Insect net lamella and method of producing the same
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Solution Overview
Problem
Conventional insect nets in greenhouses impair air flow due to double weft inserts, leading to elevated temperatures and humidity issues, and existing solutions like full width weaving looms are inefficient for producing flexible net constructions.
Innovation Solution
A one-step ultrasonic cutting and welding method is used to produce insect net strips with monofilament thermoplastic yarns, creating a reinforced edge by melting together weft yarns to form a consolidated edge portion, optimizing air permeability and insect exclusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional band weaving technique is used to produce insect net lamellas, then the lamellas can be easily produced with closed longitudinal edges suitable for confectioning, but double weft inserts are created that decrease air flow through the net by 30-50%
Solution Approach 1:
The invention extracts and eliminates the problematic double weft inserts from the conventional band weaving process. By using a one-step ultrasonic cutting and welding method on full width woven nets, the process removes the need for separate lamella production that creates double weft inserts, thereby maintaining air flow while still producing closed edges suitable for confectioning.
Solution Approach 2:
The invention merges the cutting and welding operations into a single ultrasonic process step. This combination eliminates the need for separate lamella production and assembly operations, removing double weft inserts while efficiently producing net strips with closed edges in one operation, thus improving both air flow and manufacturing efficiency.
2Adaptability or versatility
If full width weaving loom is used to produce wide insect nets, then any weaving pattern can be chosen to optimize ventilation and insect exclusion, but the nets must be cut into lamellas which requires additional processing steps
Solution Approach 1:
The ultrasonic cutting and welding device performs multiple functions: it cuts the full width net into strips and simultaneously welds closed edges on both sides of each strip. This multi-functionality eliminates the need for separate cutting and sewing operations, reducing device complexity while maintaining the ability to produce nets with optimized weaving patterns.
Solution Approach 2:
The invention replaces traditional mechanical cutting and sewing systems with an ultrasonic system. The ultrasonic vibration enables both cutting and welding in one operation, substituting complex mechanical assembly processes with a more efficient ultrasonic field-based process that reduces overall device complexity.
3Productivity
If conventional cutting methods are used to cut woven nets, then the nets can be divided into strips, but the edges are not closed and require additional sewing operations
Solution Approach 1:
The invention merges cutting and welding operations into a single ultrasonic process. The ultrasonic tool simultaneously cuts the net into strips and welds closed edges on both sides of each strip, eliminating the need for separate sewing operations and reducing device complexity while improving production efficiency.
Solution Approach 2:
The ultrasonic cutting and welding device performs multiple functions in one operation: it divides the net into strips and creates closed edges on all strip edges. This multi-functionality eliminates the need for additional sewing equipment, reducing device complexity while maintaining high production efficiency.
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 method increases air flow by up to 30-50% and enhances the flexibility of insect net constructions, allowing for improved ventilation and insect prevention in greenhouses.
Implementation Method 1
feeding the woven insect net into an ultrasonic cutting device comprising an ultrasonic surface and at least two ultrasonic cutting and welding tools
Implementation Method 2
at least 90% of gaps between adjacent weft yarns in the deformation zone are closed by at least the weft yarns being melted together
Data Source
AI summary
Described is an insect net strip produced from a wide insect net which has been cut in a warp direction (xnet) by means of a one-step ultrasonic cutting and welding process. The insect net strip includes warp yarns and weft yarns extending substantially perpendicular to each other and at least 90% of the warp and weft yarns are monofilament yarns made of a thermoplastic material. After cutting and welding process the insect net strip has a first and a second edge extending parallel to said warp yarns each including a deformation zone being constituted by consolidated thermoplastic material deriving at least from said weft yarns. The deformation zone has a width (wdz) in the transverse direction (ystrip) of between 0.5-35 times the weft yarn diameter (øwe). At least 90% of gaps between adjacent weft yarns in the deformation zone are closed by consolidated thermoplastic material at least from the weft yarns which has been melted together to form a continuous or substantially continuous reinforced band-shaped edge portion of said insect net strip. The insect net strip is suitable for use in accordion-style constructions in greenhouse ventilation openings. A method for producing the insect strips is also described.