Foamed Product with Localized Decorative Particles and Controlled Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional foamed products with decorative parts over the entire surface appear monotonous and lack design, and existing foaming methods struggle to balance foaming time and temperature to achieve desired levels of foaming without damaging the foamable medium.
Innovation Solution
A foamed product design featuring a foamed part with protrusions and a less foamed part with recesses, where decorative particles are only applied and fused to the recesses, and a foaming apparatus with a first heater at a lower temperature than the foaming temperature to control foaming time and prevent medium damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If decorative parts are formed over the entire surface of the foam medium, then the surface is fully decorated, but the appearance becomes monotonous with poor design level
Solution Approach 1:
The patent applies local quality by forming decorative parts only in specific regions (second part with lower degree of foaming) rather than uniformly across the entire surface. This creates varied visual interest with contrasting foamed and non-foamed regions, resolving the contradiction between comprehensive decoration and aesthetic design.
2Productivity
If heating temperature is increased to shorten foaming time, then foaming speed increases, but the foamable medium is likely to be damaged by heat
Solution Approach 1:
The patent changes the heating parameter strategy by using a two-stage heating process: first heating to a temperature below the foaming temperature to pre-condition the medium, then raising to the foaming temperature. This resolves the contradiction by achieving adequate foaming speed while preventing heat damage through controlled temperature progression.
3Productivity
If foaming time is excessively shortened to increase productivity, then manufacturing efficiency improves, but insufficient foaming occurs
Solution Approach 1:
The patent applies preliminary action by heating the foamable medium to a temperature below the foaming temperature before initiating full foaming. This pre-heating stage prepares the medium for rapid foaming, enabling sufficient foaming degree to be achieved in a shorter overall time, thus resolving the contradiction between productivity and foaming quality.
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 approach creates a high-design appearance with visually recognizable decorative elements and reduces foaming time and temperature, preventing medium damage while maintaining sufficient foaming, resulting in a product with enhanced aesthetics and manufacturing efficiency.
Implementation Method 1
a first heater that heats a foamable medium including a foam layer that is foamed by heating at a heating temperature that is equal to or higher than a foaming temperature, conveyed in a predetermined conveyance direction, at a first temperature that is lower than the foaming temperature
Implementation Method 2
a second heater that heats the foamable medium heated by the first heater, at a second temperature that is equal to or higher than the foaming temperature, to foam the foamable medium
Implementation Method 3
a foam layer that is foamed by heating at a heating temperature that is equal to or higher than a foaming temperature
Data Source
AI summary
Provided are a foamed product with a high level of design, and the like. The problem is solved by a foamed product including: a foam medium with a first part protruded by foaming and a second part that is lower than the first part; and a decorative part with a plurality of decorative particles, formed only in the second part of the first part and the second part, and a manufacturing method for a foamed product, including: a first step of foaming a foam medium to form, in the foam medium, a first part protruded by the foaming and a second part that is lower than the first part; and a second step of fixing a plurality of decorative particles only to the second part of the first part and the second part.