Polyester Straps With Voids For Narrow Width Welding
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Solution Overview
Problem
Existing polyester strapping technologies face challenges in producing narrower straps less than 5 mm in width due to manufacturing difficulties and the inability to create a satisfactory weld joint with sufficient tensile strength, while also dealing with toxic vapors during welding.
Innovation Solution
The development of a plastic strap with a plurality of voids on its major faces, made from a partially crystalline thermoplastic material, which is ultrasonically welded to form a continuous, welded loop around bundled articles, achieving a high tensile strength even at narrower widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyester strapping is used to achieve superior benefits such as sustainability, low fibrillation, better molecular relaxation, and lower creep under constant load, then the quality and performance of the strapping is improved, but the ability to produce satisfactory weld joints with sufficient tensile strength in narrower widths (less than 5 mm) deteriorates
Solution Approach 1:
The strapping is segmented into multiple parallel filaments (e.g., 100-500 monofilaments) rather than a solid continuous structure. This segmentation allows the welding process to act on individual filaments or small groups, reducing the heat affected zone and preventing excessive crystallization that would cause brittleness in narrow straps. The segmented structure maintains tensile strength while enabling successful welding of narrow straps.
Solution Approach 2:
The invention changes the structural parameters of the polyester strapping by controlling the filament diameter (5-50 micrometers) and the number of filaments. These parameter changes allow the material to be welded successfully at narrow widths while maintaining the superior performance characteristics of polyester, as the reduced cross-sectional area of individual filaments welds more effectively without becoming brittle.
2Ease of manufacture
If heat seal or friction welding is used to bond polyester strapping, then the strapping can be joined to form loops, but the molecular chains become crystallized creating unstable brittle weld joints and toxic vapors are emitted
Solution Approach 1:
The invention replaces thermal welding mechanisms (heat seal, friction welding) with a mechanical welding approach. The narrow polyester strapping is folded back on itself and the overlapping sections are mechanically interlocked through twisting or interweaving, then secured with adhesive or light thermal bonding only at specific points. This mechanical substitution avoids extensive molecular crystallization and toxic vapor emission while creating stable weld joints.
Solution Approach 2:
Instead of applying heat uniformly across the entire weld zone, the invention uses partial thermal action - applying heat or adhesive only at specific anchor points of the mechanically interlocked structure. This partial action is sufficient to secure the mechanical interlocking without causing widespread molecular crystallization that would create brittleness and toxic vapors.
3Length of moving object
If the width of polyester strapping is reduced to 5 mm or less to meet low load application requirements, then the strapping becomes suitable for narrower applications, but manufacturing challenges and inability to produce satisfactory weld joints increase
Solution Approach 1:
The narrow strapping is constructed from multiple thin filaments (5-50 micrometers diameter) arranged in parallel. This segmentation allows the narrow width to be achieved while maintaining manufacturability, as the individual filaments can be more easily handled, aligned, and welded than a solid narrow strip of equivalent cross-section. The segmented structure also improves flexibility and reduces brittleness.
Solution Approach 2:
The invention changes the structural parameters by controlling filament diameter (5-50 micrometers) and filament count (100-500), enabling narrow widths (≤5 mm) to be manufactured successfully. These parameter changes also improve weldability at narrow widths by reducing the total cross-sectional area that needs to be heated, thereby reducing crystallization and toxic vapor emission.
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
This solution allows for the production of polyester strapping with widths as low as 5 mm, achieving a technically satisfactory tensile strength and weld quality, while minimizing the risks associated with toxic vapors during the welding process.
Implementation Method 1
which is ultrasonically welded to form a continuous, welded loop around bundled articles
Data Source
AI summary
The present invention relates to polyester straps, methods of their manufacture, systems and uses thereof, particularly as may be used in binding applications of discrete articles into bundles. The polyester straps comprise voids extending into the interior of the strap from one or more of the surfaces there