Segmented Cushioning Elements for Breathable Impact Protection
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Solution Overview
Problem
Existing cushioning technologies in athletic and protective gear often compromise on breathability, flexibility, and launderability while providing impact protection, and there is a need for a manufacturing process that efficiently integrates cushioning elements into various products with customizable properties.
Innovation Solution
A cushioning element configuration comprising a first material layer, a second material layer, and a plurality of pad components secured through thermal bonding or a combination of thermal bonding and stitching, with a manufacturing process using a die and extractor system to cut and bond the pad components to the material layers, ensuring breathability, flexibility, and low mass while maintaining impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cushioning materials are used to provide impact protection, then impact force attenuation is improved, but breathability and flexibility deteriorate
Solution Approach 1:
The cushioning element is divided into multiple discrete pad components arranged in an array rather than using a single solid cushioning material. This segmentation allows breathability through the spaces between pads while maintaining impact protection through the distributed pad structure
Solution Approach 2:
Different regions of the cushioning element can have different pad densities, sizes, or material properties tailored to specific impact zones. The pad components can be selectively positioned to provide localized cushioning where needed while maintaining breathability in other areas
2Strength
If traditional cushioning materials are used to provide impact protection, then impact force attenuation is improved, but launderability deteriorates
Solution Approach 1:
The segmented pad component structure allows each pad to be independently secured to the substrate, enabling the entire assembly to be machine-washed without the cushioning material degrading or losing its protective properties
Solution Approach 2:
The cushioning element combines multiple materials including the substrate material, pad component materials, and bonding agents to create a composite structure that maintains impact protection while being washable and durable
3Adaptability or versatility
If a complex manufacturing process is used to integrate cushioning elements, then customization and performance are improved, but manufacturing efficiency and cost deteriorate
Solution Approach 1:
Pad components are pre-formed and prepared separately before being positioned and bonded to the substrate. This preliminary preparation allows for efficient batch production of pads that can be quickly assembled into various cushioning element configurations
Solution Approach 2:
The manufacturing process allows easy adjustment of pad parameters such as size, density, material composition, and arrangement pattern by changing molding or cutting parameters, enabling customization without requiring completely different manufacturing processes
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 provides enhanced breathability, flexibility, and launderability while maintaining effective impact force attenuation, with customizable properties tailored to specific applications, and a streamlined manufacturing process that integrates cushioning elements efficiently into diverse products.
Implementation Method 1
The polymer material is compressed between the die and the extractor, the die elements cut the polymer material to form a plurality of pad components
Implementation Method 2
the first material layer and the second material layer are joined through thermalbonding or a combination of thermalbonding and stitching
Data Source
AI summary
A method for manufacturing the cushioning elements may include utilizing a die with a plurality of die elements positioned in a particular arrangement. A polymer material, which may be a polymer foam material, is located between the die and an extractor. The polymer material is compressed between the die and the extractor, and the die elements cut the polymer material to form a plurality of pad components, which are arranged like the die elements. The die and the extractor are separated, and the pad components are secured to the extractor in the arrangement of the die elements. Additionally, the pad components are bonded to at least one material layer such that the pad components remain in the arrangement of the die elements.