Molded Foam Member Rigid Plate Positioning
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Solution Overview
Problem
The challenge is to prevent positional displacement of a rigid plate due to foaming pressure during the molding of a molded foam member, while ensuring precision molding at both faces of the rigid plate.
Innovation Solution
A method involving placing a foam molded first body and a rigid plate in a forming mold, pressing and fixing the rigid plate, and pouring a foaming agent to foam a second molded body that surrounds the rigid plate, thereby suppressing positional displacement and achieving precise molding. This includes using restriction and support protrusions within the mold to stabilize the rigid plate and prevent foaming agent overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid plate is used to improve shock absorption performance, then shock absorption performance is improved, but positional displacement occurs due to foaming pressure during molding
Solution Approach 1:
The rigid plate is pre-positioned and fixed to the first molded body before the foaming process begins. Restriction protrusions are pre-installed in the mold to prevent displacement during subsequent foaming, ensuring the plate remains in the correct position when the foaming pressure is applied.
Solution Approach 2:
Restriction protrusions are designed into the mold structure beforehand to counteract the foaming pressure that will be applied later. These protrusions physically constrain the rigid plate in the desired position, preventing the displacement that would otherwise occur during the foaming process.
2Manufacturing precision
If the rigid plate is fixed before foaming, then positional stability is improved, but the foaming agent may overflow and cause displacement
Solution Approach 1:
Guidance protrusions are pre-installed in the mold structure to guide the foaming agent into the cavity through controlled pathways. These protrusions ensure the foaming agent flows in the correct direction and prevents overflow that would cause displacement of the fixed rigid plate.
Solution Approach 2:
The guidance protrusions act as intermediaries between the foaming agent and the mold cavity. They control the flow path of the foaming agent, directing it properly into the cavity while preventing uncontrolled overflow that would disrupt the positioned rigid plate.
3Ease of manufacture
If through holes are provided in the rigid plate for foam flow, then foam molding is enabled, but structural integrity is reduced
Solution Approach 1:
Instead of creating through holes that would compromise the rigid plate's structural integrity, the patent extracts the foam flow pathway function by providing separate flow paths through the mold structure itself. The foaming agent flows through gaps between the plate and mold, or through dedicated channels in the mold, rather than through holes in the plate.
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 method effectively suppresses positional displacement of the rigid plate and enables precise molding of the molded foam member at both faces, improving the positioning accuracy and stability of the shock absorbing member.
Implementation Method 1
pouring a foaming agent into the forming mold and foam molding a second molded body
Implementation Method 2
foaming agent... foam molding
Implementation Method 3
the rigid plate is pressed against and fixed to the first molded body
Implementation Method 4
the first molded body supports the rigid plate during placement
Data Source
AI summary
A molded foam member manufacturing method including: a first process of placing a foam molded first portion and a rigid member in a second portion forming mold, and pressing and fixing the rigid member against the second portion forming mold; and a second process of pouring a second portion-forming synthetic resin raw material into the second portion forming mold and foam molding a second portion so as to surround at least a portion of the rigid member and to form an integral unit with the first portion.