Textile Fabric Sheet With Ultrasonic Welded Edges

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Solution Overview

Problem

Existing methods for fixing textile fabrics on profiles for stretched structures, such as false ceilings and walls, face issues with unreliable grip over time and the need for leveling, which complicates maintenance and replacement, leading to increased costs, management challenges, and environmental impact.

Innovation Solution

A flexible textile fabric sheet with attachment means welded to its peripheral edge using a material with a melting temperature lower than or equal to that of the attachment means, often made of thermoplastic fibers or coated with a fusion film, allowing for secure and easy assembly and disassembly through high-frequency welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If textile fabric is fixed on profiles by pinching or wedging, then the structure can be assembled, but the grip is not guaranteed over time and the fabric may unhook

Engineering Contradiction:

Improvegrip reliabilityVSAvoidfixing durability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical fixing systems (pinching, wedging, reeds, flexible lips) with ultrasonic welding, a thermal-field-based joining method. This substitution eliminates the grip reliability issues inherent in mechanical systems by creating a permanent fusion between the attachment means and the textile fabric through melting and bonding of thermoplastic materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention utilizes phase transitions of thermoplastic materials during ultrasonic welding. The attachment means and textile fabric (containing thermoplastic fibers or coating) undergo melting under ultrasonic vibration, then solidify to form a strong bond. This phase change mechanism ensures reliable and durable fixation that does not deteriorate over time like mechanical gripping systems.

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If the canvas is leveled once fixed to remove excess material, then the appearance is improved, but it is no longer possible to raise or replace the canvas

Engineering Contradiction:

Improvecanvas levelingVSAvoidcanvas replaceability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent segments the fixing process into two distinct phases: first, the attachment means are welded to the textile fabric along the peripheral edge to create a secure bond; second, the canvas can be easily raised or replaced by detaching the attachment means from the profile. This segmentation allows the canvas to maintain both precise positioning during installation and full replaceability during maintenance, eliminating the permanent fixation problem.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If smooth profiles with flexible lips are used to fix the canvas, then the structure is simple, but leveling is required and replacement is complicated

Engineering Contradiction:

Improveprofile structureVSAvoidmaintenance ease

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent replaces the mechanical gripping system of smooth profiles with flexible lips with an ultrasonic welding system. The attachment means are welded directly to the profile, eliminating the need for complex leveling operations and facilitating easy replacement by simply detaching the welded connection. This substitution maintains structural simplicity while dramatically improving maintenance ease.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a reliable and efficient attachment system that ensures a strong grip and easy maintenance of the textile fabric on profiles, allowing for quick reassembly and reducing environmental impact and costs associated with frequent replacements.

Implementation Method 1

said attachment means being welded to the textile fabric, along the peripheral edge of the latter, by means of a material with which the textile fabric is provided

Methodology Applied

Scientific EffectHigh-frequency welding: Welding

Implementation Method 2

The material with which the textile fabric is provided advantageously has a melting temperature lower than or equal to that of the material in which the attachment means are made so as to allow the fusion of the textile fabric with the attachment means during the welding operation

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

Methodology Applied

Scientific EffectPhase change (melting): Phase Change

Data Source

PatentEP3647507A1Sheet for producing a structure with stretched textile fabric, method for manufacturing such a sheet and false wall comprising such a sheet

Publication Date: 2020.05.06 NORMALU

AI summary

The invention relates to a fabric for the construction of a stretched fabric structure, such as a false ceiling, comprising a flexible textile fabric and means for attaching it to profiles provided for this purpose, said means for attaching it being welded to the textile fabric, along the peripheral edge of the latter, by means of a material with which the textile fabric is provided.