Streamlined Edge Moulding for Impact-Resistant Pads
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Solution Overview
Problem
Existing methods for manufacturing flexible, impact-resistant pads result in pads with square edges, which are aesthetically unpleasing and increase air resistance and drag when worn, particularly in sports and protective gear.
Innovation Solution
A method involving a sheet of impact-absorbing material is cut and moulded using a contoured mould tool to create streamlined edges, with additional flexible layers bonded using hot-melt adhesives and a heated press, allowing for efficient production of pads with radiussed, tapered, or chamfered edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sheet of impact-absorbing material is cut into spaced separate elements using a cutter pressed into the sheet, then the pad can be manufactured efficiently with simple equipment, but the edges around the pad become square and unstreamlined
Solution Approach 1:
The method applies preliminary action by moulding the impact-absorbing material to a contoured tool before cutting. This preliminary shaping step creates the streamlined edge profile in advance, so that subsequent cutting operations do not destroy the desired shape. The material is pre-formed to the final edge contour before being separated into individual elements.
Solution Approach 2:
The invention directly applies curvature by using a contoured mould tool with a streamlined profile (radiussed, tapered, or chamfered edges) to shape the impact-absorbing material. The contoured tool imprints its curved profile onto the material, transforming square edges into aerodynamic shapes that reduce air resistance.
2Shape
If additional steps are added to mould the impact-absorbing material to create streamlined edges, then the aesthetic appeal and aerodynamic performance improve, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges multiple functions into a single contoured mould tool. The tool simultaneously performs shaping (creating streamlined edges), cutting (separating elements), and positioning (holding elements in place during bonding). This consolidation reduces the number of separate manufacturing steps and equipment needed, despite adding the streamline shaping capability.
Solution Approach 2:
The contoured mould tool is designed with multi-functionality, serving as both a shaping device for creating streamlined edges and as a cutting tool for separating the impact-absorbing material into individual elements. This universal tool eliminates the need for separate shaping and cutting operations, reducing overall process complexity.
3Shape
If the contoured mould tool is pressed into the impact-absorbing material to define the streamlined shape, then radiussed, tapered, or chamfered edges are achieved, but additional heating equipment and energy consumption are required
Solution Approach 1:
The invention applies parameter changes by controlling the temperature of the impact-absorbing material during moulding. The material is heated to a temperature where it becomes pliable enough to conform to the contoured tool, then cooled to set the streamlined shape. This temporary parameter change enables shaping without requiring continuous high-energy heating.
Solution Approach 2:
The method utilizes phase transitions of the impact-absorbing material, transitioning it from a rigid state to a pliable state through heating, allowing it to conform to the contoured mould tool. After shaping, the material transitions back to a rigid state upon cooling, permanently retaining the streamlined edge profile.
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 method produces pads with streamlined edges that enhance the aesthetic appeal and reduce air resistance and drag, improving comfort and performance in clothing and protective wear.
Implementation Method 1
heating the impact-absorbing material or the mould tool
Implementation Method 2
heating the impact-absorbing material or the mould tool; and pressing the mould tool into the impact-absorbing material to mould the impact-absorbing material
Implementation Method 3
bonding one side of the first, flexible layer of material to the spaced, separate elements
Implementation Method 4
bonding the elements to the substrate by heating the substrate either to activate an adhesive applied between said one side of the separate elements and the substrate
Data Source
AI summary
A method of manufacturing a flexible, impact-resistant pad (1), primarily for use in an item of protective wear, comprises the following steps. First, a sheet (16) of impact-absorbing material (3, 4, 4), for example a closed-cell foam is provided. The sheet (16) is cut to provide a piece (16) with a profile required for the pad (1) and this piece (16) is then cut into a plurality of spaced, separate elements (2), which are retained within the required profile of the pad (1). A first, flexible layer (17, 4) of material (3) is provided and one side of same is bonded to the spaced, separate elements (2). The edge (5) of the pad (1) is streamlined by the following additional steps which may be carried out either before cutting of the sheet (16) into the plurality of spaced, separate elements (2) or after bonding of the first, flexible layer (17, 4) of material (3) to the spaced, separate elements (2). First, a contoured mould tool (8) is provided that defines a recess (9) having a shape complementary to the shape required on one side of the pad (1) and a streamlined edge (10) around at least part of its periphery. The impact-absorbing material (3, 4, 4) or the mould tool (8) is heated and the mould tool (8) is then pressed into it to mould it on one side to define the shape that is required. Preferably, the method comprises the further step of bonding a second flexible layer (17, 4) of material (4) to the moulded side of the pad (1). During bonding of this second flexible layer (17, 4) of material (4), the pad (1) is preferably supported on a yielding surface (23) to enable the moulded side of the pad (1) to flatten during bonding. Also provided is a flexible, impact-resistant pad (1) Comprising a first, flexible layer (17, 4) of material (3) and a plurality of spaced, separate elements (2) that are each comprised of an impact-absorbing material (3, 4, 4) and that are bonded to one side of the first flexible layer (17, 4) of material (3). At least some of the elements (2) adjacent the edge (5) of the pad (1) are streamlined around at least part of the periphery of the pad (1).