Magnetic Foam Mold Insert for 3D Concave Seat Hook Strip Positioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing molding technologies face challenges in accurately forming complex three-dimensional shapes with foamed parts, particularly in retaining attachment strips during the molding process, which affects the precision and consistency of the final product.

Innovation Solution

Incorporating a magnetic block with a curved surface and a hook strip-receiving recess in the mold component, utilizing permanent magnets to attract and hold a ferrous metal-containing hook strip, ensuring precise attachment and shaping of the foamed part.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional molding technologies are used, then the molding process is simple, but the precision of forming complex three-dimensional shapes is insufficient

Engineering Contradiction:

Improveprecision of forming complex three-dimensional shapesVSAvoidcomplexity of mold component

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mold component is divided into multiple functional segments: a base structure, a magnetic block with curved surface, and a hook strip-receiving recess. This segmentation allows each component to perform its specific function independently, enabling precise formation of complex three-dimensional shapes while maintaining manageable device complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A magnetic block is introduced as an intermediary element between the mold component and the hook strip. The magnetic block with its curved surface and recess provides magnetic attraction to securely hold the ferrous metal-containing hook strip in the desired position, enabling precise three-dimensional shaping without complex mechanical fastening mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If attachment strips are not securely retained, then the molding process is simple, but the consistency of the final product deteriorates

Engineering Contradiction:

Improveconsistency of final productVSAvoidcomplexity of attachment retention mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical retention mechanisms with a magnetic field-based retention system. The magnetic block attracts and holds the ferrous metal-containing hook strip through magnetic force, providing reliable and consistent attachment retention without the complexity of mechanical fasteners, clips, or adhesives.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic block's curved surface and recess are designed with specific geometric parameters that optimize the magnetic attraction force and the positioning of the hook strip. By adjusting parameters such as the curvature radius, recess depth, and magnetic field strength, the system achieves reliable attachment retention while maintaining product consistency.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a magnetic block with curved surface and recess is incorporated, then the precision of attachment is improved, but the device complexity increases

Engineering Contradiction:

Improveprecision of hook strip attachmentVSAvoidcomplexity of mold component structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The magnetic block is integrated directly into the mold component structure, merging the magnetic retention function with the mold's shaping function. The curved surface and recess of the magnetic block are formed as part of the mold component, eliminating the need for separate attachment mechanisms and reducing overall device complexity while maintaining high attachment precision.

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 solution enables the precise formation of complex three-dimensional shapes by securely attaching the hook strip to the mold component, enhancing the molding process's accuracy and consistency, and facilitating the removal of the protective layer post-molding.

Implementation Method 1

utilizing permanent magnets to attract and hold a ferrous metal-containing hook strip

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentUS12172343B2Kind of foam mold design for concave seat

Publication Date: 2024.12.24 LEAR CORP

AI summary

A mold component for forming a foamed part with a three-dimensional shape includes a magnetic block having a first face that defines a curved three-dimensional surface with a hook strip-receiving recess positioned above the magnetic block. The magnetic block is configured to be placed in a mold with a hook strip placed in the hook strip-receiving recess. The hook strip has a ferrous metal-containing component such that the magnetic block attracts and holds the hook strip with the hook strip conforming to the curved three-dimensional surface. Characteristically, the mold component is configured to be applied in a molding process to mold the three-dimensional shape in the foamed part wherein the hook strip attaches to a trim cover.