Foam Insert Production Using Degradable Film Separators
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Solution Overview
Problem
Existing methods for producing complex foam seat elements face challenges in integrating objects like 3D textiles and defining boundaries between foams of different densities during injection, as the foam can block the textile cells and mix during simultaneous injection in the same mold.
Innovation Solution
A method using a degradable plastic film, such as polyethylene and starch, to separate injection zones and protect the 3D textile during foam injection, ensuring clear zone definition and integration of devices within the foam lining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If objects like 3D textiles are integrated into the foam mold before injection, then the ventilation effect is achieved, but the foam blocks the pores of the textile and hinders its operation
Solution Approach 1:
The mold is divided into multiple injection zones with separate injection needles, allowing selective foam injection in specific areas while leaving other areas (where 3D textiles are integrated) foam-free, thus preserving textile pore functionality in ventilation zones
Solution Approach 2:
Different regions of the seat element are assigned different foam densities or foam presence based on local requirements - high density foam in support areas, no foam or low density in ventilation areas with 3D textiles, achieving location-specific functional properties
2Adaptability or versatility
If foams of different densities are injected simultaneously into the same mold, then complex foam seat components are created, but the boundary between the two foams is difficult to define
Solution Approach 1:
The mold is divided into multiple injection zones with separate injection needles, each zone dedicated to a specific foam density type, ensuring clear and precise boundaries between different foam regions
Solution Approach 2:
The positions and configurations of injection needles are pre-planned and positioned before injection to ensure that foam zones with different densities are injected into predetermined areas with well-defined boundaries
3Adaptability or versatility
If multiple foam injection zones are used for different densities, then complex foam seat components are produced, but the process becomes more difficult to control
Solution Approach 1:
The injection system is segmented into multiple independent injection zones with separate needles, each capable of injecting foam with specific density characteristics, allowing complex multi-density foam components to be produced through a systematically divided process
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 allows for the production of seat elements with distinct foam densities and integrated devices, simplifying manufacturing by maintaining the integrity of the 3D textile and ensuring clear interfaces between foam zones, while the film degrades during polymerization to promote air exchange.
Implementation Method 1
a film (2) is placed in the mold (3). The film (2) separates a first foam injection zone from a second foam injection zone in the mold (3)
Implementation Method 2
the film degrades during polymerization to promote air exchange
Implementation Method 3
the foam injection zones are intended for foams of different densities
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing a seat element padding made of foam comprising the following steps: inserting, inside an injection mold (3), a plastic film (2) delimiting at least a first injection zone of the foam; injecting foam in order to produce the padding in one piece, the film disappearing with the polymerization of the foam.