Thermoplastic Wire Mesh Layer Interconnection
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Solution Overview
Problem
Existing multilayered woven meshes face challenges in reliably interconnecting their layers, particularly under high loads and stresses, which can lead to shifting or detachment of layers, compromising durability and filtration efficiency.
Innovation Solution
A wire mesh layer with thermoplastic connecting members that can be heated to interconnect with other woven layers or materials, providing a simple and reliable method to form multilayered products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a backing layer is added to support and protect the filter layer, then the stability and strength of the filter mesh is improved, but the complexity of interconnecting the layers becomes high and unreliable
Solution Approach 1:
The patent applies parameter changes by utilizing the thermal properties of thermoplastic materials in the connecting members. By changing the temperature parameter (heating), the thermoplastic material transitions from a rigid state to a softened state, enabling it to deform and interconnect layers. This resolves the contradiction by providing a simple heating-based connection method instead of complex mechanical interconnection systems.
Solution Approach 2:
The patent employs phase transitions of the thermoplastic material in the connecting members. When heated, the thermoplastic material undergoes a phase transition from solid to softened/melted state, allowing it to flow and bond the filter layer and backing layer together. Upon cooling, it returns to solid state, providing strong mechanical interconnection. This phase transition mechanism simplifies the connection process while ensuring reliable layer stability under load.
2Manufacturing precision
If the warp wires and weft wires are made of fine material for narrow-meshed filtration, then the filtration precision is improved, but the stability and durability of the mesh decreases
Solution Approach 1:
The patent applies composite materials by combining fine warp wires and weft wires for filtration with thicker, more robust connecting members containing thermoplastic material. The connecting members act as composite elements that provide both mechanical strength to support the fine filtration wires and the functional property of thermal deformability for connection. This composite approach resolves the contradiction by allowing fine wires to maintain filtration precision while the composite connecting members provide the necessary stability and durability.
3Ease of manufacture
If the connecting members are made with thermoplastic material to enable simple heating-based connection, then the ease of manufacture is improved, but the manufacturing precision required for thermal processing increases
Solution Approach 1:
The patent applies preliminary action by pre-integrating the thermoplastic connecting members into the wire mesh structure during the weaving process. The connecting members are incorporated as integral parts of the mesh before the thermal connection process. This preliminary integration simplifies the overall manufacturing by eliminating separate attachment steps and reduces the precision requirements for thermal processing, as the thermoplastic material is already positioned correctly within the mesh structure.
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 enables a strong, durable, and reliable connection between woven layers, enhancing the stability and performance of multilayered woven meshes in various applications, including filtration and architecture.
Implementation Method 1
warming up or heating up the thermoplastic connecting member allows to attach, or interconnect, a number of woven layers to, respectively with, one another
Data Source
AI summary
A wire mesh layer, including warp wires and weft wires, wherein the warp wires and the weft wires form woven meshes and open up a woven surface. A connecting member is provided, which includes a thermoplastic material. The multilayered product is provided having such a wire mesh layer and a further layer, wherein the wire mesh layer and the further layer are connected by the thermally deformed connecting member. In a method of manufacturing such a multilayered product, the wire mesh layer and the further layer are placed on top of one another in a predetermined orientation. Due to the thermal deformation of the thermoplastic material of the connecting member, the wire mesh layer and the further layer will be interconnected.