Foamed Molding Insert Frame That Follows Shrinkage and Expansion

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Solution Overview

Problem

In-mold foamed molded products experience unexpected deformation due to insert materials not following shrinkage and expansion, leading to insufficient strength and difficulty in forming desired shapes, with exposed insert materials further compromising strength and mold fabrication precision.

Innovation Solution

An in-mold foamed molded product unit featuring an insert material formed into a rectangular frame with a first extending portion entirely embedded and a second extending portion exposed, where the exposed portion is thinner and follows shrinkage and expansion, ensuring the insert material does not impede the product's dimensional changes and is firmly fixed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the insert material is entirely embedded in the in-mold foamed molded product, then the strength is improved, but the product cannot follow shrinkage and expansion leading to deformation

Engineering Contradiction:

Improvestrength of in-mold foamed molded product unitVSAvoidshape accuracy of in-mold foamed molded product

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The insert material is divided into two distinct portions: a first extending portion that is entirely embedded in the in-mold foamed molded product to provide strength, and a second extending portion that is exposed outside the product to follow shrinkage and expansion. This segmentation allows each portion to fulfill different functional requirements simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the insert material are given different properties and positions: the first extending portion is thick and entirely embedded for structural strength, while the second extending portion is thinner and exposed to accommodate dimensional changes. This local differentiation resolves the contradiction between strength and shape accuracy.

Inventive Principle:

Principle #3Local quality

2Shape

If a portion of the insert material is exposed outside the in-mold foamed molded product, then the product can follow shrinkage and expansion, but the strength becomes insufficient

Engineering Contradiction:

Improveshape accuracy of in-mold foamed molded productVSAvoidstrength of in-mold foamed molded product unit

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The insert material is segmented into embedded and exposed portions, where the embedded first extending portion maintains strength while the exposed second extending portion ensures shape accuracy during dimensional changes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert material exhibits local quality variations with the first extending portion being thicker and entirely embedded for strength, and the second extending portion being thinner and exposed for shape accommodation, resolving the strength-exposure contradiction.

Inventive Principle:

Principle #3Local quality

3Strength

If the insert material is thick throughout, then the strength is improved, but the exposed portion creates excessive deformation and mold fabrication difficulty

Engineering Contradiction:

Improvestrength of in-mold foamed molded product unitVSAvoidmold fabrication precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The insert material thickness is optimized locally: the first extending portion maintains sufficient thickness for strength, while the second extending portion is made thinner to reduce deformation during shrinkage and expansion, facilitating accurate mold fabrication.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insert material is segmented into different thickness zones, with the thinner second extending portion specifically designed to minimize deformation and improve manufacturing precision while the thicker first extending portion maintains overall strength.

Inventive Principle:

Principle #1Segmentation

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 allows for the formation of in-mold foamed molded products with sufficient strength and ease of shaping, reducing deformation deviations and facilitating mold fabrication by allowing the insert material to adapt to shrinkage and expansion without hindering the product's structure.

Implementation Method 1

The above-described in-mold foamed molded product obtained by insert molding once shrinks immediately after molding, and then expands through curing and drying (dimensional recovery). Through such shrinkage and expansion, the shape of the in-mold foamed molded product becomes a desired shape.

Methodology Applied

Scientific EffectShrinkage and expansion: Deformation

Implementation Method 2

The above-described in-mold foamed molded product obtained by insert molding once shrinks immediately after molding, and then expands through curing and drying (dimensional recovery).

Methodology Applied

Scientific EffectCuring and drying: Phase Change

Data Source

PatentEP3560391B1In-mold foamed molding unit and method for producing in-mold foamed molding unit

Publication Date: 2021.10.27 KANEKA CORP

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AI summary

An aspect of the present invention provides an in-mold foamed molded product unit which not only makes it easy to form an in-mold foamed molded product into a desired shape but also has a sufficient strength. A first extending portion (21) is substantially entirely embedded in an in-mold foamed molded product (1), and a second extending portion (22) includes an exposed portion (23) which is exposed outside the in-mold foamed molded product (1) and which follows shrinkage and expansion of the in-mold foamed molded product (1).