Injection-Molded Polyester Mesh for Strain Orientation
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Solution Overview
Problem
Conventional injection moulding techniques are unable to produce mesh articles with fine enough members for strain orientation, as they tend to break rather than strain orienting effectively, and laser cutting is a more expensive method for manufacturing large quantities.
Innovation Solution
A method of injection moulding a polymeric resin, specifically using a thermoplastic polyester elastomer like HYTREL, heated to at least 240°C, injected into a mould to form a mesh article with apertures between members, allowing for strain orientation by stretching and relaxing the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional injection moulding techniques are used to form mesh articles, then the manufacturing cost is reduced, but the members are too thick and cannot be effectively strain oriented
Solution Approach 1:
The patent changes the injection moulding parameters, specifically using a higher melt temperature (at least 240°C) than conventional techniques, to enable the formation of finer mesh members that are suitable for strain orientation while maintaining cost-effective injection moulding manufacturing
2Ease of operation
If injection moulding is used with recommended HYTREL conditions (225°C melt, 30-40°C mould), then the process is simple, but the mesh members break instead of strain orienting
Solution Approach 1:
The patent modifies the injection moulding parameters by increasing the melt temperature to at least 240°C and adjusting the mould temperature to between 40-80°C, which prevents member breakage during strain orientation while maintaining a relatively simple injection moulding process
Solution Approach 2:
The patent adds a post-moulding strain orientation step that stretches the formed mesh article, transforming the random polymer chain structure into an aligned structure, thereby achieving the desired material properties without changing the injection moulding process itself
3Manufacturing precision
If laser cutting is used to form mesh articles, then fine members suitable for strain orientation are achieved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent merges the mesh formation process with the injection moulding process by using a mould that directly forms the mesh structure, eliminating the need for separate laser cutting operations and achieving fine mesh members at lower manufacturing costs
Solution Approach 2:
The patent replaces the laser cutting mechanical system with an injection moulding system that uses molten polymer to directly form the mesh structure, providing a more cost-effective method for manufacturing large quantities of mesh articles with fine members
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 the production of mesh articles suitable for strain orientation, providing increased strength and elasticity, while maintaining cost-effectiveness compared to laser cutting methods.
Implementation Method 1
heating the resin to form a molten resin at a temperature of at least about 240° C.
Implementation Method 2
heating the resin to form a molten resin
Implementation Method 3
injecting the molten resin into a mould of a moulding apparatus to substantially fill the mould
Implementation Method 4
By stretching the article, the polymer chains become relatively aligned. That phenomenon is strain orientation. Strain orientation changes the material properties. Typically, the material becomes stronger and more elastic
Data Source
AI summary
A method of injection molding a polymeric resin to form an article that is suitable for strain orientation. A thermoplastic polyester elastomer polymeric resin is provided. The resin is heated to form a molten resin at a temperature of at least about 240° C. The molten resin is injected into a mold (22) to substantially fill the mold and form an article. At least part of the article is a sheet part with a plurality of members that are integrally formed into the sheet part, with apertures provided between at least some of the members of the sheet part of the article to form a mesh. At least the sheet part of the article is suitable for strain orientation.