Flexible Composite With Tensioned Linking Elements
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Solution Overview
Problem
Existing flexible cloths face challenges in achieving high and constant fill density due to limitations in manufacturing processes, such as needling and stitch bonding, which result in crushed linking fibers and reduced packing density, and require expensive stiff structures for powder loading, leading to increased costs and complexity.
Innovation Solution
A flexible composite design featuring a first and second layer separated by a space with a settable fill material that can become rigid or semi-rigid upon liquid or radiation exposure, where linking elements are tensioned by the fill material's pressure, allowing for higher compaction and maintaining density during handling and use, and incorporating a permeable first layer to control liquid entry and exit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If needling or stitch bonding is used to join layers through fill material, then layers are bonded together, but linking fibers are crushed and packing density of fill material is reduced
Solution Approach 1:
The invention divides the fill material into discrete particles and positions them between layers using a controlled process. The linking fibers are segmented to extend through the fill material without crushing it, allowing the fibers to be inserted separately and then locked into position, thereby maintaining high packing density while achieving layer bonding.
Solution Approach 2:
The invention performs preliminary positioning of the fill material between the layers before final bonding. The fill material is placed and compacted to achieve high packing density, and then the linking fibers are inserted and locked into position. This preliminary action ensures that the fill material is not compressed during the bonding process, maintaining its density.
2Manufacturing precision
If stiff structures are used to load powder fill, then high packing density is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention uses flexible layers that can be easily formed into the required shape and size. These layers are simple, thin structures that can be manufactured cost-effectively. The linking fibers provide the necessary structural support to maintain the shape and contain the fill material, eliminating the need for complex stiff structures.
Solution Approach 2:
The invention creates a composite structure combining flexible layers with linking fibers and fill material. This composite approach allows the fill material to be loaded efficiently while the flexible layers provide the necessary containment and shape. The combination achieves high packing density without requiring expensive stiff structures.
3Manufacturing precision
If fill material is compacted by rollers after needling, then packing density is increased, but linking fibers are crushed and cannot be loaded in tension
Solution Approach 1:
The invention performs preliminary compacting of the fill material to achieve high packing density before inserting the linking fibers. The fill material is compacted to the required density, and then the linking fibers are inserted and locked into position. This preliminary action ensures that the fill material is compacted without crushing the linking fibers, as they are inserted after compacting.
Solution Approach 2:
The invention inverts the traditional sequence by inserting the linking fibers before final compacting. The linking fibers are inserted and locked into position, and then the fill material is compacted around them. This inversion ensures that the linking fibers are not crushed during compacting while still achieving high packing density of the fill material.
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
The solution enables the flexible composite to maintain high fill density and structural integrity during manipulation, transportation, and use, while reducing manufacturing costs and complexity by using a tensioned linking element system and permeable layers to manage fill material effectively.
Implementation Method 1
a fill material located in the space between the first and second layers, which is capable of setting to a rigid or semi-rigid solid on the addition of a liquid, gas or radiation
Implementation Method 2
The first layer may be permeable to gases and/or liquids, but may be substantially impermeable to the fill material
Data Source
AI summary
A flexible composite that can be set to become rigid or semi-rigid includes a first layer and a second layer opposing the first layer and separated from the first layer by a space. A fill material capable of setting to a rigid or semi-rigid solid is located in the space. A plurality of elements extend substantially into the space from the first layer and/or the second layer and which may pass through the opposing layer or join with other elements present in the space from an opposing layer, thereby forming linking elements for joining the layers together. The unset fill material is provided in the space at a pressure such that tension is applied one or more of the linking elements and to cause the first and/or second layers to bulge outwards relative to the longitudinal length of said one or more linking elements under tension.