3D Composite Forming via Vacuum-Heated Adhesive Penetration

Solution Overview

Problem

Conventional methods for forming three-dimensional composites, such as shoe vamps, are complex and result in high production costs due to the need for cutting and sewing multiple connection sheets onto a shoe tree.

Innovation Solution

A method involving the use of flexible shaping members with orifices, pre-formed connection sheets with an adhesive layer, and a vacuum-heating process to adhere and integrate the sheets onto a mold, reducing fabrication complexity and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional cutting and sewing methods are used to form three-dimensional composite, then the connection sheets can be assembled onto the shoe tree, but the process becomes complicated and production cost increases

Engineering Contradiction:

Improveease of manufactureVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines multiple separate connection sheets into a single integrated sheet with multiple adhesive layers. This merging eliminates the need for cutting and sewing multiple separate sheets, simplifying the manufacturing process and reducing complexity while maintaining the ability to form complex three-dimensional shapes on the shoe tree

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection sheet is pre-formed with multiple adhesive layers at specific locations before the forming process. This preliminary preparation of adhesive positions allows for direct bonding to the shoe tree without requiring subsequent cutting and sewing operations, thereby reducing process complexity and improving ease of manufacture

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If conventional cutting and sewing methods are used to form three-dimensional composite, then the connection sheets can be assembled onto the shoe tree, but production cost increases

Engineering Contradiction:

Improveease of manufactureVSAvoidproduction cost

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines multiple separate connection sheets into a single integrated sheet with multiple adhesive layers. This merging eliminates the need for cutting and sewing multiple separate sheets, simplifying the manufacturing process and reducing complexity while maintaining the ability to form complex three-dimensional shapes on the shoe tree

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection sheet is pre-formed with multiple adhesive layers at specific locations before the forming process. This preliminary preparation of adhesive positions allows for direct bonding to the shoe tree without requiring subsequent cutting and sewing operations, thereby reducing process complexity and improving ease of manufacture

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple connection sheets are cut and sewn together, then the three-dimensional composite can be formed, but the fabrication process becomes time-consuming

Engineering Contradiction:

Improveforming precisionVSAvoidfabrication time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines multiple separate connection sheets into a single integrated sheet with multiple adhesive layers. This merging eliminates the need for cutting and sewing multiple separate sheets, simplifying the manufacturing process and reducing complexity while maintaining the ability to form complex three-dimensional shapes on the shoe tree

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection sheet is pre-formed with multiple adhesive layers at specific locations before the forming process. This preliminary preparation of adhesive positions allows for direct bonding to the shoe tree without requiring subsequent cutting and sewing operations, thereby reducing process complexity and improving ease of manufacture

Inventive Principle:

Principle #10Preliminary action

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 method enables the quick and cost-effective production of three-dimensional composites by securely bonding connection sheets onto shaping members using a vacuum-heating process, simplifying the manufacturing process and lowering production expenses.

Implementation Method 1

heating said each semi-finished product and vacuuming the cavity, wherein said semi-finished product in the cavity is heated until the adhesive layer of said each connection sheet melts

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the cavity is vacuumed so that the adhesive layer penetrates into said each shaping member

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS10131125B2Method of forming three-dimensional composite

Publication Date: 2018.11.20 CHAEI HSIN ENTERPRISE CO LTD

AI summary

A method of forming three-dimensional composite comprising steps of: (a) manufacturing at least one shaping member; (b) fitting each of the at least one shaping member on each of at least one mold; (c) adhering at least one connection sheet on said each shaping member so as to form each of at least one semi-finished product; (d) fixing said each semi-finished product in a cavity; and (e) heating said each semi-finished product and vacuuming the cavity. Said shaping member has at least one orifice and covers said each mold, and each connection sheet has a substrate and an adhesive layer, a melting point of the adhesive layer is less than the substrate. Said each semi-finished product in the cavity is heated until the adhesive layer melts, and the cavity is vacuumed so that the adhesive layer penetrates into said each shaping member, thus producing a three-dimensional finished product.