Methods of manufacture of cushions
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Solution Overview
Problem
The existing manufacturing process for cushioning elements is inefficient, leading to significant material waste and increased labor costs due to the use of large molds for multiple sizes, where excess material is either discarded or recycled, reducing yield and increasing expenses.
Innovation Solution
The implementation of cushioning elements constructed in different zones using a single mold, where the perimeter cushion is formed from a compressible material, and the cushion insert is designed to fit within voids defined by the perimeter cushion, allowing for efficient production and reduced material waste by utilizing a single mold for various sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large molds are used to manufacture all cushion sizes, then the same mold can produce multiple cushion sizes, but significant material waste occurs and yield decreases
Solution Approach 1:
The cushion is divided into multiple zones with different material properties (first zone with first material, second zone with second material). This segmentation allows the single mold to efficiently produce cushions of various sizes by selectively forming different zone configurations, thereby reducing material waste while maintaining mold versatility.
Solution Approach 2:
Different zones of the cushion are formed with different materials tailored to specific regions (e.g., perimeter vs. center). This local quality approach enables the single mold to optimize material placement for each cushion size variant, improving yield by ensuring material is only placed where needed rather than creating excess that must be discarded or recycled.
2Device complexity
If large molds are used for multiple cushion sizes, then equipment investment is reduced, but labor costs increase due to material handling and recycling
Solution Approach 1:
The cushion manufacturing process is segmented into distinct zone formations within the single mold. Each zone can be independently formed with appropriate materials, allowing efficient production of various cushion sizes without requiring multiple molds or complex material handling operations, thereby improving manufacturing efficiency.
Solution Approach 2:
The mold system utilizes parameter changes (such as injection timing, material viscosity, and pressure) to selectively form different cushion zones and sizes within a single mold. This enables efficient production across multiple cushion variants without increasing device complexity or labor requirements for material handling.
3Loss of substance
If excess material is discarded or recycled from large mold production, then material waste is managed, but yield and profitability decrease
Solution Approach 1:
The cushion is constructed with different materials in different zones (first zone with first material, second zone with second material) based on specific performance requirements. This ensures material is precisely placed only where needed, eliminating excess material generation and maximizing manufacturing yield while maintaining optimal cushion performance.
Solution Approach 2:
The multi-zone cushion design minimizes the need for discarding or recycling excess material by optimizing material placement during the molding process. Each zone is formed with the appropriate material quantity and properties, thereby maximizing yield and reducing post-processing material recovery operations.
Data Source
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AI summary
A method of forming a cushioning element including forming a large cushioning element, and then dividing the large cushioning element into four equal smaller cushioning elements. The four smaller cushioning elements may be substantially the same size. Each of the smaller cushioning elements may be used as separate cushioning elements.