Cushioning Element Using Electromagnetic Particle Fusion

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Solution Overview

Problem

Existing methods for manufacturing plastic components, such as cushioning elements for sports apparel, are limited by the ability to produce complex shapes and high thickness due to the need for binder materials and heat energy distribution, leading to inefficiencies and imperfections, particularly with steam-based methods which lose energy and prolong the manufacturing process.

Innovation Solution

The method involves loading a mold with particles of expanded materials and fusing their surfaces using electromagnetic fields, allowing for homogeneous energy distribution and controlled fusion without the need for binder materials or steam, enabling the production of complex shapes and high thickness components while minimizing energy loss and manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If steam or binder material is used to fuse particles, then the particles can be fused together, but energy is lost and the manufacturing process is prolonged

Engineering Contradiction:

Improveenergy lossVSAvoidmanufacturing time

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The patent replaces the thermal/chemical fusion methods (steam or binder materials) with electromagnetic radiation to fuse particles. The electromagnetic radiation directly energizes the particles without requiring steam injection or binder materials, eliminating energy loss through channels and inlet openings, and significantly reducing the manufacturing process time while maintaining effective particle fusion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If steam is used to supply heat energy, then the particles can be heated, but a major share of energy is lost in the mold

Engineering Contradiction:

Improveheating efficiencyVSAvoidenergy loss in mold

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent substitutes steam-based thermal heating with direct electromagnetic radiation heating. The electromagnetic radiation penetrates the mold and particles without requiring steam injection, eliminating the energy loss that occurs when steam condenses in the mold. This direct energy transfer method ensures that nearly all supplied energy reaches the particles for effective heating and fusion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If channels or inlet openings are provided for binder or steam infusion, then homogeneous infusion is achieved, but the component structure is compromised

Engineering Contradiction:

Improvehomogeneous infusionVSAvoidcomponent structure

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent replaces the mechanical infusion method (steam or binder through channels) with electromagnetic radiation. This eliminates the need for channels and inlet openings in the component structure, as the electromagnetic energy penetrates the particles directly without requiring structural compromises. The homogeneous energy distribution is achieved through the penetrating nature of electromagnetic radiation rather than through physical infusion channels.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If the mold is preheated to saturation temperature, then the particles can be fused, but the manufacturing process is prolonged

Engineering Contradiction:

Improvesaturation temperatureVSAvoidpreheating phase

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent substitutes thermal preheating of the mold with direct electromagnetic radiation application to the particles. The electromagnetic radiation directly energizes the particles without requiring the mold to be preheated to saturation temperature, eliminating the lengthy preheating phase. This direct energy transfer method achieves particle fusion without the time-consuming mold preheating process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for the efficient manufacture of complexly shaped plastic components with improved energy absorption and reduced manufacturing time, maintaining quality and environmental sustainability by avoiding hazardous substances.

Implementation Method 1

fusing the surfaces of the particles by supplying energy, wherein the energy is supplied in the form of at least one electromagnetic field

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Implementation Method 2

The energy is supplied in the form of at least one electromagnetic field

Methodology Applied

Scientific EffectEnergy absorption: Absorption (EM radiation)

Data Source

PatentUS20240398059A1Cushioning element and shoe

Publication Date: 2024.12.05 ADIDAS AG

AI summary

Described are methods for manufacturing a plastic component, in particular a cushioning element for sports apparel, a plastic component manufactured with such methods, for example a sole or a part of a sole for a shoe, and a shoe with such a sole. The method for the manufacture of a plastic component includes loading a mold with a first material includes particles of an expanded material and fusing the surfaces of the particles by supplying energy. The energy is supplied in the form of at least one electromagnetic field.