Laser-Processed Resin Mesh with Reinforcing Member
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Solution Overview
Problem
Conventional methods for producing meshes require changing molds to alter the design, making it difficult to modify the opening diameter, number, or shape of through-holes, which is costly and inefficient.
Innovation Solution
A method involving laser beam formation of through-holes in a resin mesh main body and a resin reinforcing member, allowing for easy design changes by adjusting laser irradiation conditions, and joining the materials through laser welding to create a mesh with varying hole diameters and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mold is used to form the mesh portion, then the mesh can be produced with consistent structure, but the design cannot be easily changed and production cost increases
Solution Approach 1:
The patent replaces the mechanical molding process with a laser-based process. The laser beam forms through-holes directly in the resin film without requiring physical molds, allowing design changes to be made by adjusting laser parameters rather than changing physical tooling. This substitution enables flexible design modification while maintaining production efficiency.
Solution Approach 2:
The patent utilizes parameter changes in laser irradiation (power, speed, pattern) to control the formation of through-holes. By adjusting these parameters, the opening diameter, number, and arrangement of through-holes can be easily modified without changing the manufacturing system itself, providing design flexibility while maintaining consistent production.
2Reliability
If conventional joining methods are used, then the mesh structure can be assembled, but the heat-affected zone is large causing uneven spray performance
Solution Approach 1:
The patent replaces conventional thermal joining methods with laser welding. The laser beam provides localized, precise heating that minimizes the heat-affected zone compared to conventional methods. This substitution enables reliable joining of the mesh structure while maintaining uniform spray performance by avoiding excessive heat damage.
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
Enables cost-effective production of meshes with customizable through-hole designs, improving spray performance and reducing the heat-affected zone for nebulization applications.
Implementation Method 1
a step of forming a plurality of through-holes using a laser beam in a mesh formation region of a first film material made of resin
Implementation Method 2
a step of joining the first film material and the second film material to each other through laser welding at a portion surrounding the opening portion
Data Source
AI summary
A method for producing a mesh including a resin mesh main body, and a resin reinforcing member configured to reinforce the mesh main body includes: a step of forming a plurality of through-holes using a laser beam in a mesh formation region of a first film material made of resin; a step of forming an opening portion in a second film material made of resin; a step of layering the first film material and the second film material so that the mesh formation region and the opening portion are arranged at positions that conform to each other; and a step of joining the first film material and the second film material to each other through laser welding at a portion surrounding the opening portion.