Foam seat element, and process and mold for producing same
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Solution Overview
Problem
Conventional dual density or dual firmness vehicular seat elements are expensive to produce and often result in 'read through' of textured surfaces through the trim cover, compromising both comfort and aesthetic requirements.
Innovation Solution
A foam seat element with internal surfaces of varying textures, where at least one surface is denser near the skin and less dense in the core, creating a contacting interface below the outer surface, allowing for different comfort zones without altering the outer surface's appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dual density or dual firmness seat elements are used to provide different comfort zones, then comfort and support are improved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by creating a textured surface layer on the foam seat element that provides different firmness zones only where needed. The textured portion contains raised and recessed areas that create variable support characteristics locally, while the bulk foam remains uniform density. This allows dual-firmness functionality without requiring dual-density foam construction throughout the entire seat element.
2Ease of operation
If textured surfaces are created on the outer surface of the foam seat element, then comfort and support are improved, but read through occurs through the trim cover compromising aesthetic appearance
Solution Approach 1:
The patent uses the textured surface layer as an intermediary between the uniform foam substrate and the trim cover. The textured portion is positioned between these two layers, providing the desired comfort and support characteristics while being hidden from external view. This intermediary layer transmits the beneficial mechanical properties to the occupant while preventing the aesthetic defect of read through to the trim cover.
Solution Approach 2:
The patent moves the textured surface from the external surface to an internal dimension within the foam structure. Instead of having the textured surface on the outer face where it would be visible through the trim cover, the textured portion is embedded within the foam body, creating a hidden internal structure that provides comfort functionality without visual exposure.
3Ease of operation
If multiple types of foam are used to create dual density seat elements, then different firmness zones are achieved, but production time increases due to separate production and assembly
Solution Approach 1:
The patent merges the functions of multiple foam types into a single uniform foam substrate with an integrated textured surface layer. Instead of producing separate foam components with different densities and then assembling them, the invention creates a monolithic foam structure where the textured portion is formed as part of the same molding process. This consolidation eliminates assembly steps and reduces production time while maintaining the dual-firmness functionality.
Data Source
AI summary
A mold is described for production of a molded element. The mold includes a first mold portion and a second mold portion engageable to define a mold cavity. The mold further includes at least one insert element having a textured surface and configured to create a first internal surface and a second internal surface opposed to one another in molded element. The textured surface may include a plurality of peak portions and a plurality of valley portions. The at least one insert element may be affixed to one of the first mold portion and the second mold portion, or is moveable with respect to one or both of the first mold portion and the second mold portion to facilitate demolding of the molded element.