Handheld Foam Displacement Indicator for On-Site IFD Measurement
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Solution Overview
Problem
The existing methods for inspecting seat foam hardness in vehicle seats are costly and time-consuming, requiring large frame machines in quality control labs, and lack the ability to perform on-site comparisons of foam hardness variations that can affect seat trim fit and comfort.
Innovation Solution
A portable, handheld seat foam inspection gage with a foam displacement indicator that measures foam displacement and converts data into indention force deflection measurements, allowing for on-site inspections and reducing the need for off-site lab measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large frame machine in a quality control lab is used to measure indention force deflection, then measurement precision is improved, but loss of time and manufacturing cost increase
Solution Approach 1:
The patent replaces the complex mechanical large frame machine with a simplified handheld device that uses a spring mechanism and displacement sensor to measure foam hardness. The spring applies a known force and the displacement indicator measures the compression, eliminating the need for expensive lab equipment while maintaining measurement capability.
Solution Approach 2:
The patent extracts the essential measurement function from the complex lab machine, isolating only the critical components needed for foam hardness measurement (spring, displacement indicator, scale). This extracted simplified system can be used handheld on the production line without requiring the full lab machine infrastructure.
2Measurement precision
If a large frame machine in a quality control lab is used to measure indiction force deflection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential measurement function from the complex lab machine, isolating only the critical components needed for foam hardness measurement (spring, displacement indicator, scale). This extracted simplified system can be used handheld on the production line without requiring the full lab machine infrastructure.
Solution Approach 2:
The patent replaces the complex mechanical large frame machine with a simplified handheld device that uses a spring mechanism and displacement sensor to measure foam hardness. The spring applies a known force and the displacement indicator measures the compression, eliminating the need for expensive lab equipment while maintaining measurement capability.
3Measurement precision
If seat foam is sent to a quality control lab for inspection, then measurement accuracy is improved, but productivity decreases
Solution Approach 1:
The patent enables the production line to perform its own quality inspection using the handheld device. Operators can measure foam hardness directly at the manufacturing location without sending samples to the lab, allowing the production process to continue uninterrupted and maintaining high throughput while ensuring quality control.
Solution Approach 2:
The patent allows for preliminary inspection of foam hardness during the manufacturing process itself, before the seats are completed and sent to the lab. This early detection of defects prevents rework later and maintains production efficiency.
4Loss of time
If a handheld foam displacement indicator is used for on-site inspection, then loss of time is reduced, but measurement precision may worsen
Solution Approach 1:
The patent replaces the complex mechanical large frame machine with a simplified handheld device that uses a spring mechanism and displacement sensor to measure foam hardness. The spring applies a known force and the displacement indicator measures the compression, eliminating the need for expensive lab equipment while maintaining measurement capability.
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 quick, cost-effective on-site inspection of seat foam hardness, reducing the time and expense associated with sending seat components to quality control labs and ensuring uniformity in seat foam manufacturing.
Implementation Method 1
a ball arranged within the body
Implementation Method 2
measures a distance of a foam displacement on a vehicle seat back or seat cushion
Implementation Method 3
a displacement indicator arranged on a top surface of the body, wherein the displacement indicator measures a distance of a foam displacement
Data Source
AI summary
A seat foam inspection gage including a foam displacement indicator is used for inspecting seat foam on site at a manufacturing plant. The seat foam inspection gage includes a cylindrical body and a ball arranged within the body. The seat foam inspection gage also includes an indicator arranged on a top surface of the body, wherein the indicator measures distance of a foam displacement of the seat foam at a seat manufacturing facility. The seat foam inspection gage may take the distance of foam displacement and convert that number into an IFD number, thus allowing for quick comparison of seat foam hardness across an entire seating surface and across all seats being manufactured in a facility without having to send the seat foam to an offsite quality control lab to measure the IFD with large frame machinery.