Thermoplastic Elastomer Sheet for Punching Tape Wear Resistance
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Solution Overview
Problem
Existing sheet materials used in punching and stamping applications lack durability and longevity, often requiring frequent replacement due to wear and tear, and do not effectively combine the necessary properties of wear resistance and support.
Innovation Solution
A sheet material composed of 10-50% random-oriented fibers and 90-50% thermoplastic or thermoplastic elastomer, with uniform fiber distribution and zero residual gas content, providing enhanced support and wear resistance through a manufacturing process involving layered composites bonded by heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional punching tapes use woven fabrics with polyurethane coating, then they provide basic support and wear resistance, but they lack durability and require frequent replacement
Solution Approach 1:
The invention uses a composite material consisting of thermoplastic elastomer as the continuous phase and random-oriented fibers as the reinforcing phase. This composite structure combines the elasticity and wear resistance of the thermoplastic elastomer with the strength and dimensional stability of the fibers, creating a punching tape that is significantly more durable than conventional woven fabric-based tapes. The random orientation of fibers in three dimensions provides uniform strength in all directions, preventing the directional weakness inherent in woven structures.
2Strength
If punching tapes use traditional materials, then they provide basic support function, but they do not effectively combine wear resistance and support properties
Solution Approach 1:
The invention creates different local properties within the punching tape material. The thermoplastic elastomer matrix provides elasticity, shock absorption, and wear resistance, while the embedded fiber network provides tensile strength and structural support. This local differentiation of functions within the composite material allows the tape to simultaneously exhibit both superior wear resistance and exceptional support capability, resolving the contradiction between these two properties.
3Ease of manufacture
If conventional punching tapes are used, then they can be manufactured with standard processes, but they lack the ability to regenerate and extend operational life
Solution Approach 1:
The invention utilizes the thermoplastic nature of the elastomer matrix, which allows the material to change its physical state with temperature. When heated above its melting point, the thermoplastic elastomer becomes moldable, enabling the punching tape to be regenerated by melting and re-forming worn surfaces or damaged areas. This parameter change (from solid to molten state and back) provides a simple regeneration process that extends the operational life of the tape without requiring complex manufacturing procedures.
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 sheet material significantly increases the service life of punching tapes and supports by offering improved mechanical resistance and the ability to regenerate, extending its operational life up to 2-3 years compared to conventional materials which typically last 6 to 12 months.
Implementation Method 1
bonding the two layered composites together by heat and pressure at a temperature at which the thermoplastic or thermoplastic elastomer melts
Implementation Method 2
bonding the two layered composites together by heat and pressure
Data Source
AI summary
A sheet material (1) consisting of an mixture consisting essentially of: a) 10-50 percent by weight of random-oriented fibres, and; b) 90-50 percent by weight of a thermoplastic or thermoplastic elastomer; the weight percentages being based on the overall homogeneous mixture; and the sheet material having at room temperature a Shore D hardness of 40 to 85, preferably of 40 to 60, more preferably of 45 to 55. The sheet material (1) is used as a support in punching applications or as the top layer in punching belts (2).