Body Support Mould Inserts for Uniform Gel Layer Thickness
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Solution Overview
Problem
Existing manufacturing processes for body supports, such as bicycle saddles, result in uneven gel layer thickness due to self-leveling issues, failing to accurately meet comfort requirements and precision.
Innovation Solution
A device with interchangeable mobile blocks in the mould, featuring distinct surfaces for separate pouring steps, ensures precise control over gel layer thickness and distribution, eliminating self-leveling problems and allowing for customized thickness and patterned designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gel is poured in fluid state directly on the covering element, then the gel layer forms naturally, but the thickness becomes uneven due to self-leveling
Solution Approach 1:
The patent applies preliminary action by preparing a flat bottom surface in the mould before pouring the gel. This flat surface is created as a preliminary condition to prevent the self-leveling effect that causes thickness variations. By establishing the correct geometric condition beforehand, the gel maintains its poured thickness without natural redistribution.
Solution Approach 2:
The patent employs periodic action through vibration during the gel pouring process. The vibration is applied intermittently or continuously during gel injection to counteract the self-leveling tendency. This periodic mechanical disturbance prevents the gel from naturally redistributing and forming uneven thickness patterns.
2Quantity of substance
If the female mould has concave areas, then the gel deposits more material in those areas, but this creates excessive thickness that does not meet comfort requirements
Solution Approach 1:
The patent applies local quality by creating a flat bottom surface specifically in the areas where gel is poured. This local geometric modification ensures that the gel layer thickness is controlled precisely in the critical areas of contact, regardless of the overall mould geometry. The flat surface is localized to the pouring area to achieve uniform thickness where needed.
Solution Approach 2:
The patent uses preliminary anti-action by designing the flat bottom surface to counteract the excessive deposition tendency in concave areas. The flat surface pre-establishes a reference plane that prevents the gel from accumulating excessively in areas that would otherwise have increased thickness due to mould geometry.
3Reliability
If gel is poured to achieve desired thickness in specific areas, then comfort requirements may be met, but the process lacks control accuracy
Solution Approach 1:
The flat bottom surface is prepared as a preliminary condition to establish a precise reference plane for thickness measurement and control. This preliminary geometric preparation enables accurate thickness control by providing a known starting plane from which the gel thickness can be precisely determined.
Solution Approach 2:
The patent implements feedback through the flat bottom surface geometry that provides a measurable reference for gel thickness. The flat surface serves as a baseline that allows for precise measurement and control of the gel layer thickness, enabling verification that comfort requirements are met with accurate thickness specifications.
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 solution enables the production of supports with consistently desired gel layer thickness and patterned surfaces, reducing material consumption, enhancing comfort, and optimizing manufacturing efficiency while maintaining cost-effectiveness.
Implementation Method 1
once poured on the covering element, the layer of gel in the fluid state is naturally positioned so as to define a free surface, i.e. it self-levels
Implementation Method 2
Following solidification, or cross-linking, of the layer of gel
Implementation Method 3
Following solidification, or cross-linking, of the layer of gel
Data Source
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AI summary
A device for manufacturing a support for the human body, of the type comprising a mould comprising a lower female portion (7) and an upper male portion capable of being coupled with one another so as to define at least one cavity (8) between them inside which at least one material in the fluid state intended to make the support (2) can be poured. The female portion (7) of the mould comprises at least one mobile block (9a, 9b) comprising at least two different surfaces (10,11) suitable for making up respective different bottoms of said cavity (8) for separate pouring steps of at least one material in the fluid state foreseen in the support (2). A process for manufacturing a support (2) for the human body is moreover presented.