Intersecting Ridge Foam Pad Anchoring
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Solution Overview
Problem
Molded foams used in vehicle interiors tend to shift position when subjected to sliding forces and can cause unusual noise due to surface contact and friction, necessitating additional fixation methods like adhesives to prevent these issues.
Innovation Solution
The molded foam features a surface design with intersecting first and second ridges, each tapered towards the top, arranged with constant pitches to provide anchoring and reduce contact area, thereby stabilizing the foam and preventing sliding and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat surface molded foam is used, then the moldability and light weight are good, but the foam shifts position when sliding force is applied
Solution Approach 1:
The invention applies curved ridge structures on the foam surface instead of a flat surface. The ridges have rounded cross-sections and curved profiles that interlock with corresponding grooves in the mating component, preventing lateral displacement while maintaining the simplicity of foam molding processes.
Solution Approach 2:
The invention transitions from a two-dimensional flat surface to a three-dimensional ridged surface with height variations. The ridges extend vertically from the foam surface, creating multiple contact points and mechanical interlocking features that prevent sliding in both longitudinal and lateral directions.
2Ease of manufacture
If a flat surface molded foam is used, then the manufacturing is simple, but unusual noise occurs due to surface contact and friction
Solution Approach 1:
The ridges are designed with curved, rounded profiles rather than sharp edges or flat surfaces. This curvature allows for smoother contact and reduced friction during relative movement, minimizing the generation of vibration and noise while maintaining the simple foam manufacturing process.
3Productivity
If a flat surface molded foam is used, then the production process is simple, but additional fixation methods like adhesives are needed
Solution Approach 1:
The foam component provides its own fixation function through the ridges that mechanically interlock with grooves in the mating component. This self-fixing mechanism eliminates the need for separate adhesives or fasteners, maintaining simple production processes while improving assembly reliability.
Solution Approach 2:
By adding vertical height to the surface through ridges, the invention creates mechanical interlocking in the vertical dimension that prevents lateral sliding. This dimensional addition provides fixation functionality without requiring additional fixation components or complex assembly procedures.
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
The ridged surface design effectively anchors other members, preventing shifting and noise by dispersing forces and reducing frictional contact, enhancing the stability and noise reduction of molded foams in vehicle applications.
Implementation Method 1
resin particles are preliminarily foamed to obtain expandable resin particles
Implementation Method 2
The expandable resin particles filled into the mold are again foamed by being heated with steam
Data Source
AI summary
A molded foam is provided in which even when a force in a sliding direction is applied to another member in contact with its surface, the occurrence of a shift in position relative to the other member can effectively be prevented and the occurrence of unusual noise due to rubbing between its surface and the other member can effectively be prevented. The molded foam is formed by heating expandable resin particles filled into a foaming mold. The molded foam has a plurality of first ridges arranged in one direction and a plurality of second ridges arranged in another direction and disposed so as to intersect the first ridges, the first and second ridges being provided on the surface of the molded foam.