Method for producing seat core material, and seat core material
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Solution Overview
Problem
The existing method of producing seat core materials with foamed molded substrates and embedded frame members experiences deformation and dimensional issues due to shrinkage, leading to misalignment and increased costs in post-processing to achieve desired dimensions.
Innovation Solution
A method involving the simultaneous formation of a foamed molded substrate with a frame member embedded within, and the creation of void cavities adjacent to the frame member to allow relative displacement during substrate shrinkage, ensuring the frame member and substrate maintain desired dimensions and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermoplastic resin expanded beads are heated in a mold cavity with a frame member disposed to fusion-bond the expanded beads and integrally mold a foamed molded substrate with the frame member embedded therein, then the seat core material can be produced with the frame member integrated directly in the molding process, but deformation of the frame member and warpage of the foamed molded substrate occur due to shrinkage after molding
Solution Approach 1:
A void cavity is formed in the foamed molded substrate at a position along and adjacent to the frame member before shrinkage occurs. This preliminary structural preparation allows the frame member to displace relative to the substrate during subsequent shrinkage, preventing deformation and maintaining dimensional accuracy while enabling direct integral molding
Solution Approach 2:
The space between the frame member and the foamed molded substrate is segmented into a void cavity region. This segmentation creates a dedicated space that accommodates relative displacement during shrinkage, allowing the frame member and substrate to move independently relative to each other while maintaining overall structural integrity
2Manufacturing precision
If a frame member is fitted into a pre-formed foamed molded substrate, then deformation due to shrinkage can be avoided, but costs and time increase due to the necessity of post processing
Solution Approach 1:
The formation of the void cavity and the embedding of the frame member are merged into a single integral molding process. The void cavity is formed simultaneously with the foamed molded substrate in the same mold cavity, eliminating the need for separate post-processing steps to fit the frame member while maintaining dimensional accuracy
Solution Approach 2:
The void cavity is preliminarily formed during the molding process itself, preparing the substrate structure in advance to accommodate frame member displacement during shrinkage. This eliminates the need for subsequent assembly operations while ensuring dimensional accuracy is maintained
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 prevents deformation and ensures accurate dimensional accuracy of the seat core material, reducing production costs and time by integrating the frame member directly within the molding process.
Implementation Method 1
heating thermoplastic resin expanded beads in a mold cavity, in which the frame member has been disposed, to fusion-bond the expanded beads to each other
Implementation Method 2
heating thermoplastic resin expanded beads in a mold cavity, in which the frame member has been disposed, to fusion-bond the expanded beads to each other
Implementation Method 3
bending of the frame member and warpage of the foamed molded substrate occur due to the shrinkage of the foamed molded substrate after it has been molded
Data Source
AI summary
A method for producing a seat core material that has a foamed molded substrate and a frame member embedded in a periphery thereof, which includes, as step (a), heating thermoplastic resin expanded beads in a mold cavity, in which the frame member has been disposed, to fusion-bond the expanded beads to each other and to obtain the foamed molded substrate with the frame member being embedded in the periphery thereof; and, as step (b), simultaneously with step (a) or after step (a), forming a void cavity S, S′ in the foamed molded substrate at a position along and adjacent to the frame member. The void cavity S, S′ has a size and shape that allows a relative displacement between the frame member and the foamed molded substrate when the foamed molded substrate shrinks after step (b).