Fluid Chamber Mat Continuous Extrusion for Vehicle Seat Comfort
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Solution Overview
Problem
Existing methods for producing air chamber mats for vehicle seats are limited by the number of air chambers per area, disruptive weld seams, and high production costs, which hinder effective contour adjustment and comfort.
Innovation Solution
A method involving a profile-generating continuous process to produce a film profile with multiple cavities, allowing for the creation of a multi-air chamber mat with fewer work steps and cost savings, using extrusion or continuous welding to connect film sections without disruptive welds, enabling a larger number of fluid chambers per unit area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If individual films are connected using weld seams in a high-frequency welding process, then air chambers can be produced, but the number of air chambers per area is limited and weld seams are disruptive
Solution Approach 1:
The patent merges multiple film sections into a single continuous film profile that is extruded in one piece. This eliminates the need for weld seams between separate films, removing the disruptive effect while enabling a higher density of air chambers per area since the entire structure is formed from a continuous material flow without interruption.
2Ease of manufacture
If air chambers are produced from individual films with weld seams, then air chambers can be formed, but production effort and cost increase
Solution Approach 1:
The patent employs continuous extrusion to produce the film profile with multiple air chambers in a single uninterrupted process. This eliminates the need for separate handling, positioning, and welding of individual films, dramatically reducing production effort while maintaining high air chamber density through the continuous formation process.
3Productivity
If a film profile is produced using a profile-generating continuous process, then production time and cost are reduced, but the complexity of producing multiple cavities in the profile must be managed
Solution Approach 1:
The extrusion process uses a multi-cavity mold that segments the film profile into multiple distinct cavities during formation. Each cavity corresponds to a future air chamber location. This segmentation occurs inherently during the extrusion process itself, allowing complex multi-chamber structures to be produced efficiently without requiring post-processing or assembly of separate components.
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 approach results in a more homogeneous seat contour adjustment, increased comfort, and cost-effective production of multi-air chamber mats with improved pressure distribution and massage functions, enhancing the vehicle seat's adjustability and user experience.
Implementation Method 1
a profile-generating continuous process, producing a film profile
Implementation Method 2
continuous welding to connect film sections
Data Source
Figure 1
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AI summary
The invention relates to a method for producing a fluid chamber mat (13), in particular an air chamber mat for a vehicle seat (40). With regard to the advantageous development, the invention proposes that the method has the following method steps: producing, by means of a continuous operation, a film profile (12) which, with respect to a profile cross section which is perpendicular to the flow-through direction (DL), has a cavity (20) enclosed in the profile cross section or a plurality of cavities (20) which are arranged next to one another and are each enclosed in the profile cross section, severing a length portion of the film profile (12) extending between two longitudinal ends (14, 15) with respect to the flow-through direction (DL) and, for delimiting at least one fluid chamber (25) in the cavity (20) or for delimiting the length of at least one fluid chamber (25) in each cavity (20): at a first position (31) selected on the length portion with respect to the flow-through direction (DL) and at a second position (32) spaced apart therefrom in the flow-through direction (DL) in each case producing a connection (34, 35), which runs transversely, in particular perpendicularly, to the flow-through direction (DL), between two opposite film regions delimiting the cavity (20), and connecting a fluid line (27) to the fluid chamber (25) or a respective fluid line (27) to each fluid chamber (25). The invention also relates to a fluid chamber mat (13) and to a vehicle seat having a fluid chamber mat (13).