Flexible Three-Dimensional Structures from Decomposable Moulds
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Solution Overview
Problem
Existing methods for manufacturing flexible structures, such as inflatable structures, require complex assembly techniques like sewing, welding, or bonding, which create fragility areas and surface discontinuities, and often result in synclastic deformation in unsupported areas.
Innovation Solution
A method involving the use of a temporary mould that can be decomposed, where a support structure is positioned on the mould's peripheral surface, connected by threadlike elements, and covered with a tight envelope, allowing the mould to be decomposed and replaced by a pressurized fluid, eliminating visible assembly joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-cut shape assembly techniques are used, then flexible structures can be manufactured, but assembly joints create fragility areas and surface discontinuity
Solution Approach 1:
The patent removes the temporary mould from the final structure, extracting the formative tool while retaining the formed structure. This eliminates the need for assembly joints between mould parts, as the structure is formed in a single continuous piece during the moulding process, thereby maintaining structural integrity while enabling manufacturing flexibility.
Solution Approach 2:
The temporary mould acts as an intermediary that transfers the desired shape to the flexible material without becoming part of the final structure. The mould facilitates manufacturing by providing the forming cavity, then is completely removed, leaving no joint artifacts in the finished product.
2Adaptability or versatility
If partitions or padding systems are added to reinforce flexible structures, then shape complexity increases, but implementation techniques become complex and tricky
Solution Approach 1:
The temporary mould is divided into multiple parts that can be separately manufactured and assembled to form the complete mould cavity. This segmentation allows complex three-dimensional shapes to be created by combining simpler mould components, reducing the complexity of manufacturing the mould itself while enabling versatile final structures.
Solution Approach 2:
The mould cavity is prepared in advance with all the necessary geometric features, reinforcement structures, and shaping elements already formed. This preliminary action allows complex shapes to be achieved without complex implementation techniques during the actual forming process, as the complexity is pre-built into the mould geometry.
3Strength
If partitions or padding fastenings are used, then structural reinforcement is achieved, but unsupported areas exhibit synclastic deformation
Solution Approach 1:
The temporary mould incorporates localized reinforcement features at specific positions where structural strength is needed. These local quality variations in the mould design translate to corresponding reinforcement zones in the final structure, providing targeted strength enhancement without creating unwanted deformation in unsupported areas.
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
Enables the creation of flexible structures without visible assembly joints, providing greater shape versatility and reducing structural weaknesses.
Implementation Method 1
a temporary mould made of a material decomposable by contact with a suitable chemical decomposition product, the operation of decomposing said temporary mould being made by contact of the latter with said chemical decomposition product
Implementation Method 2
a temporary mould made of a heat-decomposable material, the operation of decomposing said temporary mould being made by contact of the latter with a source of heat
Data Source
AI summary
Disclosed is a method for manufacturing a flexible three-dimensional structure, characterised in that it includes the following steps: preparing a temporary mould defined by a peripheral surface; positioning a support structure on at least one portion of the peripheral surface of the temporary mould; decomposing the temporary mould; and extracting the decomposed temporary mould.