Foam Molded Product Air-Permeable Component Gas Venting
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Solution Overview
Problem
Conventional methods for manufacturing foam molded products often result in air pockets due to incomplete expulsion of foam gas and air from the foaming end space, leading to precision issues in the formed product.
Innovation Solution
The method involves placing an air-permeable component connected to concave gas escape grooves on the aperture cavity surface, ensuring that foam gas and air are expelled through these grooves and venting holes, preventing air pockets and improving precision by filling the foaming end space reliably.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air-permeable component is placed on the aperture cavity surface to cover gas venting holes, then gas expulsion is improved, but air pockets may remain in the foaming end space
Solution Approach 1:
The cavity surface is divided into two distinct regions: a foaming start space where foam generation begins, and a foaming end space where gas venting occurs. By spatially segmenting the cavity and placing the air-permeable component specifically at the aperture cavity surface covering gas venting holes, the patent enables differentiated gas expulsion pathways that prevent air pocket formation while maintaining reliable gas venting
Solution Approach 2:
The air-permeable component acts as an intermediary element between the foaming end space and the external environment. It selectively allows gas to pass through while preventing foam intrusion, thereby mediating the gas expulsion process to eliminate air pockets without compromising the integrity of the foam structure
2Manufacturing precision
If the foam raw material is supplied to the foaming start space and allowed to foam until it reaches the foaming end space, then complete filling is achieved, but gas and air may not be completely expelled
Solution Approach 1:
The air-permeable component is pre-installed on the aperture cavity surface before foam injection, and gas venting holes are strategically positioned to open into the foaming end space. This preliminary arrangement ensures that as foam expands from the start space to the end space, gas is continuously and completely expelled through the pre-established pathways, preventing air pocket formation
Solution Approach 2:
The cavity surface exhibits local quality differentiation: the aperture cavity surface contains gas venting holes specifically for gas expulsion, while other regions maintain sealing properties. The air-permeable component is selectively placed only at the aperture cavity surface, creating localized gas permeability that enables complete gas expulsion without affecting overall foam integrity
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 enables the formation of foam molded products with a high degree of accuracy by ensuring complete expulsion of gases and preventing air pockets, resulting in a more precise final product.
Implementation Method 1
an air-permeable component which is placed on the aperture cavity surface so as to cover the gas venting holes
Implementation Method 2
a foaming step in which the foaming of the foaming raw material continues until it reaches the foaming end space and the foaming end space has become filled with the foaming raw material so as to form the foam body
Data Source
AI summary
The present invention is an apparatus for manufacturing a foam molded product in which a foam molded product (1A, 1B) is formed by integrally adhering together a foam body (2) that is formed by the foaming of a foaming raw material, and an air-permeable component (3). A cavity (23) is provided between a plurality of mold components (21, 22, 31) and is defined by respective cavity surfaces (21a, 22a, 31a) of the mold components (21, 22, 31).