Manufacturing method of soft and hard foaming combined material

Abstract

The invention discloses a manufacturing method of a soft and hard foaming combined material, which comprises the following steps: providing a first mold for forming a hard foaming material; injecting a hard foaming raw material into the first mold, carrying out hard foaming molding, and enabling the hard foaming raw material to naturally form a crust in the first mold; providing a second mold, and replacing the second mold after the self-skinning of the hard foaming material is completed so as to adapt to the molding of the soft foaming material; the soft foaming raw material is injected into the second mold to be subjected to soft foaming forming, the soft foaming raw material is combined with the crust-formed hard foaming material to form the soft and hard foaming combined material, the soft and hard foaming combined material manufactured through the method not only retains the respective advantages of soft foaming and hard foaming, but also solves the hardening problem encountered when traditional materials are combined, and the hardness of the soft and hard foaming combined material is improved. And the application range is expanded.

Description

Technical Field

[0001] The present invention relates to a manufacturing method of polyurethane foam materials, in particular to a manufacturing method of a combined soft and hard foam material Background Art

[0002] In various application fields, foam materials are widely used due to their light weight, heat insulation, sound absorption and other characteristics. Traditionally, soft foam and hard foam materials have been applied in different fields due to their respective unique performance characteristics. Soft foam, due to its excellent flexibility and comfort, is commonly used in furniture and mattresses; while hard foam, due to its good structural strength and heat insulation performance, occupies an important position in the construction and industrial fields

[0003] In recent years, in order to integrate the advantages of these two materials, attempts have been made to use soft foam and hard foam in combination. This combination can provide a material that is both soft and strong, suitable for application scenarios with high requirements for both comfort and durability. However, in actual operation, this combination often leads to abnormal hardening of the contact surface due to the penetration effect between the materials, thereby affecting the overall comfort and functionality of the material

[0004] Especially in applications that require high softness and adaptability, such as consumer electronics products, the overly hard contact surface has led to a significant decline in the user experience. This problem not only limits the application scope of the combined soft and hard foam materials, but also hinders their promotion and acceptance in the market

[0005] In view of this, the existing technology urgently needs to be improved to solve the problem of the overly hard contact surface of the combined soft and hard foam materials, while maintaining their original advantages, such as light weight, heat insulation, sound absorption, etc. This improvement will bring more extensive application possibilities and higher market demand Summary of the Invention

[0006] The present invention provides a manufacturing method of a combined soft and hard foam material, and this process aims to solve the problem of the overly hard contact surface of the combined soft and hard foam materials in the existing technology

[0007] To solve the above technical problems, the present invention provides a manufacturing method of a combined soft and hard foam material It includes the following steps Provide a first mold for the molding of hard foam material Inject the hard foam raw material into the first mold, perform hard foam molding, and enable the hard foam material to naturally form a skin inside the first mold Provide a second mold. After the hard foam material has completed self-skinning, replace it with the second mold to adapt to the molding of soft foam material Inject the soft foam raw material into the second mold for soft foam molding, and combine it with the hard foam material that has already formed a skin to form a combined soft and hard foam material

[0008] Preferably, the cavity of the first mold is in the shape of the rigid foam material, and the remaining cavity of the second mold after placing the formed rigid foam material is in the shape of the flexible foam material.

[0009] Preferably, both the rigid foam raw material and the flexible foam raw material are polyurethanes. The polyurethane includes polyisocyanate and polyol, and the weight ratio of polyol to polyisocyanate of the rigid foam material is greater than that of the flexible foam material.

[0010] Preferably, the natural skin formation of the rigid foam in the first mold includes brushing PU paint in the first mold and then injecting the rigid foam material into the first mold for foaming.

[0011] Preferably, the foaming mold temperature of the first mold and the second mold is 40 - 50°C. Beneficial effects

[0012] A manufacturing method of a rigid - flexible foam composite material provided by the present invention makes its outer surface layer dense and smooth through the self - skin - forming method of the rigid foam, thereby reducing the penetration problem of the flexible foam. In this way, after the combination of the rigid foam and the flexible foam, the contact surface is relatively soft, making the hardness transition of the entire foam material smoother. The manufacturing method of the present invention effectively solves the hardening problem at the contact surface of traditional rigid - flexible composite materials by controlling the combination of rigid and flexible foam materials. The produced rigid - flexible foam composite material has a smoother hardness transition, improving the comfort and functionality in use. The manufacturing method of this material expands its application possibilities in multiple fields, especially in high - requirement scenarios that need to combine characteristics such as light weight, heat insulation, and sound absorption. Specific embodiments

[0013] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention clearer, the present invention is further described in detail. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0014] Material preparation: Select suitable polyurethane raw materials, including polyisocyanate and polyol. Prepare raw materials with different ratios for the rigid foam material and the flexible foam material respectively, ensuring that the weight ratio of polyol to polyisocyanate of the rigid foam material is greater than that of the flexible foam material.

[0015] Forming of the rigid foam material: Prepare the first mold, and its cavity is designed in the predetermined shape of the rigid foam material.

[0016] Paint the inside of the first mold with PU paint to promote skin formation and improve surface quality.

[0017] Inject the rigid foam raw material into the first mold for foaming and forming. Control the foaming mold temperature at 40 - 50 °C to ensure uniform foaming of the material and the natural formation of a skin within the mold.

[0018] Forming of the soft foam material: After completing the rigid foam forming, take it out from the first mold and transfer it to the second mold. The design of the second mold takes into account the presence of the rigid foam material, and the remaining cavity shape is suitable for the forming of the soft foam material.

[0019] Inject the soft foam raw material into the second mold to combine with the rigid foam material that has already formed a skin. Similarly, control the foaming mold temperature at 40 - 50 °C to promote uniform foaming and good combination between the materials.

[0020] Combination and curing of the materials: In the second mold, the rigid and soft foam materials combine with each other under controlled conditions and complete the curing process. This step is crucial to ensure a uniform and firm combination at the contact surface of the two materials.

[0021] Post - treatment and inspection: After an appropriate curing time, take out the formed rigid - soft foam combined material from the second mold.

[0022] Conduct necessary post - treatment on the product, such as trimming, cleaning, and inspection, to ensure it meets the predetermined quality standards.

[0023] Performance testing: Conduct a series of performance tests on the made rigid - soft foam combined material, including hardness testing, durability testing, and application characteristic testing, to verify that it meets the requirements of different application fields.

[0024] Application fields: This rigid - soft foam combined material is applicable to a variety of application fields, such as furniture, mattresses, automotive interiors, cushioning materials for consumer electronics products, etc. Its unique rigid - soft combination characteristics bring additional comfort and functionality to these applications.

[0025] The above - mentioned implementation manner is a specific example of the present invention, which describes the entire process from raw material preparation to finished product manufacturing. The rigid - soft foam combined material manufactured by this method not only retains the respective advantages of the soft foam and the rigid foam, but also solves the hardening problem encountered in the combination of traditional materials, expanding its application scope. The above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A manufacturing method of a combined material of soft and hard foams, characterized in that, It includes the following steps: Provide a first mold for the molding of rigid foam materials; Inject the rigid foam raw material into the first mold for rigid foam molding, and allow the rigid foam material to naturally form a skin inside the first mold; Provide a second mold. After the rigid foam material has completed self-skinning, replace it with the second mold to adapt to the molding of flexible foam materials; Inject the flexible foam raw material into the second mold for flexible foam molding, and combine it with the rigid foam material with a pre-formed skin to form a combined rigid and flexible foam material.

2. The manufacturing method of a combined rigid and flexible foam material as claimed in claim 1, characterized in that, The cavity of the first mold is in the shape of the rigid foam material, and the remaining cavity of the second mold after placing the molded rigid foam material is in the shape of the flexible foam material.

3. The manufacturing method of a combined material of soft and hard foams according to claim 2, characterized in that Both the rigid foam raw material and the flexible foam raw material are polyurethane. The polyurethane includes polyisocyanate and polyol. The weight ratio of polyol to polyisocyanate of the rigid foam material is greater than that of the flexible foam material.

4. The manufacturing method of a combined soft and hard foam material as claimed in claim 3, characterized in that, The natural formation of a skin of the rigid foam in the first mold includes brushing PU paint inside the first mold, and then injecting the rigid foam material into the first mold for foaming.

5. The manufacturing method of a combined rigid and flexible foam material according to claim 4, characterized in that, The foaming mold temperature of the first mold and the second mold is 40~50°C.