Multilayer Bellows Using Core-Shell Multifilament Textile Fabric
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Solution Overview
Problem
Multi-layer articles like bellows face challenges with high rigidity and non-uniform thickness due to monofilaments, requiring complex calendering processes and excessive polymer coating, leading to increased weight and manufacturing difficulties.
Innovation Solution
The use of textile fabrics composed of multifilament yarns with a core/sheath structure and an additional elastomeric polymeric layer based on vulcanized rubber, eliminating the need for calendering and reducing stiffness, resulting in a lighter and easier-to-manufacture product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If monofilaments are used to stabilize carrier materials, then the structural stability is improved, but the rigidity increases making processing difficult and the fabric thickness becomes non-uniform
Solution Approach 1:
The patent changes the fundamental parameter of fiber structure from monofilament to multifilament with core/sheath configuration. This parameter change reduces fabric rigidity while maintaining stability, enabling easier processing without calendering and achieving uniform fabric thickness.
Solution Approach 2:
The patent employs composite fiber structures with core/sheath configurations where different materials provide different functions. The core provides structural stability while the sheath provides flexibility and uniformity, resolving the contradiction between stability and ease of manufacture.
2Strength
If monofilaments are used with high penetration, then structural integrity is maintained, but excessive polymer material is required increasing the overall weight
Solution Approach 1:
The patent changes the fiber configuration parameter from monofilament to multifilament core/sheath structure. This enables achieving structural integrity with reduced polymer coating thickness, thereby reducing the overall weight of the multi-layer article.
Solution Approach 2:
The core/sheath structure applies local quality differentiation where the core provides structural integrity and the sheath provides surface properties. This localized functional distribution reduces the need for excessive polymer material while maintaining structural integrity.
3Manufacturing precision
If calendering process is applied to achieve uniform thickness, then fabric uniformity is improved, but the manufacturing complexity and weight increase
Solution Approach 1:
The patent implements preliminary action by designing the multifilament core/sheath structure to inherently produce uniform fabric thickness during formation. This eliminates the need for subsequent calendering processes, reducing manufacturing complexity while maintaining precision.
Solution Approach 2:
The patent changes the fiber structure parameter to multifilament core/sheath configuration, which inherently provides uniform fabric formation without requiring calendering. This parameter change resolves the contradiction between manufacturing precision and device complexity.
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 approach simplifies the manufacturing process, reduces weight, and achieves uniform thickness and surface homogeneity, leading to fuel savings and reduced CO2 emissions, particularly in bellows for motor vehicles.
Implementation Method 1
an elastomeric material based on a vulcanized rubber compound which contains an uncut rubber component or a rubber component blend
Data Source
Figure 1~2
AI summary
Multilayer article comprises at least one fabric, preferably textile fabric which is constructed from at least one multifilament yarn comprising filaments (4) having a core or shell structure.