Interlocking Fiberglass Mat Joints for Scrap-Free Roll Splicing
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Solution Overview
Problem
Fabricators in the insulation industry face downtime and scrap losses due to the need for overlapping joints during roll changeovers in insulation production, leading to inefficiencies and waste.
Innovation Solution
The development of insulation products with nonlinear, interlocking ends that allow for seamless splicing without overlapping, utilizing protrusions and cutouts that align and secure adjacent pieces end-to-end, along with reinforcement members to enhance tensile strength and prevent joint separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If overlapping joints are used to splice insulation rolls, then the rolls can be connected, but the thickness increases and causes scrap loss
Solution Approach 1:
The end of each insulation roll is segmented into interlocking features: a protrusion on one roll end and a corresponding cutout on the other roll end. This segmentation allows the rolls to be connected without overlapping, as the protrusion fits precisely into the cutout, maintaining uniform thickness and eliminating scrap loss.
2Adaptability or versatility
If roll changeover is performed, then new rolls can be used, but production downtime occurs
Solution Approach 1:
The interlocking features (protrusions and cutouts) are pre-formed on the roll ends during manufacturing. This preliminary action allows for rapid splicing during roll changeover, as the features are already in place and simply need to be aligned and connected, significantly reducing production downtime.
3Ease of manufacture
If traditional straight edge ends are used, then rolls are easy to manufacture, but splicing requires overlapping and causes waste
Solution Approach 1:
Instead of symmetric straight edges on both roll ends, the invention uses asymmetric interlocking features: one roll end has a protrusion while the other has a corresponding cutout. This asymmetric design eliminates the need for overlapping during splicing, preventing material waste while remaining manufacturable.
4Productivity
If multiple rolls are spliced together, then production continuity is maintained, but joint strength decreases
Solution Approach 1:
The protrusion of one roll is nested within the cutout of the adjacent roll, creating a interlocked joint. This nesting arrangement provides mechanical interlocking that maintains joint strength while allowing multiple rolls to be spliced together for continuous production.
Data Source
AI summary
An insulation product may include an insulation material. The insulation material may include at least one material selected from the group consisting of nonwoven insulation, aerogel insulation, mineral insulation, and foam insulation. The insulation material may include a first end and a second end positioned opposite the first end. The first end may include a protrusion. At least a portion of the protrusion may widen in a direction opposite the second end. The second end may define a cutout that substantially matches a size and shape of the protrusion. The cutout and the protrusion may be aligned with one another along a length of the insulation material.