Additively Manufactured Mold Insert for Uniform Particle Fusion

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Solution Overview

Problem

Existing methods for manufacturing cushioning elements in sports apparel using particle foam materials face challenges in achieving uniform fusion of particles with complex geometries, leading to uneven energy distribution and imperfections due to the use of steam as an energy carrier, which is inefficient and difficult to control for varying thickness and curvature.

Innovation Solution

A mold insert manufactured using additive manufacturing is designed to locally adjust the electromagnetic field strength within the molding cavity based on the geometry of the cushioning element, utilizing variations in permittivity and dielectric loss factor to ensure even fusion of particles, particularly for shoe soles and midsoles with complex shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If steam is used as an energy carrier to fuse particle surfaces, then the particles can be heated and fused together, but the energy distribution becomes uneven and the manufacturing process becomes inefficient for complex geometries

Engineering Contradiction:

Improveparticle fusion qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the thermal field (steam) with an electromagnetic field for heating and fusing the particles. The electromagnetic field can be locally adjusted using a mold insert with varying permittivity to achieve uniform energy distribution throughout the cushioning element, eliminating the inefficiencies of steam-based heating while maintaining reliable particle fusion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mold insert is designed with spatially varying permittivity to locally adjust the electromagnetic field strength. This ensures that regions with different geometries (varying thickness, curvature) receive appropriate energy density for uniform fusion, solving the problem of uneven heating that plagues conventional steam-based methods.

Inventive Principle:

Principle #3Local quality

2Reliability

If steam is used to heat particles, then fusion can occur, but a major share of energy is lost heating the mold instead of reaching particle surfaces

Engineering Contradiction:

Improveparticle fusion qualityVSAvoidenergy loss to mold heating

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

By substituting steam with electromagnetic radiation, the patent eliminates the need for thermal conduction through the mold wall. The electromagnetic field can penetrate or be coupled to the particles directly, delivering energy without the significant heat loss that occurs when steam heats the metal mold first.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mold insert is pre-designed with specific permittivity characteristics to optimize electromagnetic field distribution before the actual fusion process begins. This preliminary configuration ensures maximum energy transfer to the particles from the start, preventing energy loss to the mold.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If conventional molds are used for complex geometries, then the mold can accommodate various shapes, but the heating process becomes protracted and energy consumption increases

Engineering Contradiction:

Improvegeometry accommodationVSAvoidenergy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by stationary object

Solution Approach 1:

The patent replaces thermal conduction-based heating with electromagnetic heating, which can penetrate and heat particles throughout the complex geometry simultaneously. The mold insert with varying permittivity is specifically designed to distribute the electromagnetic field uniformly across the entire volume, reducing both processing time and energy consumption while accommodating complex shapes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mold insert introduces a new dimension of control by varying permittivity in three-dimensional space. This allows the electromagnetic field to be shaped and distributed according to the specific geometry requirements, enabling efficient heating of complex shapes that would be energy-intensive with conventional uniform heating methods.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 mold insert enables the production of high-quality cushioning elements with consistent particle fusion across varying geometries, improving manufacturing efficiency and reducing energy consumption by optimizing the electromagnetic field distribution for uniform heating.

Implementation Method 1

an electromagnetic field is used as an energy carrier to fuse the particle surfaces

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 2

utilizing variations in permittivity and dielectric loss factor to ensure even fusion of particles

Methodology Applied

Scientific EffectPermittivity variation: Dielectric Permittivity

Data Source

PatentUS20250276473A1Mold insert for use in a mold for the manufacture of a cushioning element for sports apparel

Publication Date: 2025.09.04 ADIDAS AG

AI summary

An aspect of the present invention relates to a mold insert for use in a mold for the manufacture of a cushioning element for sports apparel. Further aspects of the present invention relate to a mold using such a mold insert, a method for the manufacture of a cushioning element for sports apparel using such a mold, and a cushioning element manufactured by such a method.