Foam Pad Manufacturing Interconnected Air Bubbles

The patent applies preliminary action by pre-foaming the material mixture before final shaping. The foam pad is first formed with closed air bubbles through conventional methods, then undergoes a secondary heating and pressing process that opens the air bubbles and creates interconnected porous structures. This preliminary preparation of the foam structure enables the subsequent creation of communication channels between air bubbles, transforming the harmful strong rebounding force into a more comfortable moderate rebounding effect while maintaining manufacturing feasibility.

The patent employs parameter changes by controlling temperature and pressure parameters during the foam formation and processing stages. The material is heated to specific temperature ranges (first heating at lower temperature, second heating at higher temperature) and subjected to controlled pressure during pressing. These parameter changes transform the physical state of the foam from closed-cell structure to open-cell interconnected structure, modifying the rebounding characteristics from strong to moderate, thereby eliminating discomfort during prolonged use.

The patent applies segmentation by dividing the foam pad structure into two distinct phases: first forming closed air bubbles for buffer elasticity, then creating communication channels between these bubbles through controlled heating and pressing. This segmentation allows the foam pad to maintain its buffering function while developing interconnected pathways that enable air flow between bubbles, thereby improving fatigue resistance without sacrificing the original buffer elasticity.

The patent utilizes composite material principles by combining different structural characteristics within the foam pad. It integrates closed-cell foam structures (providing buffer elasticity) with open-cell interconnected porous structures (providing fatigue resistance). The final foam pad contains both closed air bubbles and communication channels between bubbles, creating a composite structure that simultaneously delivers buffer elasticity and improved fatigue resistance, overcoming the limitation of conventional single-structure foam pads.