Integral Skin Foam with Natural Leather Lining
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Solution Overview
Problem
Existing integral skin foam molded articles using natural leather as surface material face challenges with increased manhours and costs due to the need for bonding with wadding material, which can lead to looseness and damage in appearance quality, and leakage issues with foam resin material during component mounting.
Innovation Solution
Incorporating a lining material with a smaller shrinkage rate than the wadding material to maintain the natural leather's feel without bonding, and using a sealing part that impregnates foam resin to prevent leakage during component mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If natural leather is bonded with wadding material to maintain appearance quality, then appearance quality is improved, but manufacturing complexity and cost increase due to additional processing steps
Solution Approach 1:
The invention extracts the fuzz from the back surface of the natural leather through cutting, separating the problematic surface feature from the main material. This allows the natural leather to be used without bonding while maintaining appearance quality, as the cut fuzz prevents protrusion and eliminates the need for additional bonding processes.
Solution Approach 2:
The invention uses a resin coating layer as a temporary or sacrificial element that is applied only to the back surface of the natural leather. This coating layer provides the necessary surface properties for appearance quality without requiring permanent bonding structures, simplifying the overall manufacturing process.
2Manufacturing precision
If natural leather is bonded with wadding material to prevent looseness, then appearance quality is improved, but manufacturing time and cost increase
Solution Approach 1:
By cutting the fuzz from the back surface of the natural leather, the invention eliminates the source of looseness without requiring bonding. This extraction of the problematic feature allows the natural leather to maintain its appearance quality independently, reducing manufacturing time by eliminating bonding steps.
Solution Approach 2:
The resin coating layer serves as a simple, quick-to-apply surface treatment that provides the necessary properties for preventing looseness and maintaining appearance quality without the time-consuming process of bonding natural leather to wadding material.
3Reliability
If elastic material is expanded by storage body to prevent foam resin leakage, then leakage prevention is improved, but mounting difficulty increases due to resistance from tightened elastic material
Solution Approach 1:
The elastic material is pre-installed in the mounting hole before the storage body is inserted. This preliminary positioning allows the elastic material to expand and conform to the storage body during insertion, preventing leakage without creating excessive resistance that would make mounting difficult.
Solution Approach 2:
The elastic material acts as a flexible sealing element that can deform and adapt to the storage body's shape. This flexibility allows it to prevent foam resin leakage effectively while still permitting easy insertion of the storage body, as the material can compress and expand as needed during mounting.
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 reduces manhours and costs, improves appearance quality by minimizing looseness, and ensures easy component mounting while preventing foam resin leakage.
Implementation Method 1
a foam resin material is injected into a skin formed by sewing a plurality of skin pieces in a bag shape, the foam resin material is foamed in the skin, and a resin foam is molded integrally with the skin
Implementation Method 2
A shrinkage occurs when the foam resin material is hardened. The wadding material contacting with the foam resin material follows the hardening and shrinkage of the foam resin material
Data Source
AI summary
An integral skin foam molded article includes: a skin formed by sewing a plurality of skin pieces in a bag shape; and a resin foam which is molded inside the skin integrally with the skin, wherein: at least one skin piece among the plurality of skin pieces has a surface material made of a natural leather, and includes a wadding material stacked on a back side of the surface material in a non-surface joined state and a lining material stacked on the wadding material; and in a shrinkage rate with respect to an in-plane compression load, a shrinkage rate of the lining material is smaller than a shrinkage rate of the wadding material.