Open Mesh Bags Using Composite Filaments for Dimensional Stability
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Solution Overview
Problem
Traditional open mesh materials used in bags lack dimensional stability, are weak, and are costly to manufacture, with limited application due to variations in material properties and high weight per area.
Innovation Solution
A method of producing form fill and seal bags using open mesh materials with composite filaments that intersect and are thermally bonded, providing a low mass per unit area and high strength-to-mass ratio, ensuring dimensional stability and reduced carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional open mesh materials are used in bags, then manufacturing cost is reduced and ease of manufacture is improved, but dimensional stability deteriorates and strength decreases
Solution Approach 1:
The patent applies composite materials by combining a base mesh material with a coating layer containing bonding agents. This composite structure provides both the cost-effectiveness and ease of manufacture of traditional mesh materials while adding dimensional stability through the coating that bonds to the mesh and resists stretching and bulging under load.
2Ease of manufacture
If traditional open mesh materials are used in bags, then manufacturing cost is reduced and ease of manufacture is improved, but strength deteriorates
Solution Approach 1:
The composite structure with coating layer reinforces the base mesh material, providing enhanced strength while maintaining the cost advantages of the traditional mesh. The coating layer acts as a strengthening agent that distributes and reinforces the structural integrity of the bag.
Solution Approach 2:
The patent modifies the surface properties of the mesh material by applying a coating layer with specific bonding agents. This parameter change in surface chemistry and structure enhances the overall strength of the material without fundamentally changing the base mesh construction, thereby maintaining manufacturing simplicity.
3Stability of the object's composition
If heavier materials are used to improve dimensional stability and strength, then dimensional stability is improved and strength is improved, but weight per area increases
Solution Approach 1:
The patent uses a thin coating layer applied to the mesh material to provide dimensional stability and strength enhancement. This thin film approach achieves the desired mechanical properties without the weight penalty of using substantially heavier materials, as the coating layer is sufficiently thin to minimize added mass while effectively performing its reinforcing function.
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 results in bags with improved dimensional stability, reduced material usage, and lower production and handling costs, while maintaining high strength and durability.
Implementation Method 1
the bonding portion of each composite filament being thermally bonded to other filaments at at least some points of intersection
Data Source
AI summary
A method is provided of making form fill and seal (FFS) bag formed at least in part from an open mesh material that includes filaments that intersect one another. At least some of the filaments are composite filaments having a carrier portion of a relatively high melting point and a bonding portion of a relatively low melting point, the bonding portion of each composite filament being thermally bonded to other filaments at points of intersection. The material may be a non-woven fabric that contains at least two layers of weft filaments that may be bordered on one or both sides by a layer of warp filaments. When compared to other open mesh materials, the open mesh material disclosed herein has a superior combination of some or all of high strength, light weight, high dimensional stability, and openness.