3D-Printed Padding with Multi-Plane Void Structure
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Solution Overview
Problem
Existing paddings for sports gear, such as chamois and gloves, made from polyurethane foam suffer from poor breathability, skin irritation, and mechanical property inconsistencies, leading to discomfort and increased production costs.
Innovation Solution
A padding produced via 3D printing with a multi-plane structure comprising overlapping layers defined by alternations of solids and voids, featuring variable plan view conformations and cross-sectional irregularities, utilizing thermoplastic elastomer materials for enhanced comfort and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane foam is used for padding, then protective function is provided, but breathability is poor causing skin irritation
Solution Approach 1:
The padding uses a porous material structure with interconnected voids and channels that allow air circulation and moisture wicking, directly addressing the breathability issue while maintaining protective function. The porous structure enables heat and moisture to escape, preventing skin irritation.
Solution Approach 2:
The invention employs composite material construction combining different foam densities and materials (open-cell and closed-cell foams) to achieve both protection and breathability. The composite structure allows optimization of each layer's properties - denser layers for protection, more porous layers for ventilation.
2Adaptability or versatility
If multiple foam layers with different densities are overlapped and glued, then varied mechanical properties are achieved, but production complexity and cost increase
Solution Approach 1:
The invention merges multiple foam layers into a single integrated structure where different density foams are bonded together as one unit. This eliminates the need for separate assembly and gluing operations, reducing production complexity while maintaining varied mechanical properties through the integrated multi-density construction.
Solution Approach 2:
The varied mechanical properties are built into the padding structure during the foam expansion and bonding process itself, rather than requiring subsequent assembly operations. The different density layers are pre-configured and bonded together before final product completion, simplifying the overall manufacturing process.
3Manufacturing precision
If precise cutting and assembly are performed, then mechanical property specifications are met, but processing time and costs increase
Solution Approach 1:
The invention controls foam expansion parameters (density, thickness, cell structure) during the manufacturing process to directly achieve the desired mechanical properties. By adjusting foam formulation and expansion conditions, consistent mechanical properties are obtained without requiring precise post-manufacturing cutting and assembly operations.
Solution Approach 2:
The invention replaces mechanical cutting and assembly operations with a chemical/physical process approach where foam is expanded and bonded in situ to achieve precise dimensions and mechanical properties. This substitution eliminates the need for subsequent mechanical processing, increasing productivity while maintaining precision.
4Reliability
If low density foam is used, then breathability is improved, but protective capability is reduced
Solution Approach 1:
The invention uses composite material construction combining open-cell foam (for breathability) with closed-cell foam (for protection). The open-cell portion provides ventilation and moisture management, while the closed-cell portion delivers impact protection. This composite approach allows both requirements to be satisfied simultaneously within the same padding 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 3D-printed padding achieves high breathability, improved comfort, and consistent mechanical properties, eliminating the need for assembly and reducing waste, while maintaining durability and recyclability.
Implementation Method 1
A padding according to the present invention is produced by means of 3D printing
Implementation Method 2
printing by deposition of a filament made of thermoplastic elastomer material (TPE)
Data Source
AI summary
Padding (10) produced by means of 3D printing and comprising a multi-plane structure (11) comprising a plurality of overlapping layers (12), each of which is defined by an alternation of solids and voids, wherein the plan view conformation of each of said layers (12) is made according to at least one open and/or closed pattern, and in that said plan view conformation is variable.