Method for manufacturing a cushion and cushion
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Solution Overview
Problem
Existing methods for producing fluid-filled orthopedic cushions struggle with achieving optimal configuration and precision in wall thickness and surface structure, leading to a high rate of defective cushion parts that cannot be used for further production.
Innovation Solution
The method involves compression molding to produce 3-dimensional cushion parts with varying wall thicknesses and surface structures, allowing for precise control over contour, material thickness, and surface quality, and connecting these parts using a fluid-filled volume with multiple chambers connected by fluid connections, all within a single mold process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dipping process is used to manufacture the first cushion part, then the production process is simple, but the manufacturing precision of wall thickness and surface structure is poor, resulting in high defect rates
Solution Approach 1:
The patent changes the manufacturing process parameter from dipping to compression molding, which allows for precise control of wall thickness and surface structure through mold design, thereby resolving the contradiction between process simplicity and manufacturing precision
Solution Approach 2:
The patent replaces the mechanical dipping process with a compression molding process that uses controlled mechanical pressure and heat to achieve precise dimensional control and surface quality, eliminating the defects associated with dipping
2Ease of manufacture
If the dipping process is used to manufacture the first cushion part, then the process is easy to implement, but the productivity is low due to high scrap rates
Solution Approach 1:
By changing the manufacturing parameters from dipping to compression molding with controlled temperature and pressure, the patent achieves near-zero defect rates, thereby significantly improving productivity while maintaining ease of implementation
Solution Approach 2:
The compression molding process inherently produces defect-free parts through controlled curing between molds, eliminating the need for post-production quality control and rework, thus improving overall productivity
3Device complexity
If uniform wall thickness is used in the cushion part, then the manufacturing process is simple, but the cushioning performance is insufficient for different body pressure areas
Solution Approach 1:
The patent applies local quality by creating variable wall thicknesses in different regions of the cushion part through specialized mold design, allowing thicker sections for high-pressure areas and thinner sections for low-pressure areas, thereby optimizing cushioning performance while maintaining relatively simple manufacturing
Solution Approach 2:
The patent changes the wall thickness parameter from uniform to variable through mold design, enabling differentiated cushioning performance for different body areas while maintaining a single-manufacturing-process approach
4Device complexity
If the cushion part contour and surface structure are not precisely controlled, then the manufacturing process is simpler, but the orthopedic support function is compromised
Solution Approach 1:
The patent replaces imprecise dipping with controlled compression molding that uses mechanical pressure and heat to achieve exact contour and surface structure replication from the mold, ensuring optimal orthopedic support function
Solution Approach 2:
The patent changes the manufacturing parameters to include controlled temperature and pressure during compression molding, which enables precise replication of the mold's contour and surface structure, thereby ensuring reliable orthopedic support
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
This approach significantly reduces scrap production, allows for precise customization of cushion parts, and enhances the cushioning and supporting properties by creating a damping effect through fluid connections, resulting in improved durability and user support.
Implementation Method 1
a2) Pressing the raw material between the inner mold and the outer mold
Implementation Method 2
a3) Vulcanizing the raw material between the inner mold and the outer mold to form the first cushion part
Implementation Method 3
enhances the cushioning and supporting properties by creating a damping effect through fluid connections
Data Source
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AI summary
The invention relates to a method for manufacturing a cushion for an orthopedic device, the cushion having at least one fluid-filled volume. The method comprises the following steps: e) compression-molding a three-dimensional first cushion part from at least one first material that is preferably resilient, in a mold that has an inner mold part and an outer mold part, and f) bonding the first cushion part to at least one second cushion part such as to form the fluid-filled volume.