Extruded Mesh Seat Pad with Variable-Speed Belt Density Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing vehicle seat pads fail to effectively create variations in density across the width of the extruded body, limiting the ability to achieve desired hardness profiles and comfort levels.
Innovation Solution
A method involving a variable speed tractor section with multiple belts that control the speed of polymer filaments to create zones of varying apparent/bulk density, allowing for the formation of seat pads with distinct hardness zones by controlling the speed of tractor belts to adjust local density during the extrusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional extrusion method is used to manufacture vehicle seat pads, then the manufacturing process is simple and uniform, but the density across the width of the extruded body is uniform and cannot achieve desired hardness profiles
Solution Approach 1:
The patent applies local quality by varying the speed of different tractor belts to create zones of different densities within the same extruded body. Each belt section can be independently controlled to pull filaments at different rates, resulting in localized density variations that create distinct hardness zones in the final seat pad product.
Solution Approach 2:
The patent implements dynamics by using variable speed tractor belts that can be independently controlled. The speeds of the tractor belts are made variable and independent of each other, allowing dynamic adjustment of filament pulling rates to create different density zones during the extrusion process, transforming a static uniform extrusion into a dynamic controllable process.
2Manufacturing precision
If multiple extrusion lines are used to create density variations, then density control is improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent merges multiple density control functions into a single extrusion line by using multiple independently controlled tractor belts within one line. Instead of running multiple separate extrusion lines, the invention combines the density variation capability of multiple lines into one unified system, maintaining productivity while achieving the desired hardness profiles through differential belt speeds.
3Adaptability or versatility
If uniform speed tractor belts are used, then the manufacturing process is simple, but the ability to create zones with different bulk densities is limited
Solution Approach 1:
The patent applies segmentation by dividing the continuous extrusion process into discrete zones controlled by individual tractor belts. Each belt section can be independently controlled to create specific density zones, allowing the manufacturing system to produce varied hardness profiles by segmenting the speed control across multiple belt sections.
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 the production of vehicle seat pads with controlled density variations, resulting in enhanced comfort and tailored hardness profiles by forming zones with specific bulk densities, improving the overall quality of the seat cushions.
Implementation Method 1
a plurality of tractor belts arrayed transverse to the longitudinal direction are pulled into the cooling tank with the strip of filaments. The plurality of tractor belts are controlled to move one of a plurality of portions of the strip of filaments in the longitudinal direction at a different speed relative to one another to locally control the apparent/bulk density of the plurality of portions of the strip of polymer filaments
Implementation Method 2
The die head extrudes the polymer filaments that are then fed through a shaping funnel into a cooling tank. The polymer filaments are pulled into the cooling tank by a tractor section at a controllable rate of speed. As the preform strip is pulled into the cooling tank the polymer filaments are welded together as they are initially cooled by the water in the cooling tank
Implementation Method 3
an extruder receives resin beads that are melted in the extruder and then provided to a die head
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A body made up of a plurality of extruded polymer filaments randomly oriented and bonded together to form a three-dimensional mesh structure. The body is elongated in an extrusion, or longitudinal, direction. First zones of the extruded polymer filaments having a first density and second zones of the extruded polymer filaments having a second density less than the first density. The first and second zones are separated by boundaries, or transition areas. A method of making a seat pad with extruded polymer filaments having different zones with different densities and hardness characteristics by controlling the speed of a plurality of tractor belts in a cooling bath.