutting process is segmented into two distinct operations: first cutting the blank outline, then separately removing a strip from the parting line area. This segmentation allows the parting line to be widened without affecting the blank's dimensional accuracy, enabling easy detachment while maintaining cutting precision
Solution Approach 2:
A strip is removed from the parting line area before the blank is lifted out of the remaining fabric. This preliminary action widens the parting line and prevents locking between the blank and remaining fabric, allowing conventional gripping or suction devices to easily detach the blank without requiring high forces
2Manufacturing precision
If conventional cutting methods are used, then the cutting process is straightforward, but entanglement of cut fiber ends occurs causing clawing between cut edges
Solution Approach 1:
A strip is extracted from the parting line area between the blank and the remaining fabric. This extracted strip includes the problematic cut fiber ends that would otherwise cause entanglement and clawing, while the blank's outline cutting precision is maintained through separate controlled cutting
3Productivity
If ultrasound vibrations are applied to cut thicker fiber fabrics, then cutting capability is improved, but adhesive bridges form between the cut and remaining fabric
Solution Approach 1:
A strip is removed from the parting line area where adhesive bridges would form between the cut surface and remaining fabric. This extraction eliminates the adhesive contamination problem while allowing ultrasound vibrations to be used for effective cutting of thicker fabrics
Solution Approach 2:
The strip containing adhesive bridges and contaminated material is discarded, separating the harmful adhesive residues from the usable blank. This allows the blank to be cleanly detached without adhesive contamination affecting further processing
4Ease of operation
If a widened parting line is created by removing a scrim strip, then blank detachment is simplified, but additional cutting operations are required
Solution Approach 1:
The cutting device is designed to perform multiple functions: cutting the blank outline, cutting the parting line strip, and potentially recutting the outline for improved surface quality. This multi-functionality is achieved through a programmable robotic arm with interchangeable tools, reducing the need for separate dedicated equipment for each operation
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
Enables effortless lifting and handling of blanks using conventional devices, preventing adhesive issues and ensuring high cutting accuracy without additional equipment complexity, facilitating automation and reducing manual labor.
Implementation Method 1
the fiber structure is severed with the aid of a knife guided along the outline of the blank
Implementation Method 2
when vibrations are stimulated with ultrasound, which is particularly recommended for thicker fiber fabrics, it is to be expected that the plastic of the binding agent will be softened locally
Implementation Method 3
conventional gripping or suction devices for further processing
Data Source
Figure 1
Figure 2~3
AI summary
The method involves separating a plastic-bound nonwoven fabric (1) using a cutter (8) guided along an outline of a blank (2), and lifting the blank from a remaining nonwoven fabric (6). A separation joint between the blank and the remaining nonwoven fabric is widened by removing nonwoven strips (10) before lifting out blank from the remaining nonwoven fabric. The nonwoven fabric is separated into sections (3, 7) limited between the strips, where the section (3) is provided along the outline of the blank and the section (7) follows the section (3) at a distance outside the blank.