3D Printed Padding With Interlocking Open Cells
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Solution Overview
Problem
Conventional padding technologies for protective wear face issues such as 'hardening of edges' during manufacturing, high production costs, hazardous waste generation, high CO2 consumption, adhesive deterioration, reduced elasticity, heat retention, skin irritation, and difficulty in achieving varying load-bearing zones, leading to comfort and performance issues.
Innovation Solution
A 3D printing method using a microarchitecture of superimposed matrices with individual open cells shaped like truncated pyramids or cones, eliminating the need for adhesives and optimizing material usage to create padding with variable thickness and hardness zones, enhancing environmental sustainability and user comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the padding perimeter is joined with another material by stitching or thermoforming, then the padding is anchored and structurally reinforced, but the edges harden and create discomfort for the user
Solution Approach 1:
The padding is divided into multiple modular elements (first padding element, second padding element, etc.) that can be separately manufactured and then assembled. This segmentation allows each element to be optimized independently and joined through interlocking features rather than traditional edge joining methods, preventing edge hardening while maintaining structural reinforcement.
Solution Approach 2:
The padding elements feature nested interlocking structures where protruding portions of one element fit into recessed portions of adjacent elements. This nesting mechanism provides structural reinforcement through internal interlocking rather than external joining, eliminating the need for edge stitching or thermoforming that causes hardening.
2Object-affected harmful factors
If polyurethane foam is used for the padding, then the padding provides cushioning and protection, but it generates hazardous waste, consumes CO2, and has high production and transport costs
Solution Approach 1:
The padding elements utilize porous structures that provide cushioning and protection through their cellular architecture. This porous design maintains the protective function while using less material and enabling better breathability, reducing the environmental impact associated with traditional polyurethane foam production and disposal.
Solution Approach 2:
The invention employs composite material structures combining different padding elements with varying densities and properties. This allows optimization of protective performance while reducing overall material consumption and enabling the use of more environmentally friendly materials compared to traditional polyurethane foam.
3Strength
If the padding uses adhesives or film adhesives for joining, then the padding is anchored to the product, but the adhesives deteriorate with washing and use causing delamination
Solution Approach 1:
The padding system is segmented into multiple elements joined through mechanical interlocking features (protruding and recessed portions) rather than adhesives. This eliminates the reliability issue of adhesive deterioration while maintaining strong anchoring through the interlocking mechanism that withstands washing and use.
Solution Approach 2:
The invention replaces the chemical bonding system (adhesives) with a mechanical bonding system (interlocking protruding and recessed portions). This mechanical connection method provides durable anchoring that does not deteriorate with washing and use, solving the reliability problem inherent in adhesive-based joining.
4Ease of operation
If the padding material absorbs water or sweat, then it provides comfort during use, but it is difficult to dry and retains moisture over time
Solution Approach 1:
The padding elements utilize porous materials that manage moisture effectively by allowing rapid absorption during use for comfort, then facilitating quick evaporation and drying when exposed to air. The porous structure enables both comfort during wear and rapid drying afterward, resolving the time loss issue.
Solution Approach 2:
Different regions of the padding elements have optimized local properties - areas in contact with the body have moisture-absorbing characteristics for comfort, while external surfaces have enhanced breathability and drying characteristics. This local quality differentiation allows the padding to provide comfort during use while minimizing drying time.
5Strength
If the padding zones have varying load-bearing capacity through different foam density or thickness, then specific protection areas are achieved, but the wearability and comfort are worsened
Solution Approach 1:
The padding is segmented into multiple elements with different densities and thicknesses optimized for specific protection zones. Each element can be independently designed with appropriate load-bearing characteristics, and when assembled, they provide zoned protection without compromising overall wearability, as each segment contributes only where needed.
Solution Approach 2:
Different zones of the padding system have locally optimized properties - higher density and thickness in areas requiring impact protection, lower density in areas requiring flexibility and comfort. This local quality approach achieves varying load-bearing capacity while maintaining excellent wearability, as each region is optimized for its specific function.
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 method produces padding with consistent protection and comfort over time, reducing waste, maintaining elasticity, and improving breathability, weight, and wearability while eliminating adhesive-related issues and heat retention, at a lower cost.
Implementation Method 1
it uses 3D printing by depositing a filament according to a microarchitecture that entails the definition of superimposed matrices
Implementation Method 2
a structure composed of individual open cells, which are mutually connected
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for providing a padding (1) which uses 3D printing by depositing a filament (2) according to a microarchitecture that entails the definition of superimposed matrices that are adapted to define a structure composed of individual open cells (6), which are mutually connected and arranged mutually opposite and side by side. The open cells (6) each have a shape in plan view with a variable diameter which is obtained by way of superimposing elements that are substantially shaped like a truncated pyramid or like a truncated cone with a polygonal base.