Foamed Composite Molding with Exposed Insert for Polyurethane Adhesion
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Solution Overview
Problem
The existing methods for producing vehicle seats using in-mold foamed molded products and polyurethane foam often result in poor adhesion between the two materials, leading to potential separation and reduced passenger comfort.
Innovation Solution
A foamed composite molded product is created by exposing a portion of the insert material, which is integrated with the in-mold foamed molded product, allowing it to come into contact with the polyurethane foam, thereby improving adhesion through increased surface area contact and using materials with higher affinity for polyurethane foam.
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 deteriorates causing separation
Solution Approach 1:
The invention segments the contact interface by introducing a contact improvement layer between the in-mold foamed molded product and polyurethane foam. This layer is formed by heating a specific region of the in-mold foamed molded product to create unevenness, allowing the polyurethane foam to penetrate and mechanically interlock with the base material layer, thereby resolving the adhesion problem while maintaining integral molding efficiency
Solution Approach 2:
The invention applies local quality improvement by creating a contact improvement layer only in the contact region between the in-mold foamed molded product and polyurethane foam. The heating treatment is applied locally to specific areas (e.g., seat surface contact portions) to generate unevenness where needed, rather than treating the entire surface, thus improving adhesion at critical interfaces while maintaining overall manufacturing efficiency
2Strength
If adhesion improvement treatments are applied (heating, corona discharge, anchor coat), then adhesion strength is improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the adhesion improvement function with the existing in-mold foaming molding process. The contact improvement layer formation through localized heating is integrated into the molding cycle, eliminating the need for separate adhesion treatment steps. The heating unit is incorporated into the mold structure, allowing adhesion improvement to occur simultaneously with the foaming and molding operations
Solution Approach 2:
The invention employs self-service by utilizing the polyurethane foam's own expansion and curing properties to achieve adhesion. As the polyurethane foam expands and cures, it naturally penetrates into the unevenness of the contact improvement layer and bonds with the base material layer, eliminating the need for external adhesives or complex surface treatment equipment
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 enhances the adhesion strength between the in-mold foamed molded product and polyurethane foam, making it less likely for the polyurethane foam to separate from the in-mold foamed molded product unit, thereby improving the structural integrity and comfort of the vehicle seat.
Implementation Method 1
The contact region is heated to a temperature which is not less than 80% of a softening temperature of the molded product
Implementation Method 2
This heating causes expandable resin particles in the region of contact to soften and expand so as to form unevenness in the region of contact
Implementation Method 3
the in-mold foamed molded product and the polyurethane foam are in close contact over a large area and in a complex manner. As such, the base material layer and the polyurethane foam are unified in a laminar manner with a high bonding strength
Data Source
AI summary
Embodiments of the present disclosure relate to making 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 is configured such that a portion of an insert material is exposed to an outside of an in-mold foamed molded product, and is in contact with polyurethane foam.