Foam Pad Wire Assembly Positioning in Automotive Molding

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Solution Overview

Problem

Existing molding apparatuses for foam pads with wire assemblies in automotive vehicles create voids and weak areas due to posts extending from the mold bowl, leading to potential tears in the foam pad.

Innovation Solution

The apparatus features wire holders with upper ledges and holding elements that vertically and horizontally position the wire assembly within the mold cavity, eliminating the need for posts and ensuring the wire assembly is securely embedded in the foam pad, reducing the likelihood of tears upon removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If posts are used to hold the wire assembly within the mold cavity, then the wire assembly is supported during foam molding, but voids and weak areas are created in the foam pad

Engineering Contradiction:

Improvestructural integrity of foam padVSAvoidvoids and weak areas in foam pad

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent removes the harmful posts from the mold bowl bottom and replaces them with wire holders extending from the peripheral wall. This extraction of the problematic element (posts) eliminates the source of voids while maintaining the necessary wire assembly support function through alternative means (wire holders with ledges and holding elements).

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The wire holders serve as intermediary structures that extend from the peripheral wall into the mold cavity to support the wire assembly. These intermediaries perform the holding function without creating deep cavities, as they are integrated into the peripheral wall structure rather than extending from the bottom surface, thus preventing void formation in the foam pad.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If posts extend from the bottom surface of the mold bowl to hold the wire assembly, then the wire assembly is vertically positioned, but deep cavities and channels are left in the foam pad

Engineering Contradiction:

Improvepositioning accuracy of wire assemblyVSAvoiduniformity of foam pad structure

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent transitions from vertical positioning (posts extending from bottom surface) to a combination of vertical and horizontal positioning (wire holders extending from peripheral wall with ledges and holding elements). This dimensional change allows precise wire assembly positioning while avoiding deep vertical cavities that compromise foam pad uniformity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The wire holders with ledges and holding elements are pre-positioned on the peripheral wall before foam injection. This preliminary action ensures the wire assembly is accurately positioned in both vertical and horizontal dimensions before the foam expands, eliminating the need for deep cavities that would otherwise be required to achieve such positioning precision.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If posts are used to support the wire assembly, then the wire assembly is held in place, but holes and openings are created in the foam pad

Engineering Contradiction:

Improvesimplicity of wire assembly positioningVSAvoidstrength of foam pad

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent combines vertical positioning (via ledges on wire holders) and horizontal positioning (via holding elements on wire holders) into a single integrated structure. This merging of positioning functions maintains ease of operation while eliminating the need for separate posts that would create holes and weaken the foam pad structure.

Inventive Principle:

Principle #5Merging (Combining)

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 design prevents the formation of deep cavities and voids, enhancing the structural integrity and reducing the risk of tears in the foam pad by embedding the wire assembly within the foam pad, resulting in a more robust and stable product.

Implementation Method 1

allowing the foam material to expand to fill the mold cavity to form the foam pad with the wire assembly embedded therein

Methodology Applied

Scientific EffectFoam expansion: Foam

Data Source

PatentUS11691320B2Apparatus and method for molding a foam pad with a wire assembly

Publication Date: 2023.07.04 MAGNA SEATING INC

AI summary

An apparatus for molding a foam pad with a wire assembly for an automotive vehicle includes a mold bowl operably coupled to a mold lid to define a mold cavity therebetween. The mold bowl includes a bottom surface and a peripheral wall extending upwardly from and encircling the bottom surface. A plurality of wire holders extend inwardly from and are spaced around the peripheral wall for vertically positioning the wire assembly within the mold cavity. A holding element, such as an arcuate recess, is disposed along an upper ledge of at least one of the wire holders for horizontally positioning the wire assembly within the mold cavity. The mold cavity receives a foam material for filling the mold cavity and surrounding the wire assembly to form the foam pad with the wire assembly embedded therein.