High-resilience PU spring sponge and preparing method thereof
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Solution Overview
Problem
Current high-resilience polyurethane (PU) sponges used in mattresses and sofas suffer from performance degradation and require cumbersome manual installation of springs, leading to increased production costs and potential de-grooving issues.
Innovation Solution
A high-resilience PU spring sponge with integrated high-strength springs, where the springs are embedded in uniformly defined grooves on the sponge main body during the foaming process, eliminating the need for manual embedding and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If springs are manually embedded in grooves after foaming, then spring installation is possible, but processing procedure becomes cumbersome and production cost increases
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves and positioning structures during the foaming process itself, rather than performing these operations after the sponge is manufactured. The mold includes pre-designed groove structures that are created simultaneously with the sponge body, eliminating the need for subsequent manual grooving and spring embedding operations.
Solution Approach 2:
The patent merges the spring embedding operation with the foaming process by integrating spring positioning features directly into the mold structure. The grooves and positioning mechanisms are combined with the mold design, allowing springs to be automatically positioned and embedded as the sponge foams in place, rather than requiring separate manual operations.
2Ease of operation
If manual embedding of springs is used, then spring installation is achieved, but de-grooving problem occurs after long period of use
Solution Approach 1:
The patent uses preliminary action by creating precisely fitted groove structures and positioning features during the initial foaming process. These pre-formed structures ensure proper spring placement and secure retention from the beginning, preventing the de-grooving problem that occurs with manual embedding after the product has been in use for extended periods.
Solution Approach 2:
The patent utilizes the expansion forces generated during the foaming process itself to press the sponge material into the groove structures and secure the springs in place. The expanding foam acts as a hydraulic/pneumatic force that automatically embeds and secures the springs without manual intervention, creating a more reliable and permanent attachment.
3Ease of manufacture
If grooves are cut after foaming, then spring installation is enabled, but material waste increases and production cost rises
Solution Approach 1:
The patent applies preliminary action by forming all necessary groove structures and positioning features during the foaming process itself, eliminating the need for subsequent cutting operations. The mold includes pre-designed groove structures that are created simultaneously with the sponge body, preventing material waste that would result from cutting grooves after foaming.
Solution Approach 2:
The patent segments the mold structure into multiple sections including integrated groove formations, allowing different portions of the sponge to be formed with specific structural features built-in during foaming. This segmentation enables complex groove patterns and spring positioning structures to be created without requiring post-foaming cutting operations.
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 integrated high-strength springs enhance the sponge's elasticity, fatigue resistance, and comfort, while simplifying production and reducing costs by avoiding manual de-grooving, thus improving the overall performance and longevity of the PU sponge.
Implementation Method 1
magnetically fixing each of the high-strength springs by a magnetic mechanism arranged on a top end of a corresponding mounting column of the mounting columns
Implementation Method 2
S4: a slurry foaming curing and demolding step: foaming the slurry introduced into the mixer in the step S3
Data Source
AI summary
A high-resilience PU spring sponge and a preparing method thereof are provided. The high-resilience PU spring sponge includes a sponge main body and high-strength springs. A top portion of the sponge main body defines a sponge top surface. First grooves are defined on the sponge top surface. A bottom portion of the sponge main body defines a sponge bottom surface. Second grooves are uniformly defined on the sponge bottom surface. The preparing method includes a mold preheating and mold pretreatment step, a material mixing pretreatment step, a slurry introducing step, a slurry foaming curing and demolding step, and a natural curing and finished product processing step. The second grooves are defined on the sponge main body after the sponge main body is cured and the second grooves are formed through the perforated columns. Each of the first grooves is communicated with a corresponding second groove.