Sealed Film Expandable Structure Without Primary Folding
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Solution Overview
Problem
The manufacturing of expandable structures, such as accordion bags, is cumbersome and expensive due to the need for primary folding processes, which slows down production and increases costs.
Innovation Solution
A method involving the joining and sealing of sheets with a concertina pattern, allowing for the creation of expandable structures that can be inflated and form a rectangular shape with minimal or no folding steps, enabling efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If primary folding processes are used to manufacture expandable structures, then the structures can be formed into accordion shapes, but the manufacturing process becomes cumbersome and production speed decreases
Solution Approach 1:
The concertina pattern is pre-cut into the flat sheets of material before sealing, so that when the sheets are inflated, the pre-formed pattern automatically creates the accordion shape without requiring separate folding operations during manufacturing
Solution Approach 2:
The manufacturing process is segmented into distinct operations: cutting the concertina pattern, sealing the sheets together, and then inflating. This separates the shape-forming action (inflation) from the structure-creation action (cutting and sealing), allowing more efficient production
2Shape
If primary folding processes are used to manufacture expandable structures, then the structures can be formed into accordion shapes, but manufacturing costs increase
Solution Approach 1:
The concertina pattern is pre-cut into the flat sheets of material before sealing, so that when the sheets are inflated, the pre-formed pattern automatically creates the accordion shape without requiring separate folding operations during manufacturing
Solution Approach 2:
The inflation process itself serves the dual function of both filling the structure with air/fluid and simultaneously forming the accordion shape through the pre-cut concertina pattern, eliminating the need for separate folding machinery and operations
3Manufacturing precision
If multiple layers of heatsealable material are sealed at different temperatures in discrete steps, then sealing precision is improved, but manufacturing time increases
Solution Approach 1:
Multiple sealing operations that would traditionally be performed in discrete steps at different temperatures are merged into a single continuous sealing process, maintaining precision while reducing the time lost between sequential 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
This method allows for the efficient and cost-effective manufacturing of expandable structures that can be stored in a flat form and provide support when inflated, with the ability to create multiple inflation zones and fluid communication between cells, enhancing versatility and functionality.
Implementation Method 1
joining together a first and second sheet of material with a seal along the lengths of the sheets; joining at least a portion of the periphery of a third sheet of material to at least a portion of the periphery of the first sheet; joining at least a portion of the periphery of a fourth sheet of material to at least portion of the periphery of the second sheet
Implementation Method 2
The expandable structure is adapted to be inflated with a fluid so that the sheets form a generally rectangular shape having a concertina pattern on its sides
Data Source
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AI summary
An expandable structure is manufactured using sheets of thermoplastic material sealed together. The expandable structure has a concertina pattern on its sides that allows the structure to expand and collapse like an accordion. The concertina pattern is cut into the sheets of material rather than being folded into the material to speed up the manufacturing process.