Mould System for 3D Items Using Molten Adhesive Bonding
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Solution Overview
Problem
Traditional manufacturing methods for three-dimensional items with flexible walls, such as footwear and furniture, are labor-intensive and costly due to the need for sewing and direct injection moulds made of multiple machined metal parts, which are expensive and inflexible, limiting production efficiency and design possibilities.
Innovation Solution
An independent mould system that can be moved freely within a manufacturing plant, using interchangeable components and an elastically deformable template to join laminar parts with molten adhesive, eliminating the need for permanent machine connection and reducing material costs and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sewing and injection moulding methods are used, then manufacturing precision is achieved, but labor intensity and production cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical sewing processes with a direct injection moulding system that uses molten adhesive to bond laminar parts. This substitution eliminates the need for needles, threads, and manual sewing operations, thereby maintaining manufacturing precision while significantly reducing labor intensity and increasing productivity.
Solution Approach 2:
The invention changes the fundamental parameter of the bonding process from mechanical interlocking (sewing) to chemical bonding (molten adhesive injection). This parameter change enables automated production while maintaining the precision required for three-dimensional items with flexible walls, resolving the contradiction between precision and productivity.
2Manufacturing precision
If multiple machined metal parts are used for injection moulds, then manufacturing precision is achieved, but device complexity and cost increase
Solution Approach 1:
The mould is divided into separate components: a fixed mould part and a movable mould part, allowing for simplified construction. This segmentation enables the use of less complex materials and manufacturing processes while maintaining the precision required for producing three-dimensional items, as each segment can be manufactured independently and assembled.
Solution Approach 2:
The patent employs a mould construction that prioritizes cost-effectiveness and ease of manufacture over longevity. By using simpler materials and a segmented design, the mould can be produced more cheaply and quickly, reducing the complexity associated with traditional multi-part metal moulds while still achieving the necessary manufacturing precision.
3Manufacturing precision
If permanent machine connection is required for moulds, then manufacturing precision is maintained, but adaptability and mobility are reduced
Solution Approach 1:
The mould is designed with dynamic characteristics, allowing it to be moved between different workstations and positions during the manufacturing process. The segmented design with separate fixed and movable parts enables the mould to adapt to different operational requirements while maintaining precision, as the segments can be repositioned without compromising the accuracy of the manufactured items.
4Manufacturing precision
If sewing processes are used to join laminar parts, then manufacturing precision is achieved, but loss of time and labor costs increase
Solution Approach 1:
The laminar parts are prepared and positioned within the mould before the molten adhesive is injected. This preliminary arrangement ensures that when the adhesive is introduced, the parts are already in their final positions, eliminating the need for subsequent sewing or assembly operations. This preliminary action significantly reduces the overall manufacturing time while maintaining precision.
Solution Approach 2:
The patent replaces the time-consuming mechanical sewing process with a faster chemical bonding process using molten adhesive. This substitution maintains the precision required for joining laminar parts while dramatically reducing the time needed for the bonding operation, as the adhesive sets quickly without requiring the extended time needed for needle and thread operations.
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 efficient, flexible, and cost-effective production of three-dimensional items with improved design freedom and reduced labor costs, allowing for short production runs and enhanced manufacturing plant automation.
Implementation Method 1
an elastically deformable template to join laminar parts with molten adhesive
Data Source
AI summary
A mould for manufacturing three-dimensional items, comprising a body; a lid configured to close the body; and incorporated closing and openings configured to keep the body and the lid joined during the movement thereof is disclosed. A machine for manufacturing three-dimensional items, comprising a receiving module configured to receive the mould; a conditioning module configured to receive the mould from the receiving module and act on the incorporated closing and openings in order to separate the lid from the body; and a handling module configured to receive the body from the conditioning module and enable the placement of the components of the item to be manufactured. A method for manufacturing three-dimensional items and manufacturing plant associated with the machine.