Laminated Load Ring Structure With Offset Weld Lines
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Solution Overview
Problem
Existing load rings for balloon networks are heavy and expensive due to their metal composition, which limits the payload capacity and increases manufacturing costs, while also having potential weak points from weld lines and gates during the injection molding process.
Innovation Solution
A laminated modular load ring made from stacked, fiber-reinforced plastic ring stacking units with offset weld lines and gate tabs, which are bonded together using adhesives or ultrasonic welding, to enhance strength and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal load rings are used, then strength is improved, but weight increases and cost increases
Solution Approach 1:
The patent applies composite materials by using fiber-reinforced plastic (such as glass fiber reinforced nylon) instead of solid metal. This composite structure provides sufficient strength to handle tendon loads while significantly reducing the weight compared to traditional metal load rings, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The load ring is segmented into multiple stacked plastic rings bonded together. This segmentation allows the use of lighter plastic materials while achieving the required structural strength through the combined effect of multiple layers, reducing overall weight while maintaining load-bearing capacity.
2Strength
If metal load rings are used, then strength is improved, but manufacturing cost increases
Solution Approach 1:
By using fiber-reinforced plastic composites, the patent achieves metal-level strength at a lower material cost. The plastic matrix combined with fiber reinforcement provides the necessary mechanical properties while being more cost-effective than metal processing.
Solution Approach 2:
The patent replaces traditional metal machining and fabrication processes with injection molding for plastic rings. This substitution of manufacturing methods reduces production complexity, tooling costs, and manufacturing time, thereby lowering overall manufacturing costs while maintaining structural integrity.
3Weight of moving object
If injection molding is used for plastic rings, then weight is reduced and cost is reduced, but weak points are created from weld lines and gates
Solution Approach 1:
By dividing the load ring into multiple stacked plastic rings, the patent distributes the structural load across several components. This segmentation prevents any single weld line or gate location from becoming a critical weak point, as the load is shared across multiple bonding interfaces and structural elements.
Solution Approach 2:
The patent transitions from a single-plane structural design to a multi-layer stacked configuration. By adding the dimensional aspect of stacking multiple rings, the design compensates for potential weaknesses in individual rings through the cumulative strength of the layered structure, enhancing overall reliability.
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 laminated load ring achieves greater strength and reduced weight compared to metal rings, with improved distribution of tendon loads and increased payload capacity, while minimizing weak points from weld lines, and is more cost-effective to manufacture.
Implementation Method 1
Each of the ring stacking units may be manufactured from a fiber-reinforced material. The majority of the fibers in the ring stacking unit may be oriented in a lateral direction that extends in a direction parallel to a top surface of the ring stacking unit.
Implementation Method 2
The plurality of ring stacking units may be bonded together. In one example, an adhesive layer may be provided between each of the plurality of ring stacking units.
Implementation Method 3
The plurality of ring stacking units may be additionally or alternatively ultrasonically welded together.
Data Source
AI summary
A laminated load ring for a balloon assembly includes a plurality of ring stacking units stacked one on top of the other. Each of the ring stacking units can include a main body having a central opening, a plurality of arms, and at least one weld line. The plurality of arms may each extend away from the main body around a circumference of the main body. The at least one weld line can be formed on the main body. The plurality of arms of the plurality of ring stacking units may be aligned with one another. The weld line of each of the plurality of ring stacking units may be offset from the weld line of a directly adjacent ring stacking unit in a direction extending around the circumference of the laminated load ring.