Open Core Crash Pad Protrusion Seals Foam Liquid
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Solution Overview
Problem
Conventional open core crash pads experience quality deterioration due to the transition of plasticizers from the skin to the foam tape, leading to reduced adhesive force and detachment during heat resisting aging tests.
Innovation Solution
The design includes a core with a protrusion and a skin with a distal end having a weakened section, where the foam tape is attached to the distal end, and the protrusion seals the foam liquid, preventing contact with the foam tape and minimizing foam liquid absorption, thus enhancing the adhesive force and preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the foam tape is attached to the skin to prevent foam liquid overflow, then the foaming process is effective, but the plasticizer transitions from the skin to the foam tape causing adhesive force reduction and detachment
Solution Approach 1:
The protrusion acts as an intermediary barrier between the foam liquid and the foam tape. By positioning the protrusion to contact the foam tape and seal the foam liquid, it prevents direct contact between the foam liquid (which contains plasticizer) and the foam tape, thereby preventing plasticizer migration and maintaining adhesive force.
Solution Approach 2:
The core is segmented with a protrusion that creates a separate sealing zone. This segmentation divides the space into regions: one where the foam liquid is contained by the protrusion, and another where the foam tape is positioned without direct exposure to the foam liquid, preventing chemical interaction.
2Quantity of substance
If the foam liquid is injected into the forming space to create the foaming layer, then the cushion performance is achieved, but the foam liquid overflows onto the foam tape causing quality deterioration
Solution Approach 1:
The protrusion serves as a physical barrier that mediates between the foam liquid and the foam tape. It allows the foam liquid to be contained in the forming space while preventing it from reaching the foam tape, thus maintaining manufacturing precision without compromising the quantity of foam liquid needed for cushion performance.
Solution Approach 2:
The protrusion is pre-positioned to contact the foam tape before foam liquid injection. This preliminary action establishes a seal that prevents foam liquid overflow during the subsequent foaming process, ensuring precise containment from the outset.
3Productivity
If the foam tape is removed after foaming, then the production process is complete, but the foam tape detaches due to reduced adhesive force
Solution Approach 1:
The protrusion acts as a protective intermediary during the entire process, preventing plasticizer migration that would compromise adhesive force. This ensures the foam tape remains reliably attached through heat resisting aging tests while still allowing for efficient removal after foaming is complete.
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 solution effectively prevents the detachment of the foam tape during heat resisting tests, improving the quality and production efficiency of the crash pad by ensuring the foam tape can be easily removed and maintaining the integrity of the foaming layer.
Implementation Method 1
a foaming layer for providing a cushion performance and a shock absorption performance is interposed between the core and the skin
Implementation Method 2
the conventional crash pad has a foam liquid absorbed into a foam tape (a) during a foaming process (foaming reaction)
Implementation Method 3
a plasticizer 921 of a skin 92 is transited to a foam tape 93 (b) in a heat resisting aging test process
Data Source
AI summary
An open core crash pad includes a core and a skin abutting the core to include a forming space therebetween. A foaming layer is foam-formed by injecting a foam liquid into the forming space. A foam tape prevents an overflow of the foam liquid. The skin includes a body portion and a distal end which extends from the body portion in parallel with the core. The core comprises a protrusion protruding toward the skin and formed at which the core and the distal end contact.