Method for manufacturing foaming composite molding, in-mold foaming molding unit, foaming composite molding, and mold for foaming composite molding
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Solution Overview
Problem
In the production of vehicle seats, existing methods face challenges in preventing unnecessary polyurethane foam from being molded in unintended parts when integrating in-mold foamed molded products with polyurethane foam, leading to difficulties in attaching the composite molded product to a vehicle body and requiring removal of excess foam.
Innovation Solution
A method involving an in-mold foamed molded product unit with an exposed insert material, where the insert material is fixed using a magnetic body or engagement recess within the foamed composite molding mold, preventing polyurethane foam from entering gaps and ensuring precise positioning during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the in-mold foamed molded product unit is placed in the foamed composite molding mold without fixing the insert material, then the molding process is simple, but unnecessary polyurethane foam enters the gap between the in-mold foamed molded product unit and the mold
Solution Approach 1:
The insert material is exposed from the in-mold foamed molded product unit before molding, and fixing parts are preliminarily provided in the mold to engage with this exposed insert material. This preliminary arrangement ensures precise positioning before polyurethane liquid is introduced, preventing foam from entering gaps while maintaining manufacturing simplicity.
Solution Approach 2:
The exposed insert material serves as an intermediary element between the in-mold foamed molded product unit and the fixing parts in the mold. By engaging the fixing parts with the exposed insert material, the system achieves precise positioning and gap prevention without requiring complex fixing mechanisms, thus resolving the contradiction between simplicity and precision.
2Manufacturing precision
If the insert material is exposed to the outside of the in-mold foamed molded product, then the fixing part can effectively prevent polyurethane foam from entering gaps, but the structure becomes more complex
Solution Approach 1:
The insert material is extracted or exposed from the interior of the in-mold foamed molded product unit to the exterior surface. This extraction allows the fixing parts in the mold to directly engage with the insert material, effectively preventing polyurethane foam from entering gaps. The complexity is minimized by utilizing the existing insert material rather than adding separate fixing structures.
3Productivity
If polyurethane foam enters the gap between the in-mold foamed molded product unit and the mold, then the molding process is simple, but the foamed composite molded product requires additional processing to remove excess foam
Solution Approach 1:
The fixing parts are preliminarily positioned in the mold to engage with the exposed insert material before polyurethane liquid is introduced. This preliminary action prevents gaps from forming during molding, eliminating the need for post-processing to remove excess foam while maintaining efficient molding cycle speed.
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 effectively prevents unnecessary polyurethane foam from forming in unintended areas, allowing for precise integration and attachment of the foamed composite molded product to a vehicle body while maintaining the structural integrity and dimensions of the in-mold foamed molded product unit.
Implementation Method 1
fixing the insert material with use of a magnetic body or engagement recess in the foamed composite molding mold
Data Source
AI summary
A method of producing a foamed composite molded product includes fixing an exposed part of an insert material on a fixing part provided in a mold, the insert material being inserted in an in-mold foamed molded product made of a thermoplastic resin; introducing a polyurethane liquid into the mold; and producing the foamed composite molded product by foaming the polyurethane liquid in the mold. The foamed composite molded product includes an in-mold foamed molded product unit including the insert material and the in-mold foamed molded product; and a polyurethane foam. At least part of the insert material is exposed to an outside of the in-mold foamed molded product, and the in-mold foamed molded product unit and the polyurethane foam are integrated.