Concave-Convex Cushion Manufacturing via Negative Pressure Shaping
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Solution Overview
Problem
Conventional methods for manufacturing elastic cushions with a concave-convex structure are complex, requiring a base material with a preformed concave-convex structure or puncturing elastic sheets for air bubble release during hot pressing, making the process cumbersome.
Innovation Solution
A method involving pasting a closed-hole elastic sheet with an open-hole elastic sheet, heating, and then using negative pressure and cooling to shape the combined sheets into a concave-convex structure without a preformed base material, utilizing a mold with air extraction holes and a cooling unit to deform and harden the sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a base material with a preformed concave-convex structure is used, then the cushion body can achieve the desired surface structure, but the manufacturing process becomes more complicated and requires additional materials
Solution Approach 1:
The elastic sheet is divided into two functional layers: a first elastic sheet providing structural support and a second elastic sheet that forms the concave-convex surface structure. This segmentation allows each layer to perform its specific function without requiring a preformed complex base material, simplifying the overall manufacturing process.
Solution Approach 2:
The second elastic sheet is prepared in advance with its concave-convex surface structure before being combined with the first elastic sheet. This preliminary preparation of the surface layer eliminates the need for complex preforming of the entire base material, as only the surface layer requires the specific geometry.
2Shape
If two elastic sheets are pasted and embossed using a closed hot pressing mold, then the cushion body can be formed, but each elastic sheet must be punctured in advance to discharge air bubbles, making the process more complicated
Solution Approach 1:
The first elastic sheet is designed with localized open-hole structures at specific positions rather than puncturing the entire sheet. These localized openings are strategically placed to allow air bubble discharge during hot pressing, eliminating the need for extensive puncturing while maintaining the integrity of the elastic sheets.
Solution Approach 2:
The open-hole structures are pre-formed in the first elastic sheet during material preparation, before the assembly and hot pressing stages. This preliminary formation of discharge channels eliminates the need for in-process puncturing operations, simplifying the manufacturing workflow.
3Object-generated harmful factors
If conventional methods are used to create air bubble discharge paths, then air bubbles can be removed during hot pressing, but the elastic sheets must be punctured in advance, increasing process complexity
Solution Approach 1:
Instead of uniformly puncturing the elastic sheets, the first elastic sheet is designed with localized open-hole structures only at specific positions where air bubble accumulation is expected. This targeted approach creates effective air discharge paths without the complexity of extensive puncturing operations.
Solution Approach 2:
The open-hole structures in the first elastic sheet serve as intermediary channels that facilitate air bubble discharge during hot pressing. These pre-formed holes act as controlled pathways that mediate between the trapped air bubbles and the external environment, eliminating the need for puncturing operations.
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
This approach simplifies the manufacturing process, eliminates the need for preformed materials, and allows for the creation of cushions with varied concave-convex structures, enhancing the production efficiency and practicality of elastic cushions with anti-skid and shock-absorption functions.
Implementation Method 1
sucking under a negative pressure the first elastic sheet and the second elastic sheet that are heated from one side of the second elastic sheet
Implementation Method 2
a cooling unit provided at one side of the mold body for cooling with a fluid one of the first elastic sheet and the second elastic sheet or the mold body
Implementation Method 3
heating the first elastic sheet and the second elastic sheet that are combined
Data Source
AI summary
The present invention provides a method for manufacturing a cushion body with a concave-convex structure and a mold for manufacturing the cushion body with the concave-convex structure. A first elastic sheet is pasted on a second elastic sheet. The first elastic sheet is a closed-hole elastic material. The second elastic sheet is an opened-hole elastic material. The first elastic sheet and the second elastic sheets are combined and heated. Finally, the first elastic sheet and the second elastic sheet that are heated are sucked using the mold under a negative pressure from one side of the second elastic sheet and cooled at the same time, so that the first elastic sheet and the second elastic sheet can be deformed using the concave-convex structure of the mold and cooled to be shaped, thereby obtaining the cushion body with the concave-convex structure.