Steam-Molded Weighted Toy With ETPU Shell and Dense Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pet toys made from expanded thermoplastic polyurethane (ETPU) are too lightweight, leading to undesirable flight characteristics and limited throwing range due to air resistance.
Innovation Solution
A toy configuration with an ETPU outer shell and a denser core portion, formed via steam chest molding, where the core is suspended within the mold using projections, allowing the toy to be weighted and maintain desirable properties like durability and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the toy is made from expanded thermoplastic polyurethane (ETPU), then the toy achieves durability and elasticity, but the toy becomes too lightweight resulting in undesirable flight characteristics
Solution Approach 1:
The patent applies composite materials by combining ETPU (expanded thermoplastic polyurethane) with a denser core material. The ETPU provides durability and elasticity while the denser core material increases weight. This composite structure resolves the contradiction by integrating two materials with complementary properties to achieve both lightness/durability and sufficient weight for desirable flight characteristics.
2Strength
If the toy is made from expanded thermoplastic polyurethane (ETPU), then the toy achieves elasticity, but the toy becomes too lightweight resulting in limited throwing range
Solution Approach 1:
The patent uses composite materials combining ETPU with a denser core material. The ETPU layer maintains elasticity and bounce characteristics while the denser core material provides the necessary weight for extended throwing range. This composite approach allows the toy to simultaneously achieve desirable elasticity and sufficient weight.
3Weight of moving object
If a denser core material is added to increase weight, then the toy achieves optimal throwing characteristics, but the toy structure becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the toy into distinct components: an outer ETPU layer and an inner denser core material. This segmentation allows each layer to perform its specific function (ETPU for durability/elasticity, core for weight) while simplifying the manufacturing process through layered construction. The segmented structure resolves the complexity issue by using a straightforward multi-layer approach rather than a complex integrated design.
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 toy achieves optimal throwing and bouncing characteristics by balancing weight and elasticity, while retaining pet safety and durability.
Implementation Method 1
introducing an amount of at least partially unexpanded polyurethane beads into at least one of the first cavity, the second cavity, and/or the combined cavity, and injecting steam into the mold to cause the polyurethane beads to expand
Data Source
AI summary
In some embodiments, a toy is disclosed. In some embodiments, the toy includes an expanded thermoplastic polyurethane (ETPU) outer shell portion and a core portion formed of a material with a higher density than the ETPU forming the outer shell portion. In some embodiments, a mold for forming a toy with an ETPU outer shell portion and with a core portion formed of a different material is disclosed. In some embodiments, a method of forming a toy with an ETPU outer shell portion and core portion formed of a different material is disclosed.