PET Cellular Confinement with Injection Molded Fixing Components
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Solution Overview
Problem
The existing cellular confinement systems face issues with corrosion and limited service life due to metal connecting pieces, and they have relatively low weld strength, which affects their strength and durability in practical use.
Innovation Solution
A cellular confinement system using PET sheets with honeycomb-shaped cells and injection molded fixing components, including a rod and fixing plates, to provide strong connections and prevent disengagement, while maintaining high-temperature resistance and secure bonding through the conversion of liquid plastic into solid components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal connecting pieces are used to connect PET sheets, then connection strength is improved, but corrosion resistance deteriorates and service life is reduced
Solution Approach 1:
The patent removes metal connecting pieces from the cellular confinement system and replaces them with injection-molded plastic fixing components that are integrated directly into the PET sheets. This extraction of harmful metal elements eliminates corrosion while maintaining connection strength through the molded-in-place plastic fasteners.
Solution Approach 2:
The patent uses a composite construction where PET sheets are combined with injection-molded plastic fixing components. This composite approach allows the system to achieve both the strength needed for connection and the corrosion resistance required for long service life, as neither material degrades through corrosion like metal would.
2Reliability
If welding is used to connect PET sheets without metal pieces, then corrosion resistance is improved, but weld strength is insufficient
Solution Approach 1:
The patent replaces the welding process with an injection molding process. Instead of attempting to weld PET sheets directly, the system uses injection-molded plastic fixing components that are formed under pressure and locked into place mechanically. This substitution provides sufficient connection strength without the weaknesses of welding thermoplastic materials.
Solution Approach 2:
The patent changes the connection method from thermal welding to mechanical injection molding. By changing the parameters of the connection process—from applying heat and pressure for welding to injecting molten plastic under controlled pressure and cooling—it achieves superior connection strength and reliability without the limitations of welding PET materials.
3Reliability
If injection molding process is used to connect PET sheets, then connection strength and corrosion resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the PET sheet manufacturing process with the connection component manufacturing process. The injection-molded fixing components are created in the same production line as the PET sheets themselves, eliminating the need for separate assembly steps. This integration reduces manufacturing complexity despite the advanced connection technology.
Solution Approach 2:
The patent incorporates the fixing components directly into the PET sheets during the sheet manufacturing process itself. By performing the connection preparation in advance—molding the fixing components as part of the sheet production—the system eliminates subsequent assembly steps and reduces overall manufacturing 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
The solution enhances the overall strength and extends the service life of the cellular confinement system by providing secure connections that resist corrosion and high-temperature degradation, while maintaining a cost-effective and simple manufacturing process.
Implementation Method 1
The step 3) includes: 31) injecting molten plastic into each of the connecting holes by using a plastic injection molding machine to form a injection molded rod; 32) injecting the molten plastic to two ends of the injection molded rod by using the plastic injection molding machine to form fixing plates each at a corresponding end of the injection molded rod
Data Source
AI summary
A cellular confinement system includes PET sheets and honeycomb-shaped cells formed by intercrossing the PET sheets. A connecting hole is provided at a joint where the PET sheets are intercrossed. An injection molded fixing component for connecting the PET sheets is provided at the connecting hole. The injection molded fixing component includes an injection molded rod arranged in the connecting hole and fixing plates each arranged to be fixedly connected to a corresponding end of two ends of the injection molded rod. The fixing plates each fits against a side wall of a corresponding PET sheet. The injection molded fixing component includes the injection molded rod and the fixing piece. The injection molded rod is configured to connect the PET sheets at the joint where the PET sheets are intercrossed. The fixing plate is configured to prevent the PET sheets from being disengaged from the injection molded rod.