Overmolded Chain-Strand Running Net for Automated Skid Protection
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Solution Overview
Problem
The production of running nets for skid protection devices is cumbersome, inefficient, and often not automatable, leading to high costs due to the need for numerous manual steps in manufacturing.
Innovation Solution
A method involving inserting chain strands into mold cavities and overmolding them with plastic to create a stable bond, allowing for automated production and easy material adaptation, using processes like multi-component overmolding and modular mold designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used for running nets, then multiple manual steps are required to join individual parts, but the production process becomes cumbersome, inefficient, and expensive
Solution Approach 1:
The patent combines multiple manufacturing steps (inserting chain strands, positioning, joining, and plastic body formation) into a single integrated injection molding process. The mold cavity is designed to accommodate multiple chain strands simultaneously, and the injection molding operation performs all joining and forming operations in one cycle, eliminating the need for separate manual assembly steps.
Solution Approach 2:
The injection molding process serves multiple functions simultaneously: it acts as a joining process for connecting chain strands, a forming process for creating the plastic body, and a positioning process for precise chain strand placement. This multi-functionality eliminates the need for separate dedicated processes for each operation.
2Extent of automation
If traditional manual assembly methods are used to join individual parts, then the running net can be manufactured, but the process is not automatable and requires numerous manual steps
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated injection molding process. The injection molding machine automatically inserts chain strands into the mold cavity, positions them according to the desired pattern, and forms the plastic body that joins them, all through automated mechanical and thermal processes controlled by a computer system.
Solution Approach 2:
The patent utilizes changes in material parameters (plastic material from solid granules to molten state to solidified form) and process parameters (temperature, pressure, injection rate) to enable automation. The controlled parameter changes allow the material to flow around and join the chain strands automatically, then solidify to create the final structure.
3Productivity
If multiple individual parts are joined together to form running nets, then the required structure can be achieved, but the production becomes expensive and inefficient
Solution Approach 1:
The patent segments the mold cavity into multiple zones, each accommodating specific chain strands or groups of chain strands. This segmentation allows for efficient organization and joining of multiple chain strands in a systematic manner, while still producing the complete running net structure in a single operation.
Solution Approach 2:
The patent embeds multiple chain strands within a single plastic body that is formed in one injection molding operation. The plastic material surrounds and integrates the chain strands, creating a nested structure where the chain strands are contained within and joined by the continuous plastic body, eliminating the need for separate joining operations.
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
Enables cost-effective and efficient production of durable running nets by automating the manufacturing process and allowing for various material combinations, resulting in a stable and efficient anti-slip device.
Implementation Method 1
Overmolding the chain strand creates a stable and durable bond between it and the plastic body
Data Source
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Figure 10~11
AI summary
The invention relates to a method (1) for producing at least one section (2) of a running net (4) of a skid protection device for a land vehicle, comprising at least one chain strand (6) embedded in a plastic body (10), and comprising the method steps of: inserting the chain strand into a mold cavity (8) spatially corresponding to the plastic body; and overmolding the chain strand in the mold cavity with plastic at least in sections to form the plastic body. The invention further relates to a running net produced by this method and to a device for producing a running net of a skid protection device for a land vehicle. With the method and the device according to the invention, a durable running net for a skid protection device can be produced cost-effectively and efficiently.