Continuous Mesh Moulding via Integrated Ring Opening
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Solution Overview
Problem
Traditional methods for manufacturing mesh using interlinking link elements are time-consuming, laborious, and expensive, with limited material options and size constraints, and lack an automated process for continuous production suitable for mass-market applications.
Innovation Solution
A method and apparatus for forming mesh through moulding interlinking link elements in a continuous process using a mould with multiple sections that interconnect link elements, allowing for the production of strong, aesthetically appealing mesh with economic viability for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to manufacture chain mail/mesh by interconnecting closed metal rings with open metal rings and then closing the open rings by mechanical deformation or welding, then the mesh can be formed, but the manufacturing process becomes time-consuming, labourious and expensive
Solution Approach 1:
The invention pre-opens the rings during the moulding process itself, rather than opening them separately in a subsequent step. The ring-opening feature is integrated into the mould, so that as the ring is being formed, it is automatically opened to the required degree. This preliminary action eliminates the need for separate opening operations and reduces overall manufacturing time and complexity
Solution Approach 2:
The invention combines multiple operations into a single moulding process: ring formation, ring opening, and interconnection all occur in one continuous operation. The mould integrates the ring-opening feature with the ring-forming cavity, allowing simultaneous creation of the ring structure and its opened state for interlinking, thereby merging what were previously separate manual steps into one automated process
2Ease of manufacture
If chain mail/mesh including unclosed link elements is used, then the link elements can be interconnected, but the mesh can only be exposed to limited forces before link elements fail
Solution Approach 1:
The invention applies different qualities to different parts of the ring: the majority of the ring maintains its closed, strong structure to provide overall strength and force resistance, while only a specific local portion (the ring-opening feature) is opened to enable interconnection. This localized opening preserves the structural integrity and strength of the ring while still allowing it to be linked with other rings
3Strength
If the interlinking link elements are closed to improve strength, then the joint may detract from the appearance of the finished mesh
Solution Approach 1:
The ring-opening feature is designed to be minimal and localized, affecting only a small portion of the ring while leaving the majority closed and aesthetically pleasing. The opened portion is sufficient for interconnection but small enough that it does not significantly detract from the overall appearance of the finished mesh product
4Ease of manufacture
If traditional manufacturing methods are used, then mesh can be produced, but there are limited materials that may be utilised and limited practical size of link elements
Solution Approach 1:
The invention replaces traditional mechanical manipulation methods (manual opening, bending, and connecting of metal rings) with a moulding process that can work with various materials including plastics, composites, and other non-traditional materials. This substitution of the manufacturing mechanism enables the use of diverse materials and a wider range of link element sizes that would be difficult or impossible to manipulate using conventional mechanical methods
Data Source
AI summary
A method of forming a mesh by a moulding a link element around other link elements to form a mesh in which the interlinking link elements are formed as continuous unjoined loops by a moulding process. An apparatus for forming a mesh including a plurality of first cavities for accommodating first link elements and a plurality of second cavities for forming interlinking link elements. The method and apparatus allow the continuous production of mesh formed of a range of materials including plastics materials.