Composite Foam Fabric Bonding via Punch Press
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Solution Overview
Problem
Existing methods for manufacturing protective composite materials, such as those used in shin guards and helmets, face challenges in efficiently bonding foam elements to fabric substrates, particularly in creating uniform and securely attached foam/fabric composites for diverse applications.
Innovation Solution
A method and apparatus utilizing a punch press with aligned punches and dies to cut and deposit foam elements onto a heated fabric substrate, achieving heat bonding between the foam and fabric, allowing for the creation of a composite foam/fabric material that can be used in various protective products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If foam elements are bonded to fabric substrate using conventional methods, then bonding strength may be achieved, but production efficiency and uniformity are reduced
Solution Approach 1:
The patent combines multiple operations (cutting, depositing, and heat bonding) into a single integrated apparatus. The punch press simultaneously cuts foam elements from the sheet and deposits them onto the heated fabric substrate in one continuous motion, eliminating separate handling steps and ensuring uniform bonding across all foam elements.
Solution Approach 2:
The apparatus maintains continuous operation by keeping the fabric substrate heated throughout the process. The punch press moves continuously through the foam sheet, cutting and depositing elements without interruption, while the heated substrate continuously receives and bonds the foam elements as they are deposited, eliminating idle time and ensuring consistent bonding conditions.
2Productivity
If foam elements are cut and deposited manually, then placement precision may be achieved, but production time increases
Solution Approach 1:
The patent replaces manual mechanical placement with an automated punch press system. The punch press uses precisely engineered dies and punches to cut foam elements and deposit them onto the fabric substrate with consistent positioning. The mechanical system ensures uniform spacing and alignment through precision manufacturing of the tooling, eliminating variability introduced by manual placement while maintaining high speed.
3Ease of manufacture
If multiple separate processes are used for foam/fabric bonding, then process control may be maintained, but manufacturing complexity increases
Solution Approach 1:
The patent merges cutting, depositing, and heat bonding functions into a single integrated apparatus. The punch press assembly includes cutting edges for severing foam elements and depositing surfaces for placing them on the fabric substrate, all within one mechanical unit. The heated substrate provides continuous thermal energy for bonding, eliminating the need for separate heating equipment and simplifying the overall manufacturing process.
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 efficient production of a composite foam/fabric material with strong bonding, suitable for multiple applications, including shin guards, helmets, and sports equipment, by cutting foam elements into desired shapes and adhering them to a heated fabric substrate, ensuring durability and protection.
Implementation Method 1
deposited and pressed onto a heated substrate, such as a fabric, to provide foam/fabric bonding
Implementation Method 2
partially melted to be retained thereon by heat bonding
Data Source
AI summary
The present invention is directed to a method and apparatus for manufacturing a composite, foam/fabric material for use as protective material in products, and utilizes an apparatus which includes a punch press with punches arranged in rows and correspondingly aligned dies for receiving the punches therethrough. The system operates by punching a sheet of foam material into a plurality of discrete foam elements which are transferred onto a heated fabric substrate, and retained thereon by heat bonding. The apparatus consists, in one preferred embodiment, of a clamp plate which clamps a sheet of foam material onto a die plate, and after a punching sequence, the sheet of foam material, along with the sheet of fabric material, are indexed downstream, and the process repeats.