Polyurethane Foam Toys With Flexible Cover And Adhesive Bonding

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Solution Overview

Problem

Existing polyurethane (PU) foam toys face issues such as moisture adsorption leading to mildew growth, difficulty in cleaning, and damage from muddy environments, along with limited pattern and color options due to the use of soft leather covers.

Innovation Solution

The manufacturing process involves using a flexible cover with a hardness below Shore A 70, such as PVC or TPE, and an adhesive composition of thermoplastic polyurethane, chloroprene rubber, and tackifier resin to create a strong bond between the PU body and cover, allowing for complex patterns and double-color injection molding, while preventing mildew and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If soft leather is used as the exterior cover, then the product has simple and limited surface patterns, but the manufacturing process is straightforward

Engineering Contradiction:

Improvepattern varietyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines soft leather with a PU foam layer to create a composite structure. The soft leather provides the exterior cover with pattern versatility, while the PU foam layer provides cushioning and structural support. This composite approach allows for rich surface patterns through the leather while maintaining manufacturing feasibility through the foam's easy processability.

Inventive Principle:

Principle #40Composite materials

2Strength

If PU foam is used as cushioning material, then it has good elasticity and flexibility, but it adsorbs moisture and promotes mildew growth

Engineering Contradiction:

Improveelasticity and flexibilityVSAvoidmildew growth

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses a soft leather cover as a flexible shell that encloses the PU foam cushioning material. The leather shell acts as a protective barrier that prevents moisture from reaching the PU foam, thereby preventing mildew growth while allowing the PU foam to retain its elastic and flexible properties for cushioning.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If the flexible cover is made from soft leather, then it offers simple surface patterns, but it is easy to damage during playing

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite structure where soft leather serves as the exterior cover and PU foam provides the underlying cushioning layer. This combination enhances durability by distributing mechanical stresses across two materials with complementary properties, while the leather's ease of manufacture is preserved.

Inventive Principle:

Principle #40Composite materials

4Strength

If PU foam has a large amount of open pores, then it provides good cushioning, but it causes slow drying and stain accumulation

Engineering Contradiction:

Improvecushioning abilityVSAvoidcleaning ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The soft leather cover acts as a protective shell that encapsulates the porous PU foam cushioning material. The leather shell prevents direct contact between external contaminants (mud, stains) and the foam's open pores, making the toy easier to clean while preserving the foam's cushioning properties.

Inventive Principle:

Principle #30Flexible shells and thin films

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 solution provides PU foam toys that are resistant to mildew, easy to clean, and feature durable, patterned exteriors, eliminating environmental restrictions and enhancing playability.

Implementation Method 1

vacuuming to stretch the leather to tightly attach on the negative mold chamber with the negative pressure system of the vacuum suction device

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

an adhesive composition of thermoplastic polyurethane, chloroprene rubber, and tackifier resin to create a strong bond between the PU body and cover

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

polymerization of isocyanates and hydroxyl compound group

Methodology Applied

Scientific EffectPolymerization: Chemical Bonding

Implementation Method 4

PU foam has properties of great elasticity, high flexibility, very good tensile stretch and compressive strength

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentUS9034133B2Polyurethane foam toys with no restriction on playing environment and the manufacturing method thereof

Publication Date: 2015.05.19 CHOW KWONG LAM THOMAS

AI summary

A method of manufacturing polyurethane (PU) foam toys with no restriction on playing environment comprises steps as follows: (1) Placing the prefabricated flexible cover into the foaming mold, and then vacuuming to firmly attach the cover to the inner wall of the mold; (2) Spraying adhesives at the periphery and the interior of the flexible cover while maintaining the continuous vacuum pressure; (3) Injecting the mixed polyurethane into the foaming mold; (4) Closing the mold and performing condensation reaction; (5) Opening the mold to get the product. The present invention is about the production of polyurethane form toys by formulating polyurethanes and binding the interior polyurethane body and flexible cover with adhesives. Because of its resilient and sturdy characteristics, the thermoplastic flexible cover provides protection to the interior polyurethane foam body, effectively eliminating problems like mildew growth, difficulties of cleaning and preventing damage.