Foam molded product, method for producing foam molded product, and molding die structure of foam molded product
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Solution Overview
Problem
Existing foam molded products, such as vehicle seat pads, often suffer from underfill portions due to gas accumulation in concave or convex shape deformations on their surface, which are difficult to prevent with current flow direction adjustment fins, and these solutions are costly and inefficient.
Innovation Solution
A method and structure where a columnar projected portion is integrated into the support member within the molding die, extending in the direction of the shape deformation, to guide and fill the foamable resin material effectively, preventing gas accumulation and underfill portions by ensuring the resin flows along the projected surfaces, even when abutted by the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flow direction adjustment fin is provided at the edge portion of the support member to direct foamable resin material flow, then gas accumulation in concave portions is reduced, but the fin easily falls down under material flow pressure and cannot sufficiently eliminate remaining gas
Solution Approach 1:
The flow direction adjustment fin is divided into multiple segments along the flow direction of the foamable resin material. Each segment independently guides the material flow, distributing the flow pressure across multiple smaller structures rather than one large fin. This segmentation prevents the fin from collapsing under pressure while maintaining effective flow direction control to prevent gas accumulation in concave portions.
Solution Approach 2:
The fin structure is extended in the flow direction of the foamable resin material, creating a multi-dimensional configuration. By adding length along the flow path, the fin provides continuous guidance throughout the material's progression, preventing gas accumulation at multiple points along the flow trajectory rather than just at a single location.
2Shape
If convex or concave shape deformation sections are formed on the molding die inner face to create surface features, then the foam molded product achieves desired shape, but flowability of foamable resin material is inhibited and gas easily remains causing underfill portions
Solution Approach 1:
The flow direction adjustment fin acts as an intermediary element between the convex/concave shape deformation sections and the foamable resin material. It mediates the interaction by actively directing the material flow around the shape features, ensuring the material can navigate the complex geometry without trapping gas, thus resolving the conflict between achieving desired shape and preventing gas accumulation.
Solution Approach 2:
The flow direction adjustment fin is positioned upstream in the flow path before the material encounters the convex or concave portions. It performs preliminary flow direction control, guiding the material to approach the shape deformation sections in a manner that prevents gas entrapment, rather than attempting to address gas accumulation after it occurs.
3Strength
If a sheet-shaped support member is attached to the molding die inner face, then the foam body is reinforced, but the support member blocks complete filling of convex or concave portions and causes underfill portions
Solution Approach 1:
The support member is segmented with openings or cutouts at strategic locations corresponding to convex or concave portions. This segmentation allows the foamable resin material to flow through and completely fill these difficult-to-reach areas, while the remaining portions of the support member continue to provide reinforcement to the foam body.
Solution Approach 2:
The support member is designed with varying properties in different locations - solid in areas requiring reinforcement and open or perforated in areas where complete filling is critical. This local differentiation allows the support member to simultaneously provide structural strength while enabling complete material flow and filling of all cavity portions.
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 configuration ensures complete filling of the shape deformation sections, prevents gas residue, and maintains product quality while reducing production costs by enhancing the prevention of underfill portions and gas accumulation, even in complex shape deformations.
Implementation Method 1
injecting the foamable resin material into a cavity and foaming the foamable resin material
Data Source
AI summary
A foam molded product capable of preventing generation of an underfill portion due to a concave portion and a convex portion formed on a surface of the foam molded product and suppressing increase in cost, a method for producing the foam molded product, a molding die structure of the foam molded product, and a vehicle seat pad using the foam molded product are provided. A foam molded product 10 formed by integrally molding a foam body 12 made of a foamable resin material M and including a shape deformation section 26 that is a concave strip or a convex strip on a surface, and a sheet-shaped support member 14 covering a surface opposing a formation face of the shape deformation section 26 of the foam body 12. In the support member 14 of the foam molded product 10, a projected portion 16 is provided in a region opposing the shape deformation section 26 and/or a vicinity of the region, and the projected portion 16 is in a columnar shape extending in an extending direction of the shape deformation section 26.