Mesh Cushion Extrusion With Variable Cross-Section and Density Control
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Solution Overview
Problem
Existing methods for manufacturing mesh cushions face challenges in creating a consistent and variable cross-sectional shape, particularly in forming filaments into a mesh structure with controlled thickness and density.
Innovation Solution
A system comprising an extruder subsystem, environmental control subsystem, material handling subsystem, and control subsystem is used to extrude filaments, control environmental conditions, and manipulate the rollers to form a mesh cushion with a variable cross-sectional shape by rotating rollers with recesses and end plates, and adjusting filament density through die plate configurations and robotic manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional extrusion methods are used to manufacture mesh cushions, then the manufacturing process is simple, but the cross-sectional shape consistency and variable density control are poor
Solution Approach 1:
The patent employs dynamic roller systems with adjustable recesses that can be modified during operation to change filament compression and mesh density. The rollers incorporate movable components that allow real-time adjustment of the extrusion parameters, enabling variable cross-sectional shapes and density distributions throughout the mesh cushion structure.
Solution Approach 2:
The die plate and roller systems are designed with locally varied geometries, including non-uniform recess patterns and variable opening sizes, that create different compression forces and filament arrangements in different regions of the mesh cushion. This enables controlled variation in mesh density and mechanical properties across different zones of the final product.
2Manufacturing precision
If rollers with recesses are used to form variable cross-sectional shapes, then the mesh cushion density and shape control are improved, but the device complexity increases
Solution Approach 1:
The roller system is divided into multiple independent rollers, each with specific recess configurations that perform distinct functions in the filament forming process. The die plate is also segmented into multiple opening patterns that work in combination with the rollers to create the desired mesh structure through cumulative effect rather than requiring a single complex component.
Solution Approach 2:
The rollers serve multiple functions: they guide the extruded filaments, apply compression forces, create the mesh pattern, and control filament spacing. The same roller components that shape the cross-section also influence the density distribution, eliminating the need for separate mechanisms for shape and density control.
3Manufacturing precision
If environmental control subsystems are added to manage extrusion conditions, then the manufacturing precision and consistency are improved, but the device complexity and cost increase
Solution Approach 1:
The environmental control functions (temperature regulation, humidity control, contamination prevention) are integrated into the existing extrusion system architecture rather than added as separate standalone systems. The control subsystem communicates with and coordinates the roller mechanisms and die plate configurations, creating a unified system where environmental management and mechanical forming work together seamlessly.
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 system effectively produces a mesh cushion with a variable cross-sectional shape and controlled thickness and density, enhancing the manufacturing process's precision and consistency.
Implementation Method 1
extruding a material through a plurality of filament forming openings in a die plate to form a plurality of filaments
Implementation Method 2
The first roller and the second roller may be rotated to direct the filaments into the first recess and the second recess and through a gap that is located between the first roller and the second roller
Data Source
AI summary
A method of making a mesh cushion. The method includes extruding a material through a plurality of filament forming openings in at least one die plate to form a plurality of filaments. The filaments may be at least partially submerged into a fluid to cool and harden the filaments into the mesh cushion.