Layer Pad Warping Prevention via Raised Formations

Solution Overview

Problem

Prior art layer pads tend to warp during manufacturing, which affects their stability and functionality when used between layers of a load.

Innovation Solution

A layer pad design featuring raised frustoconical formations on both faces, with a 30% increased thickness at these regions, and a manufacturing method using a mould with injection ports at recesses to reduce stress and prevent warping, employing a molten plastics material that cures within the mould.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a prior art layer pad design is used, then the pad can be manufactured, but the pad tends to warp after manufacturing

Engineering Contradiction:

Improvepad shape stabilityVSAvoidpad warping

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by providing relief features at specific locations on the pad - namely, recesses in the first face and corresponding protrusions on the second face. These localized structural modifications create differential stress distribution that compensates for warping tendencies in specific regions, thereby maintaining overall pad flatness and dimensional stability after manufacturing

Inventive Principle:

Principle #3Local quality

2Stability of the object's composition

If the pad thickness is increased to prevent warping, then stability improves, but the pad becomes more complex to manufacture

Engineering Contradiction:

Improvepad anti-warping stabilityVSAvoidmould complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies inversion by creating the counter-warping effect through surface relief features (recesses and protrusions) rather than increasing the overall pad thickness. This approach achieves the desired dimensional stability by modifying the surface geometry in a way that creates compensating stress patterns, avoiding the need for a thicker pad design

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If uniform thickness is maintained throughout the pad, then manufacturing is simpler, but the pad is more prone to warping

Engineering Contradiction:

Improveuniform thickness manufacturingVSAvoidpad shape control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by providing relief features at specific locations on the pad - namely, recesses in the first face and corresponding protrusions on the second face. These localized structural modifications create differential stress distribution that compensates for warping tendencies in specific regions, thereby maintaining overall pad flatness and dimensional stability after manufacturing

Inventive Principle:

Principle #3Local quality

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 layer pad design and manufacturing method prevent warping, ensuring stability and uniform crystallization, thus maintaining the pad's shape and functionality.

Implementation Method 1

injecting the moulding material into the mould space to fill the relatively narrow region and the relatively wide region, allowing the moulding material to cure

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS11964808B2Method of forming a pad

Publication Date: 2024.04.23 LOADHOG LTD

AI summary

A layer pad (10) comprises a substantially flat sheet (12) having first and second opposite substantially planar faces (14, 16). The layer pad (10) further includes at least one raised formation (18) on at least one of the faces (14, 16).