3D Netted Cushion Forming With Direct Heating and Fast Release
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Solution Overview
Problem
Existing methods for forming three-dimensional netted structures, such as those used in cushion manufacturing, require lengthy mold release times and complex secondary processing steps, which hinder production efficiency and flexibility.
Innovation Solution
Direct heating of the three-dimensional netted structure instead of the mold, combined with compression and cooling steps, to expedite the formation process and reduce mold release time, allowing for faster production and customization of cushion shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the mold is heated to thermally soften the three-dimensional netted structure, then the cushion can be formed with original shape conforming to individual build, but the mold release time becomes significantly long due to large mold size and slow cooling
Solution Approach 1:
The patent extracts the heating function from the mold and applies it directly to the three-dimensional netted structure. A heating device is positioned to heat the netted structure directly while it is being formed in the mold, rather than heating the mold itself. This allows the mold to remain at ambient temperature and release the cushion quickly after forming, dramatically reducing mold release time while still achieving thermal softening for shape formation.
Solution Approach 2:
The patent separates the heating process from the mold system, treating them as independent components. The heating device operates independently on the netted structure, while the mold simply provides the forming cavity. This segmentation allows the mold to be small and cool quickly, reducing release time, while the heating function is performed separately on the workpiece.
2Ease of manufacture
If conventional four-face forming method is used with molten filaments extruded from die, then alignment is enhanced and post finishing step is not required, but the method lacks flexibility for customization and requires complex drawing machine arrangements
Solution Approach 1:
The patent performs the alignment and forming actions during the extrusion process itself, rather than requiring separate post-finishing steps. The drawing machines are positioned to draw the extruded filaments into the mold cavity while they are still molten and pliable, achieving alignment and shape formation in one continuous operation. This preliminary action eliminates the need for subsequent alignment adjustments or finishing operations.
3Volume of moving object
If compression molding is used with long mold stroke, then thinner cushion is produced, but production time increases due to extended heating and cooling cycles
Solution Approach 1:
The patent extracts the heating function from the mold system and applies it directly to the netted structure during forming. This allows the mold to remain cool and small, enabling rapid release after forming regardless of cushion thickness. The heating time is decoupled from the mold cycle time, allowing thin cushions to be produced quickly without extended heating and cooling cycles of large molds.
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 shortens the mold release time, enhances production efficiency, and enables the creation of customized cushion shapes and sizes with improved impact resistance and load-bearing properties, addressing the inefficiencies of previous methods.
Implementation Method 1
the three-dimensional netted structure is directly heated to enhance the efficiency, instead of heating the mold
Implementation Method 2
compression molding method enables formation of any original shape conforming to the individual build
Implementation Method 3
The three-dimensional structure is allowed to cool down and cure
Data Source
AI summary
A method for forming cushions including the following four steps: (1) a compression step in which the structure (2) is compressed in a mold (3); (2) a thermal softening step in which the structure (2) is thermally softened by means of a heating medium; (3) a curing step in which the structure (2) directly undergoes forced cooling in a cooling medium, and is then cured; and (4) a mold release step in which the structure (2) is released from the mold (3).