Foamed Polymer Articles with Embedded Cores for Bonding Strength
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Solution Overview
Problem
Existing articles comprising a foamed member and a core face challenges in achieving enhanced bonding strength and structural integrity, particularly when the core is partially or fully exposed, necessitating improvements in their manufacturing methods.
Innovation Solution
A method involving the use of a molding device with a supporting member to embed a core within a mold cavity, followed by injecting a polymeric material that foams to form a foamed member, ensuring at least partial coverage of the core's surfaces, and optionally incorporating patterns or layers to enhance bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core is partially or fully exposed in the article structure, then the manufacturing process is simpler and the core is easier to access, but the bonding strength and structural integrity between the foamed member and core are reduced
Solution Approach 1:
The core is embedded within the foamed member, with the foamed member completely or partially covering the core surfaces. This nesting structure enhances bonding strength and structural integrity while maintaining manufacturing simplicity through a one-step injection molding process that forms both components together
Solution Approach 2:
The article combines two different materials - a solid core and a foamed polymeric material - to create a composite structure. The foamed member completely covers the core surfaces, creating strong interfacial bonding while maintaining the structural integrity of both materials
2Strength
If the foamed member completely covers the core surfaces, then the bonding strength and structural integrity are enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The manufacturing process merges the core placement and foamed member formation into a single injection molding operation. The core is positioned in the mold cavity before injection, and the foamed material is injected to completely cover the core surfaces in one step, eliminating the need for separate covering operations and reducing precision requirements
Solution Approach 2:
The core is pre-positioned in the mold cavity on a supporting member before the foamed material is injected. This preliminary placement ensures the core is correctly positioned and supported during the injection process, allowing the foamed member to naturally conform to and completely cover the core surfaces with appropriate bonding
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 results in improved bonding strength and structural integrity of the article, allowing for the foamed member to cover the core's surfaces effectively, enhancing its mechanical properties.
Implementation Method 1
injecting a first material into the mold cavity; and foaming the first material to form a first foamed member
Data Source
AI summary
An article includes a foamed member including a polymeric material, and a core embedded in the foamed member, the core includes a first surface, a second surface and a sidewall, the foamed member covers at least a portion of the first surface, and covers the entire sidewall and the entire second surface. A method of manufacturing an article includes providing a molding device including a first mold and a second mold, the first mold includes a supporting member protruded from an inner wall. The method further includes disposing a core on the supporting member; disposing the second mold over the first mold to form a mold cavity, the core is disposed within the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member is in contact with the core.