Universal Heat Press Tool for Fluid-Filled Chamber Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing fluid-filled chambers for footwear require multiple specific mold tools for different shoe sizes and shapes, leading to inefficiencies and increased production costs.
Innovation Solution
A method involving a heat press tool with a jig that maintains a gap between polymer sheets to form a peripheral bond, allowing for the production of fluid-filled chambers with a tensile element to prevent expansion, which can be adapted for various sizes and shapes without the need for multiple mold tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple specific mold tools are used for different shoe sizes and shapes, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent employs a universal mold tool that can manufacture fluid-filled chambers for multiple shoe sizes and shapes. The mold includes adjustable components such as a movable mold wall and adjustable spacing mechanisms that allow the same mold to be reconfigured for different chamber dimensions and shapes, eliminating the need for multiple dedicated molds for each shoe size.
Solution Approach 2:
The mold tool incorporates dynamic and adjustable elements, including movable mold walls, adjustable spacing devices, and reconfigurable support structures. These dynamic components enable the mold to adapt its configuration during the manufacturing process to produce chambers of varying sizes and shapes suitable for different shoe applications.
2Manufacturing precision
If multiple specific mold tools are used for different shoe sizes and shapes, then manufacturing precision is improved, but production efficiency decreases
Solution Approach 1:
The universal mold tool can manufacture fluid-filled chambers for multiple shoe sizes and shapes, allowing a single mold to perform the functions of multiple dedicated molds. This multi-functionality improves production efficiency by eliminating the need to switch between different molds for different shoe sizes, while maintaining manufacturing precision through adjustable configuration capabilities.
Solution Approach 2:
The mold tool is pre-configured with adjustable components and positioning mechanisms that allow quick reconfiguration between different chamber sizes and shapes. This preliminary preparation of adjustable elements enables rapid adaptation to different manufacturing requirements without time-consuming mold changes, thereby improving production efficiency.
3Manufacturing precision
If multiple specific mold tools are used for different shoe sizes and shapes, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent describes a universal mold tool that can manufacture fluid-filled chambers for multiple shoe sizes and shapes, allowing a single mold to perform the functions of multiple dedicated molds. This multi-functionality reduces manufacturing cost by eliminating the need to invest in multiple specialized molds, while maintaining manufacturing precision through adjustable configuration capabilities.
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 approach enables the efficient and cost-effective manufacturing of fluid-filled chambers that can be tailored to different shoe sizes and shapes, improving production efficiency and reducing the need for multiple mold tools.
Implementation Method 1
a heating element operable to heat the second polymer sheet to a predetermined temperature
Implementation Method 2
heating one of the two substantially flat surfaces of the tool to heat one of the first polymer sheet and the second polymer sheet
Implementation Method 3
moving a second substantially flat surface of the tool into contact with the second polymer sheet
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method includes positioning a first polymer sheet (301) on a substantially first flat surface (501) of a tool (500), positioning a second polymer sheet (302) on the first polymer sheet (301), and moving a second substantially flat surface (502) of the tool (500) into contact with the second polymer sheet (302). The method also includes maintaining a gap between the first polymer sheet (301) and the second polymer sheet (302) at a predetermined area (340) and heating one of the two substantially flat surfaces (501, 502) of the tool (500) to heat one of the first polymer sheet (301) and the second polymer sheet (302). The method further includes joining the first polymer sheet (301) and the second polymer sheet (302) together at locations outside of the predetermined area (340) to define a peripheral bond (350) of the chamber (300).