Funnel-Lined Extrusion for Complex Vehicle Seat Cushion Mesh
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Solution Overview
Problem
Existing methods for producing vehicle interior components, such as nonfoam cushions, are inefficient and costly, particularly in postprocessing operations, and lack the ability to create complex geometries effectively.
Innovation Solution
A system and method that utilizes a funnel to consolidate extruded polymeric filaments into a porous mesh structure, which is then formed into a desired shape for use as a vehicle interior component, such as a cushion blank for a vehicle seat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to produce vehicle interior components, then manufacturing processes are well-established, but production efficiency is low and postprocessing costs are high
Solution Approach 1:
The patent applies preliminary action by designing the die plate with a funnel-shaped cavity that pre-forms the complex geometry of the cushion during the extrusion process itself. This eliminates the need for subsequent postprocessing operations such as cutting, shaping, or assembling, thereby significantly improving production efficiency while maintaining ease of manufacture through a single-step continuous extrusion process
2Adaptability or versatility
If complex geometries are required for vehicle interior components, then design flexibility is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent resolves this contradiction by transitioning from traditional multi-step manufacturing approaches to a single-step three-dimensional extrusion process. The die plate's funnel-shaped cavity enables complex geometries to be formed in the extrusion dimension, allowing design flexibility for complex shapes while simplifying manufacturing by consolidating multiple operations into one continuous process
3Loss of time
If postprocessing operations are minimized, then production time is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent replaces traditional mechanical postprocessing operations with a precision extrusion system. The die plate is designed with precise funnel-shaped cavities that directly form the desired geometry during extrusion, substituting subsequent mechanical cutting, shaping, or assembling operations with a single precision-forming step that maintains geometric precision while minimizing production time
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
The method enables the efficient production of complex-shaped non-woven thermoplastic cushions with reduced time and cost, while maintaining the structural integrity and comfort required for vehicle interior components.
Implementation Method 1
The extruder melts and extrudes the material into filaments
Implementation Method 2
The filaments are consolidated into a porous mesh structure
Data Source
AI summary
An assembly is provided with a funnel having one or more side walls extending from an entrance to an outlet, and a liner having one or more elastic panels, with the liner extending over an inner surface of the one or more side walls. A system is provided with the assembly, a die, a fluid bath, and at least one hose to direct fluid from the fluid bath onto the liner of the assembly. A method includes covering an inner surface of a funnel with a liner comprising one or more elastic panels, wetting the liner, and forming a stranded mesh material member by extruding material from a die and through the funnel. A stranded mesh material member is provided and formed using the method.