Inflatable pad
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Solution Overview
Problem
The existing manufacturing process of inflatable pads with sponge structures results in significant material waste and increased product cost due to the need for multiple cutting phases and waste sponge removal, which is not efficiently addressed by current methods.
Innovation Solution
A manufacturing process where the sponge is cut in a staggered manner to form alternating protrusions and grooves on both sides, allowing for efficient production of identical sponges without waste by aligning and engaging concave-convex structures during cutting, thereby simplifying the process and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the sponge is cut in a conventional manner to form protrusions and grooves, then the sponge structure provides necessary support and shape, but significant material waste is generated and manufacturing cost increases
Solution Approach 1:
The sponge is divided into multiple identical units, each with protrusions on one side and grooves on the other side. These segmented units can be manufactured independently and then assembled, allowing for more efficient material utilization and reduced waste during the cutting process.
Solution Approach 2:
The sponge units are designed with asymmetric features where one side has protrusions and the opposite side has grooves. This asymmetric design allows the units to interlock in a staggered arrangement, maximizing material efficiency while providing the necessary structural support and eliminating the need for waste removal operations.
2Productivity
If multiple cutting phases are used to create the sponge structure, then the structural integrity is maintained, but the manufacturing time and productivity are reduced
Solution Approach 1:
The sponge units are pre-cut with the complete protrusion-groove structure in a single phase, eliminating the need for subsequent waste removal operations. This preliminary action of creating the final structure in one step significantly reduces manufacturing time and increases productivity.
Solution Approach 2:
Instead of cutting the sponge and then removing waste material, the invention inverts the approach by directly cutting the sponge into the final protrusion-groove structure in one operation. This inverted manufacturing sequence eliminates unnecessary steps and accelerates production.
3Ease of manufacture
If waste sponge is removed after cutting, then the final structure is achieved, but the product cost increases due to additional processing steps
Solution Approach 1:
The cutting process is designed so that what would traditionally be waste material becomes the grooves and protrusions needed for the structure. By converting the harmful waste removal step into a beneficial structure-creation step, the process simplifies manufacturing while improving material utilization efficiency.
Data Source
AI summary
The present application discloses an inflatable pad, the pad including a sponge comprising: a base extending in the length direction of the sponge and comprising a first side and a second side in the thickness direction of the sponge; a plurality of first protrusions arranged at intervals on the first side of the base, two adjacent of the plurality of first protrusions defining a first groove, and the plurality of first protrusions affixed to with a first wall of the pad; and a plurality of second protrusions arranged at intervals on the second side of the base, two adjacent of the plurality of second protrusions defining a second groove, wherein one of the first grooves is aligned with one of the plurality of second protrusions in the thickness direction of the sponge. The present embodiments reduce the waste of sponge, simplify the cutting process and improve the cutting efficiency.