Cushion Manufacturing Tool With Buckled Thermoplastic Strands
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Solution Overview
Problem
Existing seat cushion manufacturing methods require dedicated tooling for each foam cushion component, leading to inefficiencies and increased costs due to the need for multiple molds and secondary forming processes.
Innovation Solution
A system utilizing an extrusion die and tooling plate to shape and cool molten thermoplastic resin strands into a non-woven mesh cushion, eliminating the need for dedicated molds and secondary forming processes by guiding and cooling the strands to form the desired shape before solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tooling and multiple molds are used for each foam cushion component, then manufacturing precision can be maintained, but device complexity and production time increase significantly
Solution Approach 1:
The patent applies a universal tooling plate that can form multiple different cushion shapes and contours through a single extrusion process, eliminating the need for separate dedicated molds for each cushion variant. This multi-functional approach maintains manufacturing precision while significantly reducing device complexity.
Solution Approach 2:
The invention changes the manufacturing parameters by using an extrusion die that deposits thermoplastic resin strands in controlled patterns, allowing different cushion geometries to be created by adjusting extrusion parameters rather than changing physical tooling. This maintains precision while simplifying the tooling requirements.
2Manufacturing precision
If dedicated tooling is used for each cushion component, then manufacturing precision is maintained, but productivity decreases due to multiple molds and secondary forming processes
Solution Approach 1:
The patent merges multiple cushion components and forming processes into a single extrusion operation. The tooling plate integrates the functionality of multiple separate molds and secondary forming steps into one unified process, thereby maintaining precision while dramatically improving productivity.
Solution Approach 2:
The extrusion die performs preliminary action by depositing and shaping the thermoplastic resin strands into the final cushion configuration before the material solidifies. This eliminates the need for subsequent secondary forming processes, maintaining precision while accelerating production.
3Manufacturing precision
If multiple molds and secondary forming processes are used, then manufacturing precision can be achieved, but loss of time and increased costs occur
Solution Approach 1:
The tooling plate is segmented into multiple receptacles, each capable of forming different cushion shapes simultaneously or sequentially in a single extrusion cycle. This segmentation allows for efficient production of multiple cushion variants without requiring separate molds for each, reducing production cycle time while maintaining contour accuracy.
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
Enables efficient and cost-effective production of seat cushions with customizable shapes and contours using a single tooling plate, reducing production time and material waste.
Implementation Method 1
The tool 36 guides the strands 34 into the fluid chamber 38. The fluid chamber 38 may retain a fluid to resist and cool the strands 34
Implementation Method 2
The strands 34 are cooled in the fluid chamber 38 by the fluid to form a unitary non-woven thermoplastic cushion 22
Data Source
AI summary
A method of manufacturing a product, dispenses, through a tool with an aperture sized to match an overall perimeter of a product, a molten thermoplastic resin. The tool generates a plurality of strands through the tool aperture while maintaining the plurality of strands within the overall perimeter of the product. The strands are buckled by resisting a flow of the plurality of strands. The buckled strands intersect as a unitary non-woven body in a shape of the overall perimeter of the product.