Foam Form-Cutting with Sequential Pressing for Deep Contours
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Solution Overview
Problem
Existing methods for producing molded foam objects are not suitable for creating complex shaped cuts, such as narrow angled recesses at different depths, resulting in imprecise edges and rough surfaces.
Innovation Solution
A method involving two work steps, where a first shape or contour cut is followed by pressing the foam into a second negative mold using a pressure stamp that approximates the first cut, allowing for precise creation of complex shapes with sharp contours and smooth surfaces by superimposing additional cuts that extend deeper into the foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single negative mold is used to cut foam contours, then the manufacturing process is simple, but complex shaped cuts with narrow angled recesses at different depths cannot be created precisely
Solution Approach 1:
The patent divides the cutting process into multiple sequential work steps, each creating a specific shaped cut at a defined depth. Instead of attempting to create all complex shapes in a single step, the method segments the overall shaping task into multiple manageable cutting operations, where each work step produces a portion of the final complex geometry. This allows precise creation of narrow angled recesses at different depths by treating each depth level as a separate cutting operation.
Solution Approach 2:
The patent applies preliminary action by creating initial shaped cuts at shallower depths before proceeding to deeper cuts. Each work step prepares the foam by creating a preliminary version of the final shape, which then serves as the basis for subsequent deeper cuts. This preliminary shaping at each stage ensures that when deeper recesses are cut, the surrounding material is already properly positioned, enabling precise creation of complex multi-level geometries.
2Manufacturing precision
If shallow cuts are made first followed by deeper cuts in the same area, then complex multi-level shapes can be created, but the edges and surfaces become rough and imprecise
Solution Approach 1:
The patent applies local quality by using different cutting tools or cutting parameters for different regions of the foam at different depth levels. Each work step is optimized for its specific depth and shape requirements, with tools and parameters selected to produce the desired local quality. This ensures that edges remain sharp and surfaces remain smooth even as cuts progress to greater depths, because each local cutting operation is independently optimized for its specific task.
Solution Approach 2:
The patent changes cutting parameters between work steps to maintain precision at different depths. This includes adjusting cutting speed, tool engagement depth, and potentially tool selection based on the required depth and shape complexity. By dynamically changing these parameters for each work step, the method maintains sharp edges and smooth surfaces throughout the multi-level cutting process, preventing the degradation of surface quality that would occur with constant parameters.
3Manufacturing precision
If multiple negative molds are used to create different depth levels, then complex shapes at greater depths can be achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent makes the negative mold universal by designing it to accommodate multiple work steps without requiring physical changes between steps. The same negative mold is used repeatedly for different cutting depths, with only the cutting tool or parameters being changed. This multi-functional approach allows the mold to serve all depth levels throughout the production process, eliminating the need to physically exchange molds between work steps and significantly reducing setup time and process complexity.
Solution Approach 2:
The negative mold is prepared in advance with all the necessary cavity geometries for different depth levels, allowing sequential cutting operations to proceed without mold changes. The preliminary configuration of the mold includes provisions for creating multiple shaped cuts at different depths, enabling the production process to maintain a consistent, efficient rhythm without interruptions for mold exchange, thus reducing total production time while maintaining depth precision.
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 shapes with sharp edges and smooth surfaces at greater depths, suitable for various foam types, including viscoelastic and polyether foams, by repeating the process with different tools.
Implementation Method 1
a method for producing a body from a blank made of foam, hard foam or the like by means of a heating wire, thermal cutting device or the like
Implementation Method 2
pressing part of the first preliminary version of the object in the area of the first shape or contour cut into a second negative mold with the aid of a pressure die
Data Source
Figure 1~5
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.