Tool with integrated fluid lines to form a cushion assembly
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Solution Overview
Problem
Existing cushion assemblies for seating systems face challenges in efficiently forming nonrectangular shapes without material waste and ensuring uniform porosity and density, particularly in manufacturing seat cushions with integrated fluid lines for cooling and shaping.
Innovation Solution
A manufacturing system using a die plate to extrude thermoplastic resin into filaments, which are consolidated and cooled in a water tank, then cut to form a nonrectangular cushioning pad with increased density around the perimeter and recesses for integrated components, utilizing a tool with fluid lines for precise cooling and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional cushion manufacturing methods are used, then production is simpler, but material waste increases and uniform porosity/density cannot be achieved
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated extrusion process. The die plate with integrated fluid lines merges cooling function with shaping function, allowing simultaneous formation of cushion perimeter, porosity control, and fluid line integration in one continuous operation, eliminating material waste from secondary processing
Solution Approach 2:
The die plate serves multiple functions simultaneously: it shapes the cushion perimeter, controls porosity through fluid delivery, integrates cooling channels, and forms recesses for components. This multi-functional tooling eliminates the need for separate operations, reducing both material waste and overall system complexity
2Manufacturing precision
If conventional cushion manufacturing methods are used, then the process is easier to implement, but uniform porosity and density cannot be achieved
Solution Approach 1:
The die plate delivers fluid through specifically positioned fluid lines and outlets to different regions of the extruded cushion material. This localized fluid delivery creates controlled porosity variations - higher porosity in seating areas for comfort, and appropriate density at perimeters for structural support - achieving uniform local properties throughout the cushion
Solution Approach 2:
The patent uses fluid (hydraulic/pneumatic system) delivered through the die plate to control the porosity and density of the extruded thermoplastic material. The fluid acts as a blowing agent or expansion medium during extrusion, enabling precise control of cellular structure and material properties without complex post-processing
3Shape
If nonrectangular shapes are formed without integrated tooling, then device complexity is reduced, but material waste increases
Solution Approach 1:
The die plate integrates shaping contours for nonrectangular cushion profiles with fluid delivery channels and cooling lines in a single tooling component. This merging allows the extrusion process to directly form complex geometries with integrated features, eliminating the need for cutting or trimming operations that would generate material waste
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 system enables efficient production of nonrectangular cushioning pads with uniform porosity and density, minimizing material waste and allowing for seamless integration of fluid lines for cooling and shaping, enhancing the manufacturing process.
Implementation Method 1
Fluid is dispensed through a fluid line formed through the tool to cool the tool and the plurality of dispensed strands
Implementation Method 2
A manufacturing system using a die plate to extrude thermoplastic resin into filaments, which are consolidated and cooled in a water tank
Data Source
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AI summary
A product is provided with a body with a nonrectangular cross section with a mesh of strands of expanded thermoplastic resin. A density of the mesh of strands about a perimeter of the nonrectangular cross section is greater than within the perimeter. The perimeter is provided with at least one recess formed therein.