Intra-Moulded Headgear Strap Assembly for Textile Alignment
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Solution Overview
Problem
Existing headgear arrangements for breathing apparatuses face manufacturing challenges due to the non-linear shape and geometry of junction portions, which make it difficult to align and secure textile layers within a mould tool, leading to misalignment and displacement during the moulding process.
Innovation Solution
A headgear strap assembly is formed with a first and second substrate, each having a textile casing attached, and an intra-moulded core between them, using a molten plastic material to create a unified structure with retaining structures like posts and sockets for secure attachment, ensuring the textile casings remain aligned during moulding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional intra-moulding technique is used with non-linear junction portions, then headgear arrangements can be formed with plastic core and textile layers, but the textile layers become difficult to align and secure within the mould tool, leading to misalignment and displacement
Solution Approach 1:
The textile layers are pre-assembled with the headgear components (straps, junction portions, buckles) outside the mould tool to form a complete sandwich structure before insertion. This preliminary assembly ensures proper alignment and positioning of all textile components, eliminating alignment issues during the moulding process. The pre-assembled structure includes inner and outer textile layers properly positioned around the plastic core with all fastening elements in place.
Solution Approach 2:
The headgear arrangement is divided into discrete components (straps, junction portions, buckles, textile layers) that are separately manufactured and then pre-assembled. This segmentation allows each component to be optimized independently and facilitates easier handling and alignment during pre-assembly, improving both manufacturability and alignment precision.
2Productivity
If textile layers are loosely positioned in the mould tool, then the mould can be closed, but the injected plastic material pushes the textile layers out of position
Solution Approach 1:
The textile layers are pre-assembled with rigid headgear components to create a stable sandwich structure that maintains its shape and position during moulding. This pre-assembly creates internal structural support that prevents the textile layers from being pushed out of position by the injected plastic material, ensuring position stability while maintaining manufacturing efficiency.
Solution Approach 2:
The headgear components are constructed as composite structures combining rigid materials (plastic junction portions, metal buckles) with flexible textile layers. This composite construction creates a stable framework that maintains the positioning of textile layers during the injection moulding process, preventing displacement while allowing efficient production.
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 provides a reliable and manufacturable headgear strap assembly with a smooth, durable edge finish, enhancing stability and user comfort by preventing textile layer misalignment and displacement during moulding.
Implementation Method 1
The first and second substrates, the first and second textile casings and the intra-moulded core are formed as an integral structure by the application of a molten plastic material between the first and second textile casings
Data Source
AI summary
A headgear portion or assembly for use in combination with a breathing apparatus in some configurations is at least substantially inelastic and is three dimensional in shape. The headgear portion or assembly can comprise a plastic core, a substrate and a textile casing. The substrate and textile casing have retaining structures to attach the textile casings to the substrates and the substrates to each other.