Foam Molded Product With Integrated Insert Material

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Solution Overview

Problem

Conventional resin molded products with integrated touch sensors have a hard texture on the backside, which is uncomfortable to touch and may apply excessive load to the insert material during the molding process, potentially causing damage.

Innovation Solution

A foam molded product is created with a foam body formed on the backside of the insert material, incorporating a flexible layer and a soft seal material, and using a manufacturing method that injects and foams a resin at lower pressure and temperature to avoid damaging the insert material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If injection molding is used to manufacture the molded product with insert material, then the molded product can be obtained by one injection molding process, but excessive load may be applied to the insert material causing damage

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidinsert material integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The manufacturing process is divided into two separate stages: first, the insert material is mounted on the surface material in a low-pressure environment; second, the foam body is formed by injecting and foaming resin at lower pressure and temperature. This segmentation avoids subjecting the insert material to excessive loads while maintaining manufacturing efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The resin is injected and foamed at lower pressure and temperature compared to conventional injection molding. This parameter change ensures that the insert material is not damaged by excessive load while still achieving complete filling and proper foaming of the resin to form the foam body.

Inventive Principle:

Principle #35Parameter changes

2Strength

If hard resin is used on the back side of the insert material, then structural strength is provided, but the hard texture is transmitted to the finger when touched

Engineering Contradiction:

Improvestructural strengthVSAvoidtouch comfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Different regions of the molded product have different material properties: the surface material and foam body provide soft texture for comfort, while the insert material and base substrate provide structural strength. This local differentiation allows the back side to have soft texture without compromising overall structural integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The molded product uses composite construction with multiple materials: surface material, foam body, insert material, and base substrate. The foam body and surface material provide soft touch comfort, while the insert material and base substrate provide structural strength, achieving both comfort and strength requirements.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If foam resin is injected and foamed at high pressure and temperature, then complete filling of the molding space is achieved, but the insert material may be damaged

Engineering Contradiction:

Improvemolding completenessVSAvoidinsert material integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The insert material is pre-mounted on the surface material before resin injection. This preliminary action allows the insert material to be securely positioned and protected before the foam resin is injected and foamed, preventing damage during the molding process.

Inventive Principle:

Principle #10Preliminary action

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 foam molded product provides a soft texture to the user and prevents excessive load on the insert material, ensuring a comfortable touch experience and maintaining the integrity of the embedded components.

Implementation Method 1

injecting a foam resin into a molding space formed by closing the molds, and foaming the foam resin to form a foam body

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentUS11958219B2Foam molded product and manufacturing method therefor

Publication Date: 2024.04.16 NISSHA PRINTING CO LTD

AI summary

The present disclosure provides a foam molded product and a manufacturing method. The foam molded product is includes a foam body, an insert material having a display unit or a detection unit attached to the foam body, and a surface material affixed to a surface to which at least the insert material is attached. A manufacturing method includes: preparing a pair of molds including a first mold and a second mold; affixing an insert material and a surface material together such that the surface material is in contact with a molding surface of the first mold; closing the pair of molds; injecting a foam resin into a molding space formed by closing the molds; foaming the foam resin to form a foam body; opening the pair of molds; and removing a molded product in which the affixed part and the foam body are integrated.