Powder Application Device with Barrier Elements for Variable Stiffness
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Solution Overview
Problem
Existing methods for producing reinforcing elements, such as those for shoes and orthopedic applications, fail to create reinforcing elements with differently reinforced areas effectively, particularly in regions like toe caps and heel caps, where varying stiffness is required.
Innovation Solution
A powder application apparatus with a template and barrier elements, such as webs or pins, is used to control the flow of meltable powder onto a feeding element, allowing for areas of varying material thickness and stiffness by reducing powder supply in specific areas, ensuring a complete closed material layer is formed, and subsequently compacted with pressure and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a template is used to define the basic shape of reinforcing elements, then the powder can be applied in the desired basic shape, but it is not possible to create differently reinforced areas (e.g., toe cap, heel cap) with varying stiffness
Solution Approach 1:
The patent introduces barrier elements (such as pins, webs, or grids) within the template structure that are selectively positioned to create local variations in powder flow. These barrier elements reduce powder supply in specific areas, enabling the formation of differently reinforced zones (e.g., thicker toe cap, thinner heel cap) while maintaining the overall basic shape defined by the template. This local modification approach allows a single template to produce reinforcing elements with varying stiffness in different regions.
2Adaptability or versatility
If barrier elements are added to reduce powder supply in specific areas, then differently reinforced areas can be created, but the device complexity increases
Solution Approach 1:
The patent integrates barrier elements directly into the template structure, merging the shape-defining function and the powder-flow-controlling function into a single component system. The barrier elements (pins, webs, grids) are incorporated as part of the template assembly, allowing them to be manufactured and installed together as one unit. This integration approach enables the creation of differently reinforced areas without requiring separate, complex control mechanisms for each barrier element, thereby limiting the increase in device complexity.
3Ease of manufacture
If the powder application apparatus is designed to apply powder uniformly, then the process is simple, but it cannot produce reinforcing elements with areas of different material thickness
Solution Approach 1:
The patent introduces barrier elements as intermediary components within the powder application system that mediate between the uniform powder flow from the container and the desired non-uniform thickness distribution in the final product. These barrier elements (pins, webs, grids) act as flow modifiers that selectively impede powder flow in specific regions, enabling precise control of material thickness variations (e.g., 0.2 to 3 mm) while maintaining the simplicity of the overall powder application process.
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 apparatus enables the production of reinforcing elements with distinct areas of different material thickness and stiffness from a single material, forming one-piece elements with specific design requirements, like shoes and bags, by precisely controlling powder distribution and compaction.
Implementation Method 1
the powder can freely flow out of the outlet by gravity
Data Source
AI summary
A powder application apparatus for an at least partially meltable powder to be applied onto a feeding element for producing reinforcing elements comprises a powder container. In the area of an outlet of the powder container a template for defining a basic shape of a reinforcing element to be produced is provided. Further, a closing device for opening and closing the outlet is provided. For producing reinforcing elements having different stiffness, barrier elements in particular connected with the template are provided. The barrier elements reduce the powder supply to the feeding element such that a reinforcing element with areas of different material thickness are created. A method for producing such a reinforcing element.