3D Net Structure Manufacturing via Haul-off and Cooling Control
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Solution Overview
Problem
Conventional methods for manufacturing three-dimensional net-like structures, such as those used in mattresses and cushions, face challenges in achieving precise dimensional accuracy and surface smoothness while maintaining flexibility, and require adjustments in repulsion and cooling water management to prevent filament sticking.
Innovation Solution
A manufacturing apparatus and method involving a nozzle with extrusion holes arranged in a rectangular shape, inclined chutes for filament guidance, and haul-off machines with adjustable speed, along with cooling water supply to form tangled filaments, allowing for improved surface smoothness and dimensional accuracy by controlling the distance between haul-off machines and chutes, and optimizing the distribution of filaments for bulk density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between haul-off machines is reduced to improve dimensional accuracy, then manufacturing precision improves, but the complexity of the manufacturing apparatus increases
Solution Approach 1:
The manufacturing apparatus is divided into distinct functional modules: a nozzle assembly for extrusion, adjustable haul-off machines for tensioning, and cooling water supply systems. This segmentation allows independent optimization of each component to achieve precise dimensional control without requiring complete redesign of the entire system.
Solution Approach 2:
The haul-off machines are designed with adjustable speed and position capabilities, allowing dynamic modification of the distance between them during operation. This enables precise control of filament assembly dimensions while maintaining manufacturing flexibility and reducing apparatus complexity through programmable adjustment rather than fixed rigid structures.
2Manufacturing precision
If cooling water supply is increased to prevent filament sticking, then manufacturing precision improves, but energy consumption increases
Solution Approach 1:
Cooling water is supplied selectively to specific regions where filaments are most prone to sticking, rather than uniformly across the entire extrusion zone. This localized cooling approach prevents filament adhesion while minimizing overall water consumption and associated energy requirements for water circulation and temperature control.
Solution Approach 2:
The system dynamically adjusts cooling water flow rates and temperatures based on real-time manufacturing conditions, allowing optimization of the cooling effect to prevent filament sticking only when and where necessary, thereby reducing total energy consumption compared to continuous maximum cooling.
3Manufacturing precision
If haul-off speed is reduced to improve repulsion, then product quality improves, but productivity decreases
Solution Approach 1:
The haul-off machines operate with variable speed cycles, alternating between higher speed phases for productivity and lower speed phases for quality enhancement. This periodic variation in haul-off speed allows the system to maintain high overall productivity while periodically achieving the reduced speed necessary for improved repulsion and product quality.
Solution Approach 2:
The haul-off speed is made dynamically adjustable rather than fixed, allowing the system to optimize the balance between productivity and repulsion quality based on real-time conditions. The system can rapidly transition between speed levels to maintain both high output and high quality without compromising either parameter.
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 solution enables the production of three-dimensional net-like structures with enhanced repulsion, dimensional accuracy, and surface smoothness, reducing material usage and improving product durability and comfort, while allowing for various product specifications and shapes.
Implementation Method 1
a nozzle arranged to have a plurality of extrusion holes arrayed in an approximately rectangular shape and configured to drop downward a thermoplastic synthetic resin in a molten state extruded from the extrusion holes
Implementation Method 2
a water supplier located above the long chutes to supply cooling water to the inclined surfaces
Implementation Method 3
the plurality of filaments are tangled at random and thermally adhere to one another at the tangles to form a three-dimensional net-like structure
Data Source
AI summary
A manufacturing apparatus of three-dimensional net-like structure includes: a nozzle with a plurality of extrusion holes that are arrayed to extrude and drop downward a thermoplastic synthetic resin in a molten state and thereby form a filament assembly of a plurality of filaments; a pair of chutes arranged across longitudinal faces of the filament assembly to have inclined surfaces that are sloped toward the filament assembly and opposed to each other across a distance that is less than a short side length of the array of the extrusion holes; water supply ports arranged to supply cooling water to the inclined surfaces; and a pair of haul-off machines configured to have endless belts arranged to be in contact with the longitudinal faces of the filament assembly and haul off the filament assembly and opposed to each other across a less distance than the distance between the pair of chutes.