Foam Product with Embedded Connection Block for Accessory Bonding
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Solution Overview
Problem
Conventional foam products with embedded accessories suffer from weak bonding between the accessory and the foam body, leading to the accessory falling off over time due to collisions and stress, as the bond only exists between the accessory's outer surface and the foam body's inner wall.
Innovation Solution
A foam product design featuring a connection block made of a more flexible and tougher second foam material, embedded within the foam body, which includes an accessory bonded to the connection block using a thermoplastic adhesive layer, enhancing the bonding strength and acting as a buffer against stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the accessory is directly adhered to the foam body using adhesives, then the manufacturing process is simple, but the bonding strength is weak and the accessory is prone to fall off
Solution Approach 1:
The invention divides the foam body into two distinct parts: the main foam body and an embedded connection block. The accessory is first adhered to the connection block, which is then embedded into the foam body. This segmentation allows the bonding interface to be distributed between the accessory-connection block interface and the connection block-foam body interface, thereby increasing overall bonding strength while maintaining manufacturing simplicity.
2Strength
If the accessory is received in a through bore and screwed to secure it, then the accessory is firmly embedded, but the through bore enlarges over time due to collision and the accessory becomes prone to sway or fall off
Solution Approach 1:
The invention applies local quality by making the connection block more flexible and tougher than the main foam body. This localized difference in material properties allows the connection block to absorb collision stresses through elastic deformation, protecting the accessory from sway and preventing the through bore from enlarging over time, thereby maintaining long-term stability.
3Strength
If the connection block is made of more flexible and tougher material, then the bonding strength and stress resistance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges the accessory and connection block assembly with the foam body embedding process in a single manufacturing step. The connection block with the pre-adhered accessory is placed into a mold cavity, and the foam body is formed around it in one operation. This combining of steps eliminates the need for separate embedding operations, reducing manufacturing complexity despite the enhanced material requirements for the connection block.
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 securely attaches the accessory to the foam body, preventing it from falling off and providing a buffer against stress, ensuring a strong and durable attachment without additional adhesives.
Implementation Method 1
heating the first mold in order to turn the second foam material into a connection block and to create a bond between the accessory and the connection block via the thermoplastic adhesive
Implementation Method 2
The accessory and the connection block are tightly bonded by the adhesive layer
Implementation Method 3
introducing a second foam material into the cavity of the first mold; heating the first mold in order to turn the second foam material into a connection block
Implementation Method 4
The foam body is made of a first foam material. The connection block is made of a second foam material
Data Source
AI summary
The foam product includes a foam body, a connection block, an accessory and an adhesive layer. The foam body is formed of expandable polystyrene (EPS). The connection block is formed of a copolymer of expandable polyolefin and expandable polystyrene, and is completely or partially embedded inside the foam body. The accessory is made of non-expandable material and is completely or partially embedded inside the connection block. The accessory and the connection block are bonded by the adhesive layer.