Foamless Vehicle Seat Cushion Extrusion With Variable Hole Density
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Solution Overview
Problem
Existing methods for producing vehicle seat cushions often require foam materials, which can be bulky and inefficient, and lack the ability to customize density and hardness profiles for optimal comfort and functionality.
Innovation Solution
A method and apparatus for producing foamless cushions using extruded polymeric filaments, where the die plate has varying hole densities to control filament density and hardness, and a funnel to consolidate and cool the filaments, creating a stranded-mesh material that can be shaped to form customized vehicle interior components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam materials are used to produce vehicle seat cushions, then cushioning comfort is achieved, but the cushions become bulky and inefficient
Solution Approach 1:
The patent uses a stranded-mesh material with inherent porosity and open-cell structure that provides cushioning comfort without the bulkiness of traditional foam. The porous structure allows for weight reduction while maintaining the necessary compliance and comfort properties through the mesh configuration rather than material density.
Solution Approach 2:
The invention employs a composite construction combining extruded polymeric filaments arranged in a stranded-mesh configuration. This composite structure integrates multiple functional requirements (support, comfort, ventilation) into a single material system that eliminates the need for separate foam layers.
2Ease of operation
If foam materials are used for seat cushions, then cushioning is provided, but the ability to customize density and hardness profiles is limited
Solution Approach 1:
The patent implements local quality customization through a die plate with varying hole densities that create different filament densities in different regions of the cushion. This allows varying hardness and support profiles (e.g., firmer bolster areas vs. softer seating surface) to be built into the material structure itself during extrusion, enabling region-specific property adjustment without post-processing.
Solution Approach 2:
The invention enables dynamic customization by allowing the die plate hole configuration to be adjusted during production to create different density profiles. The extrusion process can be modified to produce cushions with varying degrees of filament packing, and the material can be configured to provide adaptable support characteristics suitable for different vehicle applications.
3Productivity
If traditional cushion manufacturing methods are used, then production is achieved, but material waste occurs
Solution Approach 1:
The extrusion process is inherently self-service in that the die plate directly forms the final cushion shape and density profile without requiring subsequent trimming or secondary processing. The continuous extrusion method produces material exactly as needed for the cushion geometry, minimizing off-cut waste that occurs with traditional foam molding and assembly methods.
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 allows for the creation of lightweight, customizable seat cushions with tailored density and hardness profiles, eliminating the need for foam and reducing material waste, while providing enhanced comfort and functionality.
Implementation Method 1
heating a polymeric material to a molten state
Implementation Method 2
introducing the molten polymer into a die plate to form a plurality of molten polymeric filaments
Implementation Method 3
heating arrangement operable to heat the molten polymeric filaments
Implementation Method 4
cooling the molten polymeric filaments in a cooling bath to form a consolidated filament structure
Data Source
AI summary
A method to produce a vehicular seat cushion is provided. The method may include heating a polymeric material to a molten state, dispensing the molten polymer through a die plate having a plurality of holes such that a plurality of polymeric filaments is dispensed from the die plate, and cooling the molten polymeric filaments after leaving the die plate. The die plate may include a first area having a plurality of first holes therethrough and a second area containing a plurality of second holes therethrough. The plurality of first and second holes may respectively define a first open space per unit area in the first area and a second open space per unit area in the second area. The first open space per unit area may be greater than the second open space per unit area.