Thermoforming System for Cushioning Pod Structure
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Solution Overview
Problem
Traditional methods for forming cushioning articles, such as shoe soles, face challenges in achieving optimal impact attenuation and conformance due to pre-loaded stress, which affects the ability to effectively attenuate impact forces.
Innovation Solution
A thermoforming system with multiple stations, utilizing a thermal source, vacuum, and positive pressure sources to efficiently form a cushioning pod structure from a polymeric film, allowing for shared resources and reduced costs and energy consumption, while enabling precise control over the thermoforming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-loaded stress is applied to conform the cushioning article, then conformance is improved, but impact attenuation ability deteriorates
Solution Approach 1:
The cushioning article is divided into multiple cushioning elements (e.g., cushioning pods or beads) that are distributed throughout the structure. This segmentation allows each element to independently absorb and attenuate impact forces without requiring pre-loaded stress on the entire structure, thereby maintaining both conformance and impact attenuation ability.
Solution Approach 2:
The invention changes the physical state and arrangement parameters of the cushioning material by using discrete, movable cushioning elements rather than a continuous pre-loaded structure. These elements can shift and deform independently during impact, providing both shape conformance and effective impact attenuation without the trade-off present in pre-loaded designs.
2Ease of manufacture
If traditional molding methods are used, then manufacturing simplicity is maintained, but energy consumption and cost increase
Solution Approach 1:
Multiple cushioning elements are combined within a single article (such as a shoe sole) to achieve the desired cushioning performance. This merging approach allows for more efficient energy distribution and better impact attenuation across multiple points, while the elements themselves can be manufactured using simpler, more energy-efficient processes compared to traditional single-piece molding.
3Device complexity
If a single thermoforming station is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The thermoforming system is segmented into multiple independent stations that can operate simultaneously or in sequence. Each station handles a specific portion of the manufacturing process, allowing for parallel processing and increased productivity without requiring a completely complex integrated system. The stations share common resources such as heating elements and vacuum systems, balancing complexity and efficiency.
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 system efficiently forms a cushioning pod structure with improved impact attenuation and conformance, reducing costs and energy consumption through shared components and precise thermal management, enhancing the performance of cushioning articles like shoe soles.
Implementation Method 1
The thermal source is effective to increase a temperature of the film to a deformation temperature of the film
Implementation Method 2
A vacuum is drawn through one or more apertures extending through a molding surface of the thermoforming mold to draw in the film
Implementation Method 3
The cooling source is effective to remove thermal energy from the film to a temperature below the deformation temperature
Data Source
AI summary
A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.