Continuous Flexible Complex Manufacturing via Anti-Adhesive Pocket Sealing
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Solution Overview
Problem
Current methods for manufacturing flexible complexes with tight pockets are discontinuous, time-consuming, and require additional operations like continuous vulcanization, making them costly and inefficient.
Innovation Solution
A continuous manufacturing process involving the deposition of an anti-adhesive agent on coated fabric sheets, followed by simultaneous heating and pressure assembly, which integrates vulcanization for rubber-coated fabrics, allowing for autogenous assembly without supplementary materials and enabling uniform, decorative, and personalized products with reduced bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discontinuous manufacturing methods are used to assemble pockets by adhesion or thermal welding, then manufacturing precision and product resistance are improved, but production time and manufacturing cost increase significantly
Solution Approach 1:
The patent implements continuous manufacturing by passing coated fabric sheets through a continuous vulcanization press where pockets are formed and sealed in one uninterrupted operation. The fabric moves continuously through heating zones that vulcanize the rubber coating, creating sealed pockets without stopping to assemble individual components, thus maintaining high production speed while ensuring reliable pocket formation through controlled thermal processing.
Solution Approach 2:
The invention combines multiple operations into a single continuous process: the coating deposition, pocket formation, and vulcanization sealing are merged into one integrated manufacturing step. The coated fabric sheets are vulcanized continuously in the press, simultaneously forming the pockets and sealing them, eliminating the need for separate adhesion or welding operations that would slow production.
2Reliability
If additional continuous vulcanization operations are performed before or after pocket manufacturing, then product resistance and durability are improved, but manufacturing complexity and time consumption increase
Solution Approach 1:
The patent integrates the vulcanization process directly into the pocket manufacturing operation. The coated fabric sheets are placed in the continuous vulcanization press with pockets formed between them, and the entire assembly is vulcanized in one continuous operation. This eliminates the need for separate pre-vulcanization or post-vulcanization steps, reducing process complexity while ensuring complete vulcanization for durable, resistant pockets.
Solution Approach 2:
The continuous vulcanization press serves multiple functions simultaneously: it forms the pockets, seals them, and vulcanizes the rubber coating in one operation. This multi-functional device eliminates the need for separate vulcanization equipment and operations, simplifying the overall manufacturing process while ensuring reliable product durability through thorough vulcanization.
3Reliability
If supplementary materials like adhesive bands are added during assembly, then pocket sealing reliability is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent employs the rubber coating material itself to perform the sealing function that would otherwise require supplementary adhesive materials. The rubber coating on the fabric sheets is vulcanized in the continuous press, causing it to bond directly to itself and form sealed pockets without needing additional adhesive bands or compounds. This self-sealing approach eliminates extra materials and simplifies the manufacturing process while ensuring reliable pocket sealing.
Solution Approach 2:
The invention removes the need for supplementary adhesive materials by utilizing the inherent properties of the rubber-coated fabric. The rubber coating is extracted from its role as merely a surface layer and transformed into the primary sealing mechanism through vulcanization, eliminating the need for separate adhesive applications and reducing manufacturing complexity.
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 process results in a cost-effective, efficient, and aesthetically pleasing flexible complex with reduced bulkiness, enabling continuous production without stops and allowing for simultaneous decoration and assembly, while ensuring the pockets are resistant and uniformly coated.
Implementation Method 1
depositing an anti-adhesive agent on at least one sheet of coated fabric in zones for forming the pocket or pockets
Implementation Method 2
continuously assembling the sheet of coated fabric on which the anti-adhesive agent was deposited with the sheet of coated fabric by heating and/or pressure
Implementation Method 3
continuously assembling the sheet of coated fabric on which the anti-adhesive agent was deposited with the sheet of coated fabric by heating and/or pressure
Implementation Method 4
a specific manufacturing process permitted the problems presented above to be resolved entirely or at least in part. Thus, I provide a process for the continuous manufacture of tight pockets comprising, in particular for fabrics coated with rubber, a vulcanization integrated into the described process
Data Source
AI summary
A process for continuous manufacture of a flexible complex including at least one tight pocket including the steps of depositing an anti-adhesive agent on at least one sheet of coated fabric in zones for forming the pocket or pockets, and continuously assembling the sheet of coated fabric on which the anti-adhesive agent was deposited with the sheet of coated fabric by heating and/or pressure.