Flexible Composite With Tensioned Linking Elements for Dense Fill
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexible cloths face challenges in achieving high and constant fill density due to crushing of linking fibers during compaction, leading to poor structural support and material displacement, and require expensive, stiff preformed structures for effective powder loading.
Innovation Solution
A flexible composite with a first and second layer separated by a space, containing a settable powder fill material under pressure, and linking elements under tension, allowing the layers to bulge outward and maintain compaction, enabling high fill density and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rollers are used to compact the fill material after needling, then the packing density of the fill is increased, but the linking fibres are crushed and cannot support internal pressure
Solution Approach 1:
The patent applies preliminary action by needling the linking fibres into the fill material before compaction, establishing the fibre network in advance. The fibres are inserted through the fill material to create a three-dimensional structure that will later provide structural support after the fill sets and hardens, preventing the fibres from being crushed during subsequent compaction operations
Solution Approach 2:
The patent segments the compaction process from the fibre insertion process. Needling is performed first to insert linking fibres without compression, then compaction is applied separately to increase density. This segmentation allows each process to optimize its function without interfering with the other, maintaining fibre integrity while achieving high packing density
2Strength
If needling or stitch bonding is used to bond layers through fill material, then the layers are joined together, but the needle volume displaces powder and reduces fill density
Solution Approach 1:
The patent extracts the bonding function from the compaction process. Instead of combining bonding and compaction into a single operation that compromises density, the needling bonding is performed as a separate preliminary step, allowing the fill material to be compacted to maximum density afterward without the constraint of needle displacement
Solution Approach 2:
The bonding operation is performed in advance before compaction. The linking fibres are needled through the fill material to establish mechanical bonds between layers, and only after this preliminary bonding is complete is the compaction applied to maximize fill density without disrupting the already-established fibre network
3Ease of manufacture
If the flexible cloth is made stiff to maintain shape during powder loading, then powder can be loaded effectively, but the cloth becomes expensive and difficult to manufacture
Solution Approach 1:
The patent applies dynamics by making the fabric structure adaptable to different operational states. The fabric is designed with sufficient flexibility to be easily manufactured and handled, yet can maintain adequate shape during powder loading through the temporary application of vibration or airflow during the filling process, eliminating the need for permanently stiff preformed structures
Solution Approach 2:
The patent changes the physical parameters of the fabric temporarily during the loading process. Vibration or airflow is applied to assist powder loading, and these parameter changes enable effective filling without requiring the fabric to be permanently stiff or complex in structure, thus reducing manufacturing cost and 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 composite maintains high fill density and structural integrity during handling, transportation, and use, preventing fill material movement and ensuring consistent setting properties.
Implementation Method 1
The powder material is capable of setting to a rigid or semi-rigid solid mass on the addition of a liquid and may comprise cement that will set to solid cement or concrete on the addition of a water-based liquid
Data Source
Figure 1(a)~3(c)
Figure 4(a)~6(c)
Figure 7(a)~9(c)
AI summary
The present invention relates to a flexible composite that can be set to become rigid or semi-rigid, the composite comprising: a first layer; a second layer opposing the first layer and separated from the first layer by a space; a fill material located in the space between the first and second layers, which is capable of setting to a rigid or semi-rigid solid on the addition of a liquid, gas or radiation; a plurality of elements extending substantially into the space from the first layer and/or the second layer and which may pass through the opposing layer or join with other elements present in the space from an opposing layer, thereby forming linking elements for joining the layers together; and wherein the unset fill material is provided in the space at a pressure such that tension is applied one or more of the linking elements and to cause the first and/or second layers to bulge outwards relative to the longitudinal length of said one or more linking elements under tension.