Automated Cast Polyurethane Forming with Vacuum Bubble Extraction
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Solution Overview
Problem
Conventional methods for forming cast polyurethane are inefficient and wasteful, leading to irregular product quality, excessive rejections, and high labor costs due to manual scraping and vacuum processes.
Innovation Solution
An automated system for forming cast polyurethane using a mold with a conveyance mechanism, a liquid phase polyurethane mixture dispensing system, air dispersal, vacuum bubble removal, and a flexible blade for excess polyurethane removal, minimizing waste and improving product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual scraping is used to distribute polyurethane and remove excess material, then workers can control the polyurethane distribution, but labor costs increase and material waste increases
Solution Approach 1:
The patent replaces manual scraping with an automated squeegee mechanism that mechanically removes excess polyurethane. The squeegee is actuated by a crank mechanism driven by a motor, providing consistent, repeatable removal of excess material without human intervention, thereby eliminating labor costs while maintaining precise control over material removal
Solution Approach 2:
The patent implements a vacuum system that recovers and reuses liquid polyurethane that would otherwise be wasted. The vacuum pump draws off excess liquid polyurethane from the mold cavity and collects it in a reservoir, where it can be reused in subsequent cycles, significantly reducing material waste
2Reliability
If repeated manual scraping and vacuum steps are performed, then air bubbles can be removed, but labor costs and process time increase
Solution Approach 1:
The patent employs a vacuum system that operates continuously during the polyurethane forming process rather than requiring repeated intermittent vacuuming. The vacuum pump maintains continuous suction to remove air bubbles throughout the curing cycle, eliminating the need for multiple scraping-vacuum-scraping cycles and reducing overall process time while maintaining product quality
Solution Approach 2:
The patent replaces repeated manual scraping operations with an automated squeegee mechanism that continuously removes excess polyurethane and facilitates bubble removal. The mechanical squeegee action combined with continuous vacuuming eliminates the need for multiple manual intervention cycles, reducing both labor requirements and process time
3Loss of substance
If automated dispensing is used to distribute polyurethane, then material waste decreases, but system complexity increases
Solution Approach 1:
The patent employs a dispensing system that performs multiple functions: it dispenses polyurethane into the mold cavity, distributes the material evenly across the mold surface, and controls the amount of material used. The dispensing mechanism is integrated with the existing mold and curing infrastructure, allowing a single system to handle multiple operations without requiring separate devices for each function
Solution Approach 2:
The dispensing system is designed to automatically regulate its own operation based on the mold position and curing requirements. The system self-adjusts dispensing rates and patterns to match the specific needs of different mold configurations, eliminating the need for complex external control mechanisms while maintaining precise material application
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 automated system reduces waste, improves product quality, and decreases labor costs by precisely dispensing and distributing polyurethane, extracting air bubbles efficiently, and removing excess material effectively.
Implementation Method 1
a vacuum may be applied to the liquid phase polyurethane mixture on the mold to extract bubbles from the liquid phase polyurethane mixture
Implementation Method 2
excess liquid polyurethane may be removed from the flat surface face of the mold using a flexible blade that contacts and moves across the flat surface face of the mold
Data Source
AI summary
Cast polyurethane parts for shoes or other items may be formed in an automated fashion. A dispensing mechanism may dispense a predetermined amount of a liquid phase polyurethane mixture onto a flat surface face of a mold. A dispersal mechanism may distribute the liquid phase polyurethane mixture over the flat surface face of the mold to fill at least one cavity in the form. A vacuum may be applied to remove air bubbles from the liquid phase polyurethane mixture. Excess liquid phase polyurethane mixture may be removed from the flat surface face of the mold using a flexible blade that contacts and moves across the flat surface face. One or more conveyance mechanism may transport molds through the desired stages of a system and/or method in accordance with the present invention.