Thermoformed PPE Padding Structure for Stable Comfort Fit
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Solution Overview
Problem
Existing personal protective equipment padding, such as helmet liners and pads, suffer from instability and discomfort due to the use of multiple independent sections with varying thicknesses, leading to inadequate comfort and stability over time.
Innovation Solution
A continuous, two- or three-dimensional padding structure with uniform thickness and engagement means like buttons or notches, formed through a thermoforming process, ensuring stable adhesion to the inner layer of protective devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple independent sections with varying thicknesses are used, then the padding can be assembled to fit different body parts, but the padding becomes unstable and uncomfortable over time
Solution Approach 1:
The patent merges multiple independent padding sections into a single continuous padding structure that extends from the front to the back of the protective device. This continuous structure eliminates the instability and discomfort caused by multiple separate sections while maintaining the ability to fit different body parts through its extended coverage and engagement means distributed along the entire surface.
Solution Approach 2:
The continuous padding is segmented into multiple engagement sections, each with engagement means positioned at specific locations along the padding surface. These engagement sections can independently engage with the protective device at different positions, allowing the padding to adapt to various body shapes and sizes while maintaining overall structural stability as a single continuous piece.
2Adaptability or versatility
If multiple independent sections with varying thicknesses are used, then the padding can be customized for different regions, but the thickness variation causes discomfort
Solution Approach 1:
The continuous padding maintains a substantially uniform thickness throughout its entire surface, providing consistent comfort across all contact areas. The local quality is achieved through the uniform thickness while the adaptability is maintained through the extended surface area and strategically positioned engagement means that allow the padding to conform to different body shapes and sizes without requiring varying thicknesses.
3Ease of operation
If a continuous padding structure with uniform thickness is used, then comfort is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs thermoforming technology to transform a flat or substantially flat sheet material into a three-dimensional continuous padding structure with uniform thickness. By controlling the forming process parameters and using a mold with the desired geometry, the manufacturing complexity is managed while achieving the comfort benefits of a uniform, continuous structure that conforms to the protective device's shape.
4Stability of the object's composition
If engagement means are added to the padding, then attachment stability is improved, but the device complexity increases
Solution Approach 1:
The engagement means are integrated into the continuous padding structure during the thermoforming process itself, rather than being added as separate components afterward. The mold used in the thermoforming process incorporates the engagement means, allowing them to be formed simultaneously with the padding body. This preliminary integration maintains attachment stability while minimizing the increase in device complexity by avoiding additional assembly steps.
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 padding provides enhanced user comfort and stability by maintaining consistent thickness and secure attachment, addressing the issues of instability and discomfort in traditional padding designs.
Implementation Method 1
its thermoforming process
Data Source
Figure 1~2
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Figure 5
AI summary
Padding thermoforming process comprising the steps of - making padding elements (1, 1') of nylon or expanded plastic or fabric-covered polyurethane; - making engagement portions (2, 2') having the same shape as the covering element (1, 1') so that the two contact surfaces fit together perfectly - applying the engagement portions (2, 2') above the covering element (1, 1') to obtain the padding (100, 101); - placing the padding (100, 101) inside a mold which blocks the reciprocal positions of the covering element (1, 1') and the engagement portions (2, 2'); - heating the mold to 180° C and maintaining this temperature for a predetermined time depending on the thickness; - pulling out the padding (100, 101) obtained and fixing it inside the personal protective equipment.