Self-Locking Film Structure for Industrial Textiles
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Solution Overview
Problem
Existing industrial textiles require a separate bonding process to join two film layers together, which is time-consuming and prone to inaccuracies, and do not inherently self-lock or interlock, leading to potential misalignment and lack of self-retention.
Innovation Solution
A film structure comprising two similarly profiled layers with protrusions and apertures that interlock when aligned, featuring a coplanar latching mechanism that allows the layers to snap together without additional bonding, providing a self-locking and self-retaining configuration while allowing for minor movements to accommodate internal strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate bonding process is used to join two film layers, then the layers can be securely connected, but the manufacturing time increases and alignment accuracy decreases
Solution Approach 1:
The film layers are designed with self-locking protrusions that automatically interlock when the layers are brought together, eliminating the need for external bonding processes. The protrusions on one layer fit into corresponding recesses on the other layer, creating a self-retaining connection that secures the layers without additional time-consuming bonding steps.
Solution Approach 2:
The protrusions and recesses are pre-formed during film manufacturing, so that when the film layers are assembled, the interlocking components are already in place and ready to engage. This preliminary preparation of joining features eliminates the need for separate bonding operations during assembly.
2Strength
If a separate bonding process is used to join two film layers, then the layers can be securely connected, but alignment accuracy decreases due to potential misalignment
Solution Approach 1:
The protrusions are designed with asymmetric geometries including tapered surfaces and complementary recesses that guide the relative positioning of the two film layers. The asymmetric shape of the protrusions ensures they can only engage in one correct orientation, automatically achieving precise alignment when the layers are assembled without requiring high-precision positioning equipment.
Solution Approach 2:
Instead of using precise alignment equipment to position the layers before bonding, the invention inverts the approach by designing the protrusions to self-align during assembly. The geometric constraints of the interlocking features automatically correct any minor misalignments, achieving precise positioning through the assembly process itself rather than through pre-alignment.
3Strength
If the film structure is made rigid to maintain structural integrity, then it resists compressive loading better, but it cannot accommodate internal strain
Solution Approach 1:
The film structure incorporates flexible elements and movable joints within the protrusion-recess assembly that allow the structure to dynamically adjust to internal strains. The protrusions can flex and the joints can rotate slightly, enabling the rigid-looking structure to accommodate dimensional changes and thermal expansion without compromising overall structural integrity or compressive resistance.
Data Source
AI summary
A profiled film structure, textiles comprising at least two layers of the structure, and methods of making the structure and textiles. Each film layer is profiled with regularly arranged protrusions, separated by planar land areas. Portions of at least one side wall of the protrusions are slit to create apertures extending through the film and top members forming coplanar latching means extending over the apertures. When the upper surface of a first layer of the film is brought into contiguous relationship with the upper surface of a second layer of the film, and the protrusions of each of the respective layers are aligned between adjacent protrusions of the other layer, the latching means of each layer are received and retained within the apertures of the opposing layer, resulting in an efficiently assembled self-locking structure having selectable permeability for fluid flow through the structure.