Segmented Foam Cushioning Layout for Breathable Impact Protection
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Solution Overview
Problem
Existing cushioning technologies lack an efficient method for manufacturing cushioning elements with specific arrangements of pad components that provide optimal impact protection and comfort while maintaining breathability, flexibility, and launderability.
Innovation Solution
A manufacturing process using a die with outwardly-extending pins and an extractor to cut and secure polymer foam pad components between two material layers, allowing for customizable arrangements and bonding techniques like thermalbonding to integrate the pad components into the cushioning elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cushioning elements are manufactured with multiple pad components arranged in specific patterns, then impact protection and comfort are improved, but manufacturing complexity increases
Solution Approach 1:
The cushioning element is divided into multiple discrete pad components (e.g., 230) that are separately formed and then arranged in specific patterns between material layers. This segmentation allows each pad component to be optimized for impact protection while the overall arrangement provides comprehensive coverage, resolving the contradiction between improved protection and manufacturing complexity.
Solution Approach 2:
The pad components are pre-formed using a die with cavities that define their shapes and arrangements before being integrated into the final cushioning element. This preliminary formation step allows for precise control of pad component geometry and arrangement, improving impact protection while simplifying the final assembly process.
2Stability of the object's composition
If pad components are securely bonded between material layers, then cushioning element stability is improved, but breathability and flexibility may deteriorate
Solution Approach 1:
The bonding between pad components and material layers is applied selectively at specific locations rather than uniformly across the entire surface. This allows pad components to be securely held in position for stability while leaving gaps and pathways open for breathability and flexibility. The bonding strength and coverage are optimized locally to balance these competing requirements.
3Manufacturing precision
If polymer foam material is compressed between die and extractor, then pad component formation precision is improved, but manufacturing time increases
Solution Approach 1:
The die with cavities is pre-configured with the exact arrangement and shapes of pad components required. The polymer foam material is then compressed into these pre-defined cavities, which automatically forms the pad components with high precision. This preliminary configuration of the die eliminates the need for complex real-time control during compression, maintaining precision while reducing manufacturing time.
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 enables the creation of cushioning elements with tailored impact protection, breathability, flexibility, and launderability, providing enhanced comfort and protection in various applications while maintaining a low overall mass.
Implementation Method 1
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
Implementation Method 2
the pad components are bonded to at least two material layers such that the pad components remain in the arrangement of the die elements
Data Source
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AI summary
A method for manufacturing the cushioning elements (200) may include utilizing a die (310) with a plurality of die elements (312) positioned in a particular arrangement. A polymer material, which may be a polymer foam material, is located between the die (310) and an extractor (320). The polymer material is compressed between the die (310) and the extractor (320), and the die elements (312) cut the polymer material to form a plurality of pad components (230), which are arranged like the die elements (312). The die (310) and the extractor (320) are separated, and the pad components (230) are secured to the extractor (320) in the arrangement of the die elements (312). Additionally, the pad components (230) are bonded to at least one material layer (210, 220) such that the pad components remain in the arrangement of the die elements.