Molded Foam with Rough Contact Surface for Friction Noise Reduction
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Solution Overview
Problem
Existing methods for reducing abnormal noise between synthetic resin foam and vehicle structures, such as surfactant application and friction-reducing coatings, are ineffective for long-term noise reduction and fail to enhance the aesthetic appeal of molded foams, which often have smooth, glossy surfaces.
Innovation Solution
A molded foam with a rough contact surface and a smooth non-contact surface, manufactured using a mold with a rough defining face, reduces friction noise and improves appearance by incorporating depressions and projections, potentially formed using wooden forms like chemical wood, resulting in a matte finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a smooth glossy surface is used for the molded foam, then the molding process is simple and productivity is high, but the aesthetic appeal is poor and friction noise is increased
Solution Approach 1:
The patent applies different surface qualities to different regions of the molded foam. The contact surface that touches the vehicle structure is given a rough texture to reduce friction noise, while other surfaces maintain smooth finishes for aesthetic appeal. This local differentiation resolves the contradiction by applying roughness only where needed for noise reduction rather than uniformly across the entire product.
2Object-affected harmful factors
If felt is attached to the molded foam to reduce abnormal noise, then friction noise is reduced, but cost increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the noise reduction function directly into the molded foam structure itself by forming a rough texture during the molding process. This eliminates the need for separate felt attachments and adhesive application steps, combining multiple functions (noise reduction and structural integrity) into a single integrated component.
Solution Approach 2:
The rough texture for noise reduction is formed during the initial molding process rather than being added as a subsequent step. By preliminarily creating the noise-reducing surface structure during foam formation, the patent avoids later manufacturing steps involving felt attachment, adhesives, and additional processing.
3Object-affected harmful factors
If a coating film with low friction coefficient is applied to the contact face, then abnormal noise is reduced, but the effect deteriorates over time and additional manufacturing steps are required
Solution Approach 1:
The patent makes the molded foam self-sufficient for noise reduction by incorporating the rough texture directly into its structure. The foam's own surface morphology provides the friction-reducing properties without requiring external coatings or attachments, ensuring long-term durability as the structure is inherent rather than applied.
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 effectively reduces grating noise and improves the aesthetic appeal of molded foams, enhancing their texture and design while maintaining low production costs and productivity.
Implementation Method 1
heated steam is introduced into the cavity to heat the expandable resin particles for molding
Implementation Method 2
When such a molded foam made of synthetic resin comes in contact with a vehicle structure and rubs against each other, they may generate high-pitched grating abnormal noise, such as squeaky sound, due to the friction between them
Data Source
AI summary
Provided are a molded foam (1) that is lightweight and can be manufactured at low cost, and can reduce abnormal noise due to friction with a vehicle structure effectively and for a long time, and a mold (10) that can mold a molded foam that is beautiful and attractive in appearance.