3D Paw Pad Sock Mold Assembly for Tactile Feedback
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Solution Overview
Problem
There is a need for a manufacturing technique that creates socks with raised features providing both visual and tactile feedback to the wearer, enhancing the experience with decorative elements that mimic animal paws.
Innovation Solution
A mold assembly and method for forming three-dimensional paw pads using urethane or polyurethane foam materials, which are then affixed to the sock bottom surface, providing a visual effect and tactile sensation, along with audible feedback as the wearer walks, utilizing a base, mold, pressure backing member, and alignment members to shape and secure the foam pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid material is deposited at spaced locations around the stocking to create slip-resistant features, then the slip-resistance is improved through solidified material with greater coefficient of friction, but the features remain flat and lack visual and tactile feedback
Solution Approach 1:
The patent transitions from flat, two-dimensional slip-resistant material deposition to three-dimensional raised features that protrude from the stocking surface. The mold assembly creates features with height, width, and depth, adding a vertical dimension that provides both tactile feedback through compression and visual appeal while maintaining slip-resistance functionality.
Solution Approach 2:
The patent changes the physical state and form parameters of the slip-resistant material from a flat liquid deposit to a three-dimensional solid structure. By controlling the molding process, the material is transformed into raised features with specific geometric parameters (height, width, shape) that simultaneously achieve slip-resistance and provide sensory feedback.
2Ease of manufacture
If three-dimensional paw pads are formed using a mold assembly with pressure relief vents, then the visual and tactile feedback is improved through realistic paw features, but the device complexity increases with multiple components including base, mold, pressure backing member, and alignment members
Solution Approach 1:
The mold assembly is divided into distinct functional segments: a base for support, a mold cavity for shaping, a pressure backing member with integrated pressure relief vents, and alignment members. This segmentation allows each component to perform its specific function efficiently while being manufactured separately and assembled systematically, reducing overall complexity.
Solution Approach 2:
The pressure backing member serves multiple functions simultaneously: it provides structural support, incorporates pressure relief vents to manage material flow and air evacuation, and integrates with the mold cavity to define the three-dimensional shape. This multi-functionality reduces the total number of separate components needed in the assembly.
3Ease of manufacture
If raised features are created to provide tactile sensation and visual effect, then the wearer experience is improved, but the manufacturing precision requirements increase to ensure proper three-dimensional shape and alignment
Solution Approach 1:
The mold cavity is pre-formed with the exact negative impression of the desired paw pad geometry, including all dimensional specifications and surface features. Alignment members are pre-positioned to ensure correct placement and orientation. This preliminary preparation of the mold and alignment fixtures ensures that when material is deposited and cured, the three-dimensional features are formed with high precision without requiring complex real-time adjustments.
Solution Approach 2:
The mold assembly is designed to self-align and self-regulate during the manufacturing process. Alignment members automatically position the mold cavity and pressure backing member in correct registration. The pressure relief vents automatically regulate material flow and air evacuation. This self-aligning mechanism reduces the need for high-precision manual assembly and maintains consistent dimensional accuracy across production batches.
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 solution effectively creates socks with raised, elastic paw pads that offer a realistic tactile and visual experience, including audible feedback, enhancing the wearer's sensory interaction with the environment.
Implementation Method 1
Each paw pad has a three-dimensional shape defined by a height, length and width and a certain elasticity
Data Source
AI summary
A sock having raised features includes one or more three-dimensional paw pads affixed thereon. More in particular, a plurality of individual three-dimensional paw pads are affixed to a bottom portion of the sock to provide a visual effect of having animal paws, and to further provide a wearer a tactile sensation of having animal paws on the wearer's foot while walking. A mold assembly and a method for the manufacture of a plurality of three-dimensional paw pads to be affixed to a sock includes at least one mold.