Three-Part Mould with Spring-Loaded Intermediate Part
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Solution Overview
Problem
Current moulds for thermoplastic materials are unable to remove suction cups with extreme flexibility and softness, such as those shaped like an open hourglass or bellows or cylinder, without damaging them, which compromises the functionality of the membrane.
Innovation Solution
A three-part mould design where the intermediate mobile part is mechanically pressed against the lower part during moulding and then springs return it to its original position, allowing for automatic removal of the suction cups without damage, while ensuring they are moulded directly onto a breathable or hydrophilic support material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional two-part mould is used for moulding flexible suction cups, then the moulding process is simple, but the suction cups cannot be removed without damage due to their extreme flexibility and softness
Solution Approach 1:
The mould is divided into three separate parts: a lower part, an intermediate mobile part, and an upper part. This segmentation allows the intermediate part to be independently manipulated - pressed down during moulding and then raised to release the suction cups, enabling damage-free removal of extremely flexible suction cups while maintaining manufacturing simplicity
2Manufacturing precision
If the intermediate mobile part is pressed against the lower part during moulding, then the suction cups are properly formed, but removal requires additional mechanical complexity
Solution Approach 1:
The intermediate mobile part is designed to be dynamically movable rather than fixed. It can be pressed down against the lower part during moulding to ensure proper suction cup formation, then raised to release the product. This dynamic movement is achieved through spring mechanisms that automatically return the intermediate part to its original position, providing precise shaping without excessive mechanical complexity
3Extent of automation
If springs are used to return the intermediate part to its original position, then automatic removal is enabled, but the device complexity increases
Solution Approach 1:
The spring mechanisms are positioned to automatically return the intermediate mobile part to its original position after moulding, enabling self-service automatic removal of suction cups without requiring external mechanical systems or complex automation devices. The springs provide the necessary force to reverse the pressing action inherently built into the mould structure
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
Enables the easy and intact removal of flexible suction cups, maintaining their functionality and enhancing the breathability and comfort of the membrane by positioning them at desired distances on the support material.
Implementation Method 1
a series of springs that bring it back to its original position
Data Source
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AI summary
The present invention concerns a mould divided into three parts for the direct moulding of a membrane equipped with a series of suction cups having the particular shape of an open hourglass or of bellows or of a cylinder onto a support made of breathable, waterproof or hydrophilic material positioned on the intermediate mobile part of the mould which is pressed against the lower part of the mould during the moulding phase and raised after moulding has been completed thanks to a series of springs that bring it back to its original position permitting automatic removal of the moulded suction cups without damage to their particular shape.