Foamed composite molding and method for manufacturing foamed composite molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing vehicle seats using in-mold foamed molded products and polyurethane foam often result in insufficient adhesion between the two materials, leading to potential separation and reduced passenger comfort.
Innovation Solution
Exposing at least a portion of the insert material within the in-mold foamed molded product allows for better adhesion with polyurethane foam, using materials with higher strength and affinity to prevent separation, and configuring the insert material's exposure through openings or protrusions to enhance contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If in-mold foamed molded product and polyurethane foam are molded integrally, then manufacturing efficiency is improved, but adhesion strength between the two materials deteriorates
Solution Approach 1:
The patent applies local quality by creating openings at specific locations on the in-mold foamed molded product where polyurethane foam can penetrate and form strong mechanical interlocking. This localized modification at the contact interface provides enhanced adhesion strength while maintaining the integral molding structure for manufacturing efficiency.
Solution Approach 2:
The patent utilizes porous materials by allowing polyurethane foam to penetrate through openings in the in-mold foamed molded product. The foam fills the porous structure created by the openings, forming a mechanically interlocked composite structure that significantly improves adhesion between the two materials while maintaining production efficiency.
2Strength
If insert material is exposed to improve adhesion with polyurethane foam, then adhesion strength is improved, but structural complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the contact interface into multiple opening locations distributed across the in-mold foamed molded product. This segmentation allows polyurethane foam to penetrate at multiple points, creating numerous adhesion zones that collectively provide strong bonding without requiring complex overall structural modifications.
Solution Approach 2:
The patent applies preliminary action by pre-forming openings in the in-mold foamed molded product before the polyurethane foam molding process. This preliminary preparation ensures that the polyurethane foam can easily penetrate and adhere to the insert material during the subsequent molding step, improving adhesion strength without adding complex post-processing steps.
Data Source
Figure 1~2
Figure 3(a)~3(c)
Figure 4(a)~4(b)
AI summary
The present disclosure makes polyurethane foam less likely to become separated from an in-mold foamed molded product unit, the in-mold foamed molded product unit including an in-mold foamed molded product and an insert material which are integrally provided. A foamed composite molded product (1) is configured such that a portion of an insert material (3), which portion is exposed to an outside of an in-mold foamed molded product (4), is in contact with polyurethane foam (2).