Lumbar Support Basket Overmolding for Simpler Seat Manufacturing

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Solution Overview

Problem

The production of lumbar support devices with arching elements and a support basket is complex and time-consuming, involving multiple manufacturing steps and high costs due to conventional methods requiring separate molding processes for the arching elements and support basket.

Innovation Solution

A method using a single molding tool for both injection molding the support basket and arching elements, allowing for one-shot overmolding and concurrent formation of overmolded attachment features, which simplifies the manufacturing process and reduces production time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate molding processes are used for arching elements and support basket, then manufacturing precision and component quality are maintained, but manufacturing complexity and production time increase

Engineering Contradiction:

Improvecomponent qualityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the molding of arching elements and support basket into a single integrated molding process using one molding tool. The molding tool includes a first mold for arching elements and a second mold for support basket that operate simultaneously or sequentially in one setup, eliminating the need for separate molding processes and reducing manufacturing complexity while maintaining component quality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molding tool is designed with multi-functionality to perform both arching element molding and support basket molding. The tool includes multiple cavities and molding sections that can produce different components in one operation, making the equipment universal and reducing the number of specialized tools needed

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple separate molding processes are used, then component quality is ensured, but production time increases

Engineering Contradiction:

Improvecomponent qualityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges the molding operations for arching elements and support basket into a single simultaneous process. Both components are molded in one cycle using the integrated molding tool, which significantly reduces production time compared to sequential separate molding processes while ensuring quality through controlled molding parameters

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conventional separate manufacturing methods are used, then component reliability is maintained, but manufacturing costs increase

Engineering Contradiction:

Improvecomponent reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple manufacturing operations into one integrated molding process, reducing the number of assembly steps, handling operations, and quality checks needed. This consolidation lowers manufacturing costs while maintaining reliability through consistent molding quality and reduced assembly variability

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If separate molding tools are used for arching elements and support basket, then molding precision is maintained, but device complexity increases

Engineering Contradiction:

Improvemolding precisionVSAvoidmolding tool complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent designs a universal molding tool that incorporates multiple molding cavities and sections for different components. The tool maintains precision through dedicated molding sections for each component while achieving simplicity through integration, eliminating the need for multiple separate specialized tools

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables efficient production of lumbar support devices by combining molding processes, reducing complexity and costs while maintaining the necessary support and adjustability features, such as pivotable components and adjustable arching elements.

Implementation Method 1

An injection molding process which forms the support basket and an injection molding process which molds the arching elements to a carrier, e.g. a wire of the lumbar support device, may be performed using the same molding tool.

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

The molding tool may comprise a first half mold and a second half mold which in combination define cavities for forming the support basket and for forming overmolds which mold the arching elements to the carrier.

Methodology Applied

Scientific EffectCavity molding:

Data Source

PatentUS10195972B2Method of producing a lumbar support device, lumbar support device and vehicle seat

Publication Date: 2019.02.05 SCHUKRA BERNDORF GES MBH

AI summary

A lumbar support device comprises a carrier, a pair of arching elements molded to the carrier, and a support basket supported by the pair of arching elements. To produce the lumbar support device, the pair of arching elements may be molded to the carrier in a molding tool and the support basket may be formed in the same molding tool.