Thermoplastic Chamber Inflation And Sealing Using A Single Tool
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Solution Overview
Problem
Conventional methods for forming fluid-filled chambers in polymer articles, such as footwear, require multiple tools and registration processes, leading to increased manufacturing time, equipment fouling, and defects due to excess polymer material accumulation.
Innovation Solution
A single tool with a cupped punch surface is used to form an aperture, inject fluid, and seal the chamber, minimizing the need for registration processes and preventing excess material accumulation by retaining the remnant material with the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple tools and registration processes are used to form apertures, inject fluid, and seal chambers, then manufacturing precision can be maintained, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent combines multiple separate tools (aperture formation tool, fluid injection tool, sealing tool) into a single integrated tool that can perform all three operations sequentially. This merging eliminates the need for multiple registration processes between different tools, reducing manufacturing time while maintaining precision through single-tool consistency.
Solution Approach 2:
The single tool is designed with multi-functionality, incorporating an aperture formation mechanism, fluid injection capability, and sealing function all in one device. This universal tool can adapt to perform different operations on the same chamber without requiring repositioning or re-registration, thereby increasing productivity while preserving manufacturing precision.
2Reliability
If multiple tools are used for aperture formation, fluid injection, and sealing, then each function can be optimized, but device complexity increases
Solution Approach 1:
The patent merges multiple specialized tools into one integrated device that performs aperture formation, fluid injection, and sealing functions. This reduces device complexity by eliminating the need for multiple separate tools and their associated registration systems, while maintaining reliability through carefully designed functional integration within the single tool.
3Ease of manufacture
If conventional punching methods are used to form apertures, then apertures can be created, but excess polymer material accumulates causing defects and equipment fouling
Solution Approach 1:
The patent extracts or removes the problematic excess polymer material during the aperture formation process itself, rather than allowing it to accumulate. The tool design incorporates a mechanism that captures and removes the displaced material, preventing it from causing defects or fouling equipment while still achieving effective aperture creation.
Solution Approach 2:
The patent converts the harmful effect of excess polymer material displacement into a beneficial outcome by designing the aperture formation mechanism to use this displaced material for sealing purposes. The excess material is redirected to form part of the seal around the aperture, eliminating the waste problem while enhancing the sealing function.
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
This method reduces manufacturing time, minimizes defects, and maintains a clean manufacturing environment by using a single tool to form, fill, and seal fluid-filled chambers in polymer articles.
Implementation Method 1
The pressurization apparatus can then be utilized to inject a fluid into the chamber through the aperture, compress the first surface against the second surface, and form a bond around the aperture and between the first surface and the second surface.
Data Source
Figure 1a~1b
Figure 2~3b
Figure 4
AI summary
A method for inflating a chamber in an article composed at least partially of polymer layers, such as thermoplastic layers. The method can allow for forming an aperture in a polymer layer, inflating a chamber or volume in fluid communication with the aperture, and then welding or sealing the chamber so that the inflation fluid is substantially retained in the chamber and/or does not escape via the aperture. In various aspects, the formation of the aperture, inflation of the chamber, and sealing of the chamber or aperture can be performed by a single tool and/or based on a single registration of the thermoplastic article with a tool. In some aspects, formation of the aperture is enabled in part by using a punch with a cupped surface that allows the top layer of a thermoplastic article to be breached without forming a hole in at least one lower layer.