Laser Tear-Off Lines for Flexible Web Sections
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Solution Overview
Problem
Existing methods for producing side-gussetted packings from synthetic fabrics or composite materials face challenges in creating effective perforation lines due to the difficulty in cutting small plastic bands, requiring expensive and inflexible tools, and are not easily adaptable for tubular webs.
Innovation Solution
The process involves using laser beam processing to create tear-off lines on flexible web materials, allowing for precise cutting and weakening of the material, which can be adjusted for various material combinations and thicknesses, enabling the production of side-gussetted packings by creating perforation or weakening lines that facilitate easy separation of web sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If punching tools are used to create perforation lines on synthetic fabrics, then perforation can be achieved, but the tools are expensive and susceptible to wear
Solution Approach 1:
The patent replaces mechanical punching tools with laser beam processing to create tear-off lines on synthetic fabrics. The laser system uses optical energy instead of mechanical force, eliminating wear-prone mechanical components while maintaining the ability to perforate and weaken the fabric structure.
Solution Approach 2:
The patent changes the processing method from mechanical punching to laser-based thermal/energy processing. By controlling laser parameters such as power, pulse duration, and scan speed, the system can adjust the penetration depth and effectiveness of the tear-off lines without requiring physical tool changes or replacements.
2Adaptability or versatility
If fixed perforation lines are used, then the structure is simple, but adaptability to varying material thickness and composition is limited
Solution Approach 1:
The patent implements a dynamic laser processing system where parameters such as power, pulse duration, and scan speed can be adjusted in real-time based on material properties. This allows the same laser system to adapt to varying material thicknesses and compositions by dynamically changing processing parameters rather than requiring physical reconfiguration.
Solution Approach 2:
The laser processing system serves multiple functions: it can create tear-off lines, perforate materials, and adjust penetration depth based on material requirements. A single laser system can handle different synthetic fabrics, composites, and material thicknesses by varying operational parameters, eliminating the need for specialized tools for each material type.
3Ease of manufacture
If complete separation of web sections is achieved, then separation is clear, but the structural integrity of the web material is compromised
Solution Approach 1:
The patent creates tear-off lines that segment the web material by introducing controlled weaknesses at specific locations. These lines divide the continuous web into separable sections while maintaining the overall structural integrity of the material. The segmentation is achieved through localized energy input that creates controlled failure points rather than complete separation.
Solution Approach 2:
The laser processing applies partial action by creating tear-off lines with controlled penetration depth that is sufficient to enable tearing but not complete through-cutting. This partial severance of fiber bonds allows sections to separate easily while leaving enough material connectivity to maintain structural strength, avoiding the excessive action of complete cutting.
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
This method allows for efficient and flexible production of web sections from tubular and flat materials, reducing maintenance and wear, and enabling the production of side-gussetted packings with adjustable tear-off lines, suitable for diverse material compositions and formats.
Implementation Method 1
the tear-off lines are produced in the web material by laser beam processing
Implementation Method 2
Using a laser beam, it becomes possible to cut a fabric of small plastic bands, to perforate it or to scratch it with a defined penetration depth
Data Source
AI summary
A process produces web sections from a flexible web material. The flexible web material is provided with tear-off lines at the distance of the length (L) of the web sections to be formed, which tear-off lines weaken the web material but do not bring about a complete separation of the web sections from the web material. The web sections are separated from the web material along the tear-off lines by tearing. The web material comprises a fabric made of small stretched plastic bands, and the tear-off lines are produced by laser beam processing.