Finite Element Plastic Selection for Flexible Web Structures
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Solution Overview
Problem
Current methods lack an efficient computerized approach to select suitable plastics for flexible web structures, such as accordion-design hoses and snap lids, which are prone to stress cracking and failure due to varying physical properties of polyolefins, necessitating a method to predict and optimize material selection for specific design requirements.
Innovation Solution
A computerized method using finite element modeling with nodes and physical property inputs to simulate flexing and stress conditions, iteratively testing different polymers to select materials that maximize flexibility and resistance to failure under specified loads, incorporating Poisson's ratio and other material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a computerized method is implemented to select plastics for flexible web structures, then material selection efficiency and design optimization are improved, but device complexity and implementation cost increase
Solution Approach 1:
The patent creates a virtual copy of the flexible web structure through finite element modeling, allowing material selection to be performed on the digital model rather than requiring physical prototyping and testing. This virtual copying enables efficient iteration through multiple material options without increasing physical system complexity.
Solution Approach 2:
The patent replaces physical mechanical testing with computerized finite element analysis. Instead of physically testing different plastic materials in flexible web structures, the system uses computational mechanics to predict material performance, thereby improving efficiency while the complexity is confined to the software domain rather than physical apparatus.
2Measurement precision
If finite element modeling with multiple nodes is used to predict plastic performance, then material selection accuracy is improved, but computational requirements and time increase
Solution Approach 1:
The patent performs preliminary finite element modeling and material evaluation during the design phase before final manufacturing decisions are made. By conducting accurate material selection computations upfront, the system avoids the need for time-consuming physical prototyping and testing later in the development process.
Solution Approach 2:
The patent utilizes finite element analysis to evaluate how different material parameters (such as elastic modulus, Poisson's ratio, yield strength) affect the performance of flexible web structures. By systematically varying these parameters in the computational model, the system achieves accurate material selection while maintaining efficient computation through parameterized analysis.
3Reliability
If iterative testing of different polymers is conducted to maximize flexibility and resistance to failure, then product reliability is improved, but manufacturing time and resource consumption increase
Solution Approach 1:
The patent uses virtual copying through finite element models to iteratively test different polymer materials. Each material option is evaluated through computational simulation of flexing and stress conditions, allowing multiple iterations of material testing without consuming physical materials or requiring manufacturing time, thereby maintaining high reliability assessment capability while preserving productivity.
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 the selection of cost-effective plastics that meet design criteria by predicting the number of flexes until failure, maximum stress, or minimum deflection, effectively addressing the challenges of stress cracking and material variability in polyolefins.
Implementation Method 1
entering into the model from step 1 the radius of curvature of the web in use, the planes of flexation of the web, the load force along said planes of flexation, the angle or degree of flexation, the elastic modulus of the plastic, the tangent modulus of the plastic, the Poisson's ratio of the plastic, the yield strength of the plastic
Implementation Method 2
the Poisson's ratio of the plastic
Implementation Method 3
U.S. Pat. No. 6,874,370, issued Apr. 5, 2005 to Vachon, teaches a method to calculate the strain and fatigue damage of a part undergoing repetitive deformation using finite element analysis and a detectable physical observation of the product under deformation
Data Source
AI summary
A plastic may be selected for a thin web application by finite element analysis of the part including the properties, including Poission's ratio of potential polymers from which the part may be made and subjecting the computer model of the part to loads to determine the deflection of the part under a specified series of loads or when the part breaks or subjecting the part to a number of use cycles to determine when the part fails. The process is iteratively repeated for each plastic and the results are compared to select a preferred plastic for the part.