Modular Mold Assembly for Thermoforming Polymeric Bladders
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Solution Overview
Problem
Traditional mold assemblies are inflexible and costly, as they can only produce one size of bladder and require different assemblies for varying configurations or characteristics, making it time-consuming and expensive to manufacture bladders with different configurations or characteristics.
Innovation Solution
A modular mold assembly with removable mold tools that have unique topographies, allowing for the thermoforming of bladders with nonuniform surfaces, enabling the production of bladders with different configurations or characteristics using the same base mold assembly by swapping removable tools, thus reducing the need for multiple mold assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mold assemblies are used, then manufacturing precision is maintained, but device complexity and cost increase due to requiring different assemblies for varying bladder configurations
Solution Approach 1:
The mold assembly is divided into a base mold and removable mold tools. The base mold contains the cavity, while separate removable tools with different topographies can be inserted to create different bladder configurations. This segmentation allows one base mold to produce multiple bladder types by simply changing the removable tool, reducing overall device complexity while maintaining versatility.
Solution Approach 2:
The base mold assembly is designed to be universal and can accommodate different removable mold tools with various topographies. This multi-functionality allows a single base mold to produce different bladder configurations, sizes, and surface characteristics by simply swapping the removable tools, thereby improving adaptability without proportionally increasing device complexity.
2Adaptability or versatility
If traditional mold assemblies are used, then manufacturing precision is maintained, but loss of time increases due to time-consuming production of bladders with different configurations
Solution Approach 1:
By separating the mold into a base component and removable tools, the system enables quick switching between different bladder configurations. Instead of redesigning or repositioning an entire mold assembly, only the small removable tool needs to be changed, significantly reducing the time lost when producing different bladder types.
Solution Approach 2:
The removable mold tools are pre-designed with specific topographies corresponding to different bladder configurations. These tools can be prepared and stored separately, allowing for rapid insertion and immediate production of different bladder types without time-consuming on-site modifications to the mold assembly.
3Adaptability or versatility
If traditional mold assemblies are used, then manufacturing precision is maintained, but cost increases due to requiring different assemblies for varying configurations
Solution Approach 1:
The mold system is segmented into a reusable base mold and interchangeable removable tools. The base mold, which constitutes the majority of the mold cost, is reused for all bladder types. Only the inexpensive removable tools need to be replaced when changing configurations, significantly reducing the overall manufacturing cost compared to requiring complete mold assembly replacements.
Solution Approach 2:
The base mold is designed as a universal component that can work with multiple different removable tools. This multi-functionality allows the expensive base mold to serve multiple purposes across different bladder configurations, amortizing its cost over multiple product variants and reducing the per-unit manufacturing cost for each bladder type.
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 quick and cost-effective production of bladders with varying nonuniform topographies by allowing different removable mold tools to be used within the same modular mold assembly, enhancing design flexibility and reducing production costs.
Implementation Method 1
a base having a mold surface that partially defines a mold cavity for thermoforming a polymeric bladder
Data Source
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AI summary
A method of manufacturing a wearable article may include providing a modular mold assembly that defines a mold cavity. The modular mold assembly may include a base and a first removable mold tool that interfits with the base. The base may have a mold surface partially defining the mold cavity and the first removable mold tool may have a mold surface disposed at and further defining the mold cavity of the modular mold assembly. A topography of the mold surface of the first removable mold tool may be nonuniform and different than a topography of the mold surface of the base. The method may include disposing polymeric material at the mold cavity, and then thermoforming a bladder in the mold cavity from the polymeric material. The bladder may have an outer surface with a nonuniform topography imparted by the topography of the mold surface of the first removable mold tool.