Foam Die Cutting With Superimposed Deep Contour Cuts
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Solution Overview
Problem
Existing methods for creating die-cut objects from foam are not suitable for producing complex, sharply angled cutouts with smooth surfaces and precise edges, as they result in rough cuts and are limited to shallow depths.
Innovation Solution
A two-step process involving a first die cut followed by a second work step where the foam is pressed into a negative die using a plunger that matches the initial cut, allowing for deeper and more complex cuts with smooth surfaces by superimposing additional cuts, enabling the creation of complex shapes with sharp contours and smooth surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single die cut is made in foam using conventional methods, then the process is simple and quick, but the cut edges are rough and complex shapes at depth cannot be achieved
Solution Approach 1:
The cutting process is divided into multiple sequential work steps, where each step creates a portion of the final complex shape. The first work step creates an initial cut, and subsequent work steps add additional cuts to achieve the desired complex geometry with smooth edges at depth.
Solution Approach 2:
The first work step performs a preliminary cut that prepares the foam for subsequent deeper cuts. This initial shaping action creates a foundation that enables later work steps to achieve the final precise complex geometry without attempting to create the entire shape in one step.
2Manufacturing precision
If conventional die cutting is used, then the process is straightforward, but only shallow cuts can be made with rough edges
Solution Approach 1:
The cutting operation is segmented into multiple work steps, each contributing to the final deep complex shape. This segmentation allows the process to achieve greater depth and edge quality by building the shape incrementally rather than attempting a single deep cut.
Solution Approach 2:
The multiple work steps are performed in sequence without removing the workpiece, maintaining continuous productive action. Each work step builds upon the previous one, with the foam remaining in place for cumulative shaping, thereby maximizing the utility of each processing pass.
3Manufacturing precision
If multiple cuts are made in sequence, then complex shapes with smooth surfaces can be achieved, but the production time increases
Solution Approach 1:
The first work step performs preliminary shaping that prepares the foam for subsequent precise cuts. This preliminary action reduces the workload for later steps, enabling faster achievement of the final complex geometry while maintaining high precision.
Solution Approach 2:
The sequential work steps are designed to be performed continuously on the same workpiece without removal or repositioning. This continuous processing minimizes setup time and handling losses, making the multi-step process more time-efficient despite the increased number of cutting operations.
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 precise creation of complex die cuts with sharp edges and smooth surfaces at considerable depths in foam materials, suitable for various densities and surface characteristics, such as viscoelastic foams and polyether foams.
Implementation Method 1
a section of the foam pressed into the negative die is then cut off... After relaxation, the foam re-expands
Implementation Method 2
The section of the foam pressed into the negative die is then cut off using an oscillating or rotating blade
Data Source
AI summary
The invention relates to a method for producing a form-cut object made of foam. The invention is based on the aim of refining a known method for producing a form-cut object made of foam in that it also allows the precise creation of complex shaped form cuts in the foam. This aim is achieved by the method according to the invention in that the first preliminary version of the object in the region of a first form or contour cut is provided with a (second) form cut, which is superimposed on the first form or contour cut and extends down to larger depths than the first cut. Preferred application areas of the claimed method and the resultant objects made of foam are pillows, for example.