Self-rising board molding using thermobonded nonwoven blanks
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Solution Overview
Problem
The production of polyurethane foams poses health, safety, and environmental concerns due to hazardous materials like toluene diisocyanates, and there is a need for a more sustainable and comfortable alternative for manufacturing three-dimensional molded components such as seating and mattresses.
Innovation Solution
A process utilizing compressed nonwoven materials as expandable substrates within a mold, where the substrates expand upon heat application to fill the mold shape, allowing for the creation of tailored three-dimensional objects with improved comfort and reduced environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyurethane foam is used for manufacturing three-dimensional molded components, then manufacturing capability and material versatility are improved, but health safety and environmental impact deteriorate due to hazardous materials like toluene diisocyanates
Solution Approach 1:
The patent extracts and removes the hazardous polyurethane foam material from the manufacturing process, replacing it with compressed nonwoven textile materials that can be thermally expanded. This eliminates exposure to toxic substances like toluene diisocyanates while maintaining the ability to produce complex three-dimensional molded components through the expansion process
Solution Approach 2:
The patent changes the physical state and properties of the nonwoven material through thermal energy input. The compressed nonwoven material undergoes phase transition and expansion when heated, transforming from a dense compressed state to an expanded three-dimensional form that fills the mold cavity, thereby achieving complex geometries without using hazardous chemicals
2Ease of operation
If polyurethane foam is used for seating and bedding applications, then cushioning and comfort are improved, but weight increases affecting fuel consumption in automotive and aerospace applications
Solution Approach 1:
The patent uses thin layers of nonwoven textile material that, when thermally expanded, create a lightweight yet cushioning structure. The expanded material forms a flexible, conforming shell that provides comfort through its ability to deform and recover, while maintaining significantly lower weight compared to traditional polyurethane foam of equivalent cushioning performance
3Productivity
If traditional polyurethane foam molding is used, then production efficiency is maintained, but environmental compliance requirements and safety regulations increase complexity
Solution Approach 1:
The patent employs a self-service approach where the nonwoven material itself performs the molding function through thermal expansion. The material automatically expands to fill the mold cavity and conform to the desired shape when heated, eliminating the need for complex molding equipment, chemical catalysts, and specialized safety systems required for polyurethane foam production, thereby simplifying environmental and safety compliance
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 method enables efficient, cost-effective, and customizable production of three-dimensional objects with enhanced comfort and reduced environmental footprint, addressing the limitations of polyurethane foam production while providing tailored attributes like firmness and breathability.
Implementation Method 1
Upon application of heat to a temperature above the melting temperature of the binder material, the expandable substrates expand to fill all or part of the mold
Implementation Method 2
the expandable substrates expand to fill all or part of the mold
Implementation Method 3
the three dimensional object is cooled within the mold, thereby allowing the binder material to harden
Data Source
AI summary
Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.