← EXPLODED VIEWL03
MATERIAL-LAYER TECHNICAL DOSSIER
Sealed Air Pocket
A still air layer reduces local conduction between the cold wall and the grip surface.
PRE-INDUSTRIAL R2LOCAL THERMAL BREAK
01 · PRINCIPLE & RATIONALE
Intended function
and associated requirement.
A still air layer reduces local conduction between the cold wall and the grip surface.
It insulates only where the hand needs it, avoiding the mass and volume of a complete double wall.
Performance depends on depth, seal continuity, suppressed internal convection and resistance to pressure, drop and thermal cycling.
02 · TECHNOLOGY STACK
Technologies, roles
and approval gates.
Material and process qualification
- Role
- Converts the design basis into a repeatable specification.
- Why
- Performance depends on the real commercial grade and process window.
- Approval gate
- Documented test evidence and approved specification.
03 · ARCHITECTURE
Function, material
and interfaces.
The pocket must remain sealed without creating an unstable protrusion under grip load.
- Wall L02
- Membrane L04
- Perimeter seal
- Drainage zones
- 01Target 0.6–0.9 mm gap
- 02Closed perimeter
- 03Suppressed convection
- 04Three grip zones
04 · MASTER PARAMETER REGISTER
Everything to be defined,
measured or certified.
A field without evidence is never filled with an invented number: it remains “To be determined”, together with the method required to close it. This is what makes the technical record verifiable.
DESIGN BASISTARGETCALCULATED / MEASUREDTO BE VALIDATEDCERTIFICATION REQUIRED
01Identification & function1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X001 | Intended use | USE | To be determined | — | To be defined | Full use cycle | Design review + user study | TO BE VALIDATED |
02Geometry & metrology1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X002 | Nominal mass | m | To be determined | g | To be defined | 23 °C / 50% RH | Balance 0.001 g | TO BE VALIDATED |
03Material1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X003 | Commercial grade and supplier | GRADE | To be determined | — | Qualified grade | Production lot | CoA + traceability | TO BE VALIDATED |
04Thermal properties1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X004 | Service-temperature range | Tservice | To be determined | °C | To be defined | Use and transport | Climate chamber | TO BE VALIDATED |
05Mechanical properties1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X005 | Drop resistance | Hdrop | To be determined | m | To be defined | Defined orientations | Instrumented drop test | TO BE VALIDATED |
06Quality control1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X006 | Process capability | Cpk | To be determined | — | Target to be defined | Critical CTQ | SPC ≥30 samples | TO BE VALIDATED |
07Food contact1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X007 | Overall and specific migration | MIG | To be determined | mg/kg | Applicable limits | Simulant/time/temperature | Accredited methods | TO BE VALIDATED |
08Recyclability1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L03-X008 | Territory-specific end-of-life route | EOL | To be determined | — | Country/area defined | Complete assembly | Infrastructure mapping | TO BE VALIDATED |
05 · INDUSTRIALISATION
From material
to final inspection.
Qualified material
Confined air; no technical gas
Process within window
Geometry forming + perimeter sealing
Controlled interfaces
Wall L02 · Membrane L04 · Perimeter seal · Drainage zones
CTQ + traceability
Geometry, sealing, leak testing and position control must be integrated into the AeroSkin station.
06 · DVP&R
A function is approved
only after passing its test.
| Test | Requirement | Risk | Method | Condition | Samples | Acceptance | Output |
|---|---|---|---|---|---|---|---|
| DVP-05 | Condensation management | Wet grip | Climate + gravimetry | 25 °C/60% RH; water 4 °C | 30 | ≥60% less retained water | Mass + images |
| DVP-06 | ThermoSnow | Incorrect threshold | Thermal/colour cycles | 0–25 °C | 30 | 8±2 °C; ≤15 s | ΔE/T curves |
| DVP-12 | Food contact | Migration/NIAS | Overall/specific migration | Cold-fill water use | 3 lots | Applicable regulatory compliance | Signed report |
07 · FAILURE MODES
Failure modes,
causes and controls.
Body brittleness
EffectBreakage/leak
CausePHA thermal window
ControlDSC/TGA, rheology, process DOE
Non-uniform walls
EffectBuckling/drop failure
CauseAsymmetric geometry
ControlBlow-moulding CAE + micro-CT
AeroSkin detachment
EffectLoss of function/loose part
CauseInsufficient seal
ControlPeel, thermal cycling and drop
08 · EVIDENCE POLICY
Traceability
for every parameter.
Uses air and very little additional mass, but an unreliable pocket would add complexity without function.
This page is the technical register for the R2 configuration. It separates design values, targets, calculations, measurements and certifications. Open fields identify the exact test or document required to close them.