Thermoforming Mold for Pressurized Fluid Chamber Inflation
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Solution Overview
Problem
Conventional methods for forming fluid-filled chambers in shoes often result in large, visually distinct seams that detract from the aesthetic appeal, making it difficult to create a uniform and visually pleasing design.
Innovation Solution
A thermoforming process using a mold with a dome-like depression and channel system allows for the inflation of fluid-filled chambers without inserting a needle, enabling a smaller seam and positioning it on an interior-facing surface, thus enhancing the chamber's appearance and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a needle is inserted into the chamber to pressurize the chamber, then the chamber can be filled with fluid, but a large seam is created around the needle entry point that is visually distinct and detracts from aesthetic appeal
Solution Approach 1:
The patent extracts the needle insertion step from the chamber formation process. Instead of inserting a needle into the sealed chamber to pressurize it, the system creates an opening in the mold itself during the forming process, allowing fluid to be introduced without requiring post-formation needle insertion. This eliminates the need for a large sealing seam around a needle entry point.
Solution Approach 2:
The patent performs the opening creation and fluid introduction preparation in advance, during the mold forming process itself. The opening is created in the mold before the membrane is sealed, allowing fluid to be introduced through this pre-positioned opening rather than requiring a separate needle insertion step after chamber formation.
2Device complexity
If the seam is positioned on an exterior-facing surface, then the chamber structure is simplified, but the aesthetic appeal is reduced due to the visible seam
Solution Approach 1:
The patent resolves the contradiction by changing the spatial dimension of seam placement. Instead of placing the seam on the exterior-facing surface (2D surface consideration), the system positions the seam on the interior-facing surface of the chamber, utilizing the third dimension of chamber orientation. This allows the seam to remain part of the chamber structure while being hidden from external view, achieving both structural simplicity and visual uniformity.
3Reliability
If a large seam is created around the needle entry point, then the sealing is more robust, but the visible surface area of the chamber is reduced
Solution Approach 1:
The patent extracts the large sealing seam from the exterior surface by removing the needle insertion step entirely. Instead of creating a large seam around a needle entry point on the visible surface, the system introduces fluid through an opening in the mold during formation, allowing the seam to be placed on the interior surface where it does not reduce visible surface area while maintaining seal integrity.
4Shape
If the chamber is formed with a hidden seam, then the aesthetic appeal is improved, but it becomes difficult for consumers to distinguish shoes with fluid-filled chambers from those without
Solution Approach 1:
The patent applies the principle of visual differentiation by making the chamber material itself visually distinctive. The membrane or film forming the chamber can be made with different colors, patterns, or transparency levels compared to surrounding materials, allowing the chamber to be visually identified without requiring a visible seam. This maintains aesthetic appeal while providing visual information to consumers.
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 process results in a more uniform and aesthetically pleasing fluid-filled chamber with a smaller seam, allowing for greater surface area visibility in shoe designs, improving the chamber's appearance and suitability for visible shoe designs.
Implementation Method 1
pressurized fluid can be delivered into the chamber through the hole formed in the pliable material
Implementation Method 2
A thermoforming process using a mold with a dome-like depression and channel system allows for the inflation of fluid-filled chambers
Data Source
AI summary
A fluid chamber for a shoe may be formed using pressure channels in a forming mold, eliminating the need to insert a nozzle or needles into the chamber for inflation. A fluid chamber so formed may have a smaller seal area than a chamber formed using an inflation needle, making the chamber more visually pleasing. Apparatus and methods for forming a fluid chamber in this fashion are also disclosed.