Ribbon Meshwork with Thermoplastic Bonding Layer
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Solution Overview
Problem
Existing meshworks made of knitted fabrics with thermoplastic ribbons suffer from high production effort and unavoidable thick places at knot points, which impair their strength and handling properties.
Innovation Solution
A meshwork design featuring ribbons intersecting in groups, fixed between two cover layers with a thermoplastic bonding layer and a carrier layer of higher tensile strength, eliminating the need for knitting and preventing thick places by using high-density polyethylene ribbons and co-extruded films for dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If knitted fabric with thermoplastic ribbons is used to form meshworks, then the meshwork can be formed with interconnected ribbons, but thick places occur at knot points which impair strength and handling properties
Solution Approach 1:
The invention extracts and eliminates the problematic knot points from the meshwork structure. Instead of knitting ribbons together which creates thick places, the patent uses a lay-in technique where ribbons are positioned flat against each other and fixed between cover layers, completely removing the source of thick places while maintaining the mesh structure
Solution Approach 2:
Instead of forming the meshwork by knitting ribbons together (traditional approach), the invention inverts the approach by first positioning ribbons flat and then fixing them between cover layers. This reversal of the formation process eliminates thick places at connection points while maintaining structural integrity
2Ease of manufacture
If knitted fabric structure is used for meshwork, then ribbons can be interconnected, but production effort becomes excessively high
Solution Approach 1:
The invention segments the meshwork formation into distinct components: ribbons laid in crosses, cover layers with bonding layer, and carrier layer. This segmentation allows each component to be prepared and positioned independently, simplifying the overall production process compared to traditional knitting methods
Solution Approach 2:
The cover layers with thermoplastic bonding layer serve as an intermediary mechanism to fix the ribbons in their mutual position. This intermediary approach simplifies the fixing process compared to traditional knitting, allowing ribbons to be secured without complex interlacing operations
3Stability of the object's composition
If ribbons are fixed between cover layers with thermoplastic bonding layer, then ribbons are secured in mutual position, but residual shrinkage or expansion may occur during thermal treatment
Solution Approach 1:
The invention carefully selects and coordinates the melting temperatures of different components: the thermoplastic bonding layer has a lower melting temperature than the ribbons themselves. This parameter differentiation ensures that during hot pressing, the bonding layer melts and secures the ribbons without deforming them, maintaining dimensional stability while preventing residual shrinkage or expansion
Solution Approach 2:
The meshwork employs a composite structure with ribbons made of high-density polyethylene and cover layers containing thermoplastic bonding material. This composite approach allows each material to perform its specific function: ribbons provide structural integrity while the bonding layer provides fixation, resulting in a stable final product with minimal dimensional change
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 simplifies production, reduces residual shrinkage, and enhances strength by ensuring ribbons are fixed in a non-displaceable manner, maintaining mesh character and stability with minimal thickness and expansion.
Implementation Method 1
the bonding layer which ensures a molten connection or hot sealing of the two cover layers as well as the cover layers and the interposed ribbons during hot pressing of the meshwork
Implementation Method 2
which layers are connected with each other via the bonding layer and with the ribbons (1, 2)
Data Source
AI summary
A meshwork made of ribbons (1, 2) is described which are connected with each other by way of a thermoplastic filler material. In order to provide simple constructional conditions it is proposed that the ribbons (1, 2) which are laid in at least two groups and intersect one another in groups are fixed between two cover layers (3, 4) with respect to their mutual position, which layers have an at least two-layer configuration with a bonding layer which faces the ribbons (1, 2) and is made of a thermoplastic material and with a carrier layer having a higher tensile strength, which layers are connected with each other and with the ribbons (1, 2) by way of the bonding layer.