Elastomeric Foam Cutting for Complex 3D Insulation Shapes

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Solution Overview

Problem

Existing methods for forming elastomeric elements for thermal insulation on complex 3-dimensional structures are time-consuming, require specialized craftsmanship, and often result in burrs and uneven sealing, especially for large ductworks and complex pipe configurations.

Innovation Solution

A method using a robot-controlled ultrasonic or oscillating tangential cutter to cut flat panels of elastomeric material into pre-designed 2-dimensional shapes, with a support system and collaborative robot for automated material positioning and real-time feedback, allowing precise cuts at various angles and minimizing material distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If hand cutting methods are used for complex piping insulation, then flexibility in handling complex structures is maintained, but time consumption increases and manufacturing precision deteriorates

Engineering Contradiction:

Improveflexibility in handling complex structuresVSAvoidtime consumption

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces manual mechanical cutting with automated ultrasonic cutting technology. The ultrasonic cutter uses high-frequency vibrations to cut insulation material precisely, eliminating the need for hand tools while maintaining the ability to handle complex pipe configurations. This substitution directly addresses the contradiction by automating the process to reduce time consumption while preserving manufacturing flexibility through programmable cutting paths.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs ultrasonic vibration (mechanical vibration at high frequency) as the cutting mechanism. The ultrasonic cutter generates vibrations that allow precise cutting of insulation material around complex pipe structures without the time consumption and imprecision associated with manual cutting. This vibrational cutting method enables both speed and precision simultaneously.

Inventive Principle:

Principle #18Mechanical vibration

2Shape

If abrasion apparatus is used to shape insulation covers, then specific shapes can be obtained, but burr formation occurs and manufacturing precision deteriorates

Engineering Contradiction:

Improvespecific shape of insulation coverVSAvoidburr formation and edge quality

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent replaces the abrasion apparatus (mechanical grinding/cutting) with ultrasonic cutting technology. The ultrasonic cutter uses high-frequency vibrations to cleanly cut and shape insulation material without the mechanical contact that causes burr formation. This substitution maintains the ability to create specific shapes while dramatically improving edge quality and eliminating burrs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The ultrasonic cutter uses mechanical vibration at ultrasonic frequencies to cut and shape the insulation material. This vibrational cutting mechanism allows precise shape formation without the mechanical abrasion that causes burrs, directly resolving the contradiction between achieving specific shapes and maintaining manufacturing precision.

Inventive Principle:

Principle #18Mechanical vibration

3Manufacturing precision

If cutting is performed with high precision to prevent burrs, then manufacturing precision improves, but time consumption increases

Engineering Contradiction:

Improvecutting precision and burr preventionVSAvoidtime consumption

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual cutting operations with automated ultrasonic cutting. The ultrasonic cutter is programmed to follow precise cutting paths, achieving high manufacturing precision without the time consumption of manual operations. The automation allows the system to maintain precision while operating continuously at high speed, resolving the time-quality tradeoff.

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

The method significantly reduces time and waste, increases precision and quality, optimizes project planning, and enhances the efficiency of forming elastomeric elements for thermal insulation on complex structures, improving the overall insulation quality.

Implementation Method 1

the cutter is selected from an ultrasonic cutter and an oscillating tangential cutter

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

the cutter is selected from an ultrasonic cutter and an oscillating tangential cutter

Methodology Applied

Scientific EffectOscillation: Harmonic Oscillator

Data Source

PatentEP4606542A1Method of forming an elastomeric foam element

Publication Date: 2025.08.27 R VAN DEN HANENBERG BV

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AI summary

The present invention relates to a method of forming an elastomeric foam element. The present invention further relates to an elastomeric foam element obtained by the method, to an assembly for forming the elastomeric foam element, to use of the method, and to a computer program comprising instructions to form the elastomeric foam element.