Foam Laminate Bonding Through Water-Induced Surface Dissolution

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Solution Overview

Problem

Conventional adhesives used to bond foam pieces together are often non-biodegradable and toxic, posing environmental and health risks, and they may not maintain the mechanical and thermal properties of the foam composites.

Innovation Solution

A method involving water-induced foam surface dissolution is used to bond foam composites by intermixing a water-soluble and hydrophilic material with a water-insoluble and hydrophobic material, where the water-soluble material dissolves to form a solubilized adhesive layer that binds the composites together upon dehydration, preserving the foam's microstructure and properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional adhesives are used to bond foam pieces together, then bonding strength is achieved, but environmental harm and health risks increase due to non-biodegradable and toxic properties

Engineering Contradiction:

Improvebonding strengthVSAvoidenvironmental harm and health risks

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The foam composite itself serves as the adhesive by utilizing its own water-soluble material component. When water is applied, the water-soluble material dissolves to form a tacky adhesive layer from the foam's own material, eliminating the need for separate adhesive substances that would be harmful to the environment and human health.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The physical and chemical parameters of the foam composite change when water is applied. The water-soluble material transitions from a solid state to a dissolved, tacky state, transforming the foam surface from non-adhesive to adhesive. This parameter change enables bonding without requiring external adhesive materials.

Inventive Principle:

Principle #35Parameter changes

2Strength

If conventional adhesives are used to bond foam pieces together, then bonding is achieved, but the mechanical and thermal properties of the foam composites are not maintained

Engineering Contradiction:

Improvebonding capabilityVSAvoidmechanical and thermal properties

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The bonding process uses the foam composite's own water-soluble material to create the adhesive layer, ensuring that the bonded interface has the same composition and properties as the bulk foam. This self-service approach maintains uniform mechanical and thermal properties throughout the foam laminate, avoiding the property mismatches that occur with conventional adhesives.

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If water-soluble material is used for bonding, then biodegradable bonding is achieved, but the bonding process requires water application and dehydration steps

Engineering Contradiction:

ImprovebiodegradabilityVSAvoidbonding process steps

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The bonding process utilizes phase transitions of water (liquid to evaporated) and the water-soluble material (dissolved to solidified). Water is applied as a liquid, causes the water-soluble material to dissolve, and then evaporates, leaving the bonded foam pieces together. This phase transition approach enables biodegradable bonding while using simple, intuitive process steps.

Inventive Principle:

Principle #36Phase transitions

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 method allows for biodegradable bonding of foam composites without external adhesives, maintaining uniform mechanical and thermal properties and achieving adhesion strengths comparable to or exceeding conventional adhesives, with dielectric heating enhancing the bonding process.

Implementation Method 1

a water-soluble material is used to bond the foam composites together. The water-soluble material dissolves to form a solubilized adhesive layer

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

dielectric heating enhancing the bonding process

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Data Source

PatentUS20250269608A1Method for foam bonding via surface dissolution and foam laminate therefrom

Publication Date: 2025.08.28 CRUZ FOAM INC

AI summary

A method for forming a foam laminate is disclosed. The method comprises applying water to a first surface of a first foam composite to convert the first surface to a solubilized foam layer. A first composition of the first foam composite includes a first material intermixed with a second material. The first material is water-soluble and the second material is water-insoluble. The solubilized foam layer includes dissolved first material corresponding to a portion of the first material at or proximate to the first surface at least partially dissolved by the water. The method further comprises contacting the solubilized foam layer to a second surface of a second foam composite to form a foam stack. The method further comprises dehydrating the solubilized foam layer to solidify the dissolved first material and bond the first foam composite to the second foam composite to form the foam laminate.