Flexible Template for Seamless 3D Item Manufacturing
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Solution Overview
Problem
Traditional methods for manufacturing three-dimensional items with flexible walls, such as footwear and seating furniture, require significant workforce and result in limited design and comfort due to seams that allow water penetration and increased manufacturing costs, while existing laminar templates are inaccurate, time-consuming, and non-reusable.
Innovation Solution
A three-dimensional flexible template made from elastically deformable material, such as silicone, is used to seal and position laminar parts within a mould and counter-mould, eliminating the need for precise adhesive fixation and allowing for the creation of items with improved sealing and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sewing or heat-sealing methods are used to join laminar parts, then the item can be manufactured, but the workforce requirement increases and three-dimensional stability is not achieved
Solution Approach 1:
The patent replaces traditional mechanical joining methods (sewing, heat-sealing) with an injection molding process where molten plastic material is injected through conduits to bond laminar parts together, eliminating the need for sequential manual or mechanical joining operations
Solution Approach 2:
The patent combines multiple operations into a single injection molding process: positioning laminar parts, injecting adhesive material, and achieving three-dimensional stability all occur simultaneously during one manufacturing cycle, rather than as separate sequential steps
2Ease of manufacture
If seams are used to join parts, then the item can be assembled, but water penetration occurs through the seam holes
Solution Approach 1:
The patent extracts and eliminates the seam structure entirely by using injected plastic material to bond laminar parts at their edges without creating holes or openings, thereby removing the pathway for water penetration while maintaining assembly capability
Solution Approach 2:
The patent uses a disposable or reusable mold system that enables seamless joining, where the mold defines the conduit paths for adhesive injection and ensures precise positioning without requiring traditional seam-based assembly methods
3Object-affected harmful factors
If impermeability is required, then special membranes or inner sealing tape must be used, but manufacturing costs increase
Solution Approach 1:
The patent makes the laminar parts themselves water-resistant by having the injected plastic material bond them at their edges, allowing the parts to serve their own sealing function without requiring additional impermeable membranes or sealing tapes
4Manufacturing precision
If adhesive is used to fix laminar parts on the template, then positioning is achieved, but great accuracy and considerable time are required
Solution Approach 1:
The patent replaces the adhesive-based positioning system with a mechanical positioning system where the mold and flexible template physically constrain and position laminar parts through geometric interfaces, eliminating the need for adhesive application and curing time
5Ease of operation
If laminar template is used to encase counter-mould, then the template facilitates placement, but it must be cut and destroyed during demoulding
Solution Approach 1:
The patent uses a flexible template made of elastomeric material that can deform and stretch during the molding process to accommodate the counter-mould, then return to its original shape for reuse, eliminating the need to cut or destroy the template during demoulding
6Ease of operation
If flexible template is used, then deformation facilitates counter-mould introduction, but sealing on conduit limits may be insufficient
Solution Approach 1:
The patent applies local reinforcement to specific areas of the flexible template where conduits exit, creating localized sealing zones with enhanced thickness or structure that maintain flexibility overall while providing reliable sealing at critical points
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 enhances the sealing and positioning of laminar parts, reduces manufacturing costs, and allows for the creation of items with improved comfort and design, while enabling the reuse of the template and reducing environmental impact.
Implementation Method 1
a three-dimensional flexible template, from an elastically deformable material, which, given that said template is compressed between the mould and counter-mould, allows for a perfect sealing of the edges or limits of the conduits
Implementation Method 2
a plastic material in a fluid state is injected which, by solidifying, serves as a means for joining the laminar parts
Data Source
AI summary
A method for manufacturing three-dimensional items with flexible walls is provided, by method of a mold and counter-mold between which a volume corresponding to that of the item to be obtained is delimited. The item is made up of laminar parts which are mounted on a template that is fixed to the inner surface of the mold. The laminar parts are joined to one another by means of a material which is injected in molten state through a network of conduits delimited between the counter-mold, template and the facing edges of adjacent laminar parts. The template is made of an elastically deformable material and has a three-dimensional configuration.