Embossed Polyurethane Foam Composite for Deep Bumpy Design
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Solution Overview
Problem
Existing composite materials with flexible polyurethane foam sheets struggle to achieve a deep bumpy design while maintaining excellent shape-imparting properties and durability due to the elasticity of the foam, which impairs cushioning performance.
Innovation Solution
A composite material is developed with a flexible polyurethane foam sheet laminated on a skin material, where the foam has a thickness of 3 to 15 mm and a compression percentage of 5% to 40% in the temperature range of 100°C to 150°C, allowing for effective embossing that forms a deep bumpy design with enhanced shape-imparting and cushioning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flexible polyurethane foam sheets are used in composite materials, then cushioning performance is improved, but shape-imparting property during embossing deteriorates due to compression resilience from elasticity
Solution Approach 1:
The invention changes the physical and chemical parameters of the flexible polyurethane foam by controlling the NCO index (isocyanate content) to be 100 or more and specifying the compression percentage at 100°C to be 5-40%. These parameter changes modify the foam's elasticity and compression resilience, enabling it to maintain cushioning performance while accepting embossing shapes effectively during heating and pressing.
Solution Approach 2:
The invention creates a composite structure by laminating the specifically formulated flexible polyurethane foam sheet onto a skin material. This composite material combines the cushioning properties of the foam with the surface characteristics of the skin material, achieving both comfort and designability in vehicle interior applications.
2Shape
If embossing is performed on composite materials with flexible polyurethane foam, then bumpy design is achieved, but sufficient shape-imparting effect cannot be obtained due to compression resilience
Solution Approach 1:
The invention modifies the foam's parameters by setting the NCO index to 100 or more and the compression percentage at 100°C to 5-40%, which reduces compression resilience and enables the foam to accept embossed shapes deeply and maintain them, achieving both bumpy design and sufficient shape-imparting effect.
Solution Approach 2:
The invention applies different properties to different parts of the foam structure by controlling the local compression characteristics through the specified NCO index and compression percentage ranges, allowing the foam to exhibit appropriate deformability during embossing while maintaining overall structural integrity and cushioning function.
3Manufacturing precision
If the flexible polyurethane foam sheet has high compression percentage, then shape-imparting property improves, but cushioning performance deteriorates
Solution Approach 1:
The invention identifies the optimal parameter range by setting the compression percentage at 100°C to 5-40%, which balances shape acceptance capability with cushioning performance. This parameter optimization ensures the foam can be embossed effectively while maintaining sufficient elasticity for comfort applications.
Solution Approach 2:
The invention creates a dynamic balance in the foam's mechanical properties by controlling the NCO index and compression percentage, allowing the material to exhibit appropriate stiffness during embossing (for shape imparting) and appropriate softness during use (for cushioning performance).
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
The solution enables the creation of embossed products with a deep bumpy design that excels in shape-imparting properties and durability, while maintaining cushioning performance, by optimizing the compression percentage and thickness of the flexible polyurethane foam sheet.
Implementation Method 1
flexible polyurethane foam sheets constituting composite materials are elastic. Therefore, even when composite materials are heated and pressed by means of embossing, in a case in which the design is a fine bumpy shape, there is a problem in that a sufficient shape-imparting effect cannot be obtained due to compression resilience attributed to the elasticity of flexible polyurethane foam sheets
Implementation Method 2
When embossing is carried out using a composite material for embossing having the above-described constitution, it is possible to obtain embossed products in which a deep bumpy design is formed
Data Source
Figure 1
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AI summary
Provided is an embossed product on which a deep bumpy design is formed and which is also excellent in terms of a bumpy design shape-imparting property and cushioning performance and durability thereof. A composite material for embossing is a composite material in which a flexible polyurethane foam sheet is laminated on one surface of a skin material, in which the flexible polyurethane foam sheet has a thickness of 3 to 15 mm and a compression percentage of 5% to 40% in a temperature range of 100°C to 150°C. In addition, an embossed product is obtained by embossing a surface of the skin material of the composite material for embossing.