Molding Subsidiary Material with Overlap-Bonded Curved Edges
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Solution Overview
Problem
Existing methods for producing subsidiary materials integrated with resin bodies, such as cushion materials for seats, often require complex molds for each design, leading to increased production costs and difficulties in creating three-dimensional shapes, especially when complex shapes are needed.
Innovation Solution
A method involving the separation of molding and overlap-bonding steps, where an irregular-shaped molded portion is created on a flat sheet material, and the notched outer peripheral edges are overlap-bonded to form a curved shape, allowing for efficient production of three-dimensional subsidiary materials without the need for a full mold for each design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a full mold is used for each design of subsidiary material, then complex three-dimensional shapes can be produced, but production cost and mold storage cost increase
Solution Approach 1:
The subsidiary material is divided into two distinct parts: a molded portion formed by molding and a non-molded portion formed by overlap-bonding notched parts. This segmentation allows the complex three-dimensional shape to be achieved through the molded portion while the non-molded portion can be produced using simpler, more cost-effective overlap-bonding processes, reducing the need for expensive full molds for each design
Solution Approach 2:
The overlap-bonding process for the non-molded portion can be applied universally across different designs without requiring custom molds for each variant. This multi-functional approach allows the same basic process to create various shapes and configurations, reducing both production costs and mold storage requirements while maintaining the capability to produce complex three-dimensional forms
2Shape
If a full mold is used for each design of subsidiary material, then complex three-dimensional shapes can be produced, but mold storage cost increases
Solution Approach 1:
By segmenting the production into molded and non-molded portions, the number of unique molds required is significantly reduced. Only the molded portion requires specialized molds, while the non-molded portion uses standard overlap-bonding processes, thereby reducing mold storage volume and costs
Solution Approach 2:
The overlap-bonding technique serves as a universal method for creating various subsidiary material configurations without requiring dedicated molds for each design, reducing the overall mold inventory needed and associated storage costs
3Ease of manufacture
If only sewing is used to produce reinforcing fabric, then production cost is reduced, but complex tridimensional shapes cannot be achieved
Solution Approach 1:
The subsidiary material is segmented into a molded portion that achieves complex three-dimensional shapes through molding processes and a non-molded portion that can be produced using cost-effective overlap-bonding methods. This segmentation allows both complex shaping and cost reduction to be achieved in different regions of the same component
Solution Approach 2:
The invention merges two different manufacturing approaches - molding and overlap-bonding - into a single integrated production process. The molded portion provides complex three-dimensional geometry while the overlap-bonded non-molded portion reduces production costs, and both are combined to form the complete subsidiary material
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 production costs and unit prices by allowing the use of smaller, common molds and enabling efficient production of complex shapes, while also simplifying storage and processing of materials.
Implementation Method 1
a nonwoven fabric or the like (subsidiary material) that is integrated with at least a part of the surface of the soft resin body
Implementation Method 2
a molding step of obtaining a molded material in which an irregular-shaped molded portion is provided on a part of a flat sheet material by molding
Data Source
AI summary
[Problem to be solved] An object is to provide a method of efficiently producing even a subsidiary material having a complex shape corresponding to a resin body.[Solution] The production method of the present invention includes, for example, a molding step of obtaining a molded material (m1) in which an irregular-shaped molded portion (10) is provided on a part of a flat sheet material by molding and an overlap-bonding step of overlap-bonding a notched portion (21) provided on an outer peripheral side of the molded material to obtain an overlap-bonded and molded material (m4) in which at least a part of the outer peripheral side is curved. Thus, a molding subsidiary material (M) is obtained which includes the overlap-bonded and molded material and is integrated with a resin body (R). The sheet material is made, for example, of a nonwoven fabric. The resin body is made, for example, of a foamed resin. When the resin body is provided with an inner cavity (air passage), for example, a through-hole corresponding to the inner cavity is formed in the molded portion. By separating the molding step and the overlap-bonding step, even a complex-shaped subsidiary material can be produced at low cost.