Method and apparatus for creating a kneeler pad using a thermoforming process
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Solution Overview
Problem
Existing methods for manufacturing rigid, plastic hollow shells for furniture are limited in size modification and upholstery durability, requiring new molds for different sizes and experiencing upholstery stretching issues over time.
Innovation Solution
A thermoforming process is used to create adjustable kneeler pad frameworks with extendable segmented extensions and a fabric tightening system to maintain upholstery tightness and extend product life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding is used to create rigid plastic shells, then manufacturing precision and strength are improved, but adaptability for different sizes deteriorates because new molds are required for each size
Solution Approach 1:
The kneeler pad framework is divided into multiple shell segments that can be connected together. Each shell is formed using the same injection molding process, but multiple shells can be joined to create different overall lengths, enabling size variation without requiring different molds.
Solution Approach 2:
Multiple shell segments are designed to fit together like nested dolls, where individual standardized shells can be combined in different quantities to achieve different total lengths while maintaining consistent manufacturing processes.
2Ease of operation
If upholstery is applied to rigid plastic shells, then comfort and appearance are improved, but durability deteriorates because upholstery stretches and loses shape over time
Solution Approach 1:
The framework includes adjustable tension parameters through movable shell segments and fastening mechanisms that can be tightened or loosened. This allows the upholstery to be maintained at optimal tension levels, preventing stretching and shape loss over time while preserving comfort.
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
Enables the production of lightweight, adjustable furniture with extended upholstery life and multiple size options without changing molds, addressing size limitations and upholstery durability issues.
Implementation Method 1
The manufacturing process used to create the framework is referred to as thermoforming. Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape.
Data Source
AI summary
The present invention is a system and method for manufacturing a framework for a padded cushion in the shape of a kneeler pad, wherein the framework is created using a thermoforming process to make rigid and plastic top and bottom shells that are then coupled together to form a framework to which upholstery is added to thereby form a padded kneeling cushion, wherein a fabric tightening system is also installed in the framework that enables the upholstery to be stretched tighter over the framework in order to tighten the upholstery around the cushion as the upholstery loses its shape and stretches over time, and wherein a system is provided to extend a length of the kneeler pads through the addition of expansion segments in the framework.