Method and foam die for manufacturing seat cushion material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method for manufacturing a two-layer seat cushion material for vehicle seats results in foamed polyurethane resin intruding between the die surfaces, leading to deviations in seating surface height and increased working steps when attempting to remove excess material.
Innovation Solution
A method and foam die design where the back layer pad is attached to an upper die with protrusions on the lower die that press the back layer pad against the upper die, preventing foamed resin intrusion and allowing for integrated molding of the front and back layer parts with reduced working steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the back layer pad is temporarily held on the cavity surface of the upper die by mechanical fitting or magnetic force, then the pad body can be manufactured by pouring foamed polyurethane resin raw material, but foamed resin intrudes between the cavity surface and back surface, causing height deviation and requiring additional removal steps
Solution Approach 1:
The back layer pad is pre-attached to the upper die cavity surface using magnetic force before pouring the foamed resin raw material. This preliminary positioning ensures the back layer remains stationary during foaming, preventing resin intrusion and eliminating the need for subsequent removal steps, thus maintaining height precision while simplifying the overall process
Solution Approach 2:
Magnetic force is introduced as an intermediary mechanism to hold the back layer pad on the upper die cavity surface. The magnetic field acts as a non-contact intermediary that secures the back layer without physical mechanical fittings, allowing complete contact between the back layer and cavity surface while preventing foamed resin intrusion during the molding process
2Productivity
If foamed polyurethane resin raw material is poured onto the cavity surface to manufacture the pad body, then the front layer is formed, but the resin intrudes at the end portion of the back surface and foams there, creating excess material
Solution Approach 1:
Magnetic force serves as an intermediary holding mechanism that secures the back layer pad to the upper die cavity surface, creating a barrier that prevents foamed resin from intruding into the gap between the back layer and cavity surface, thereby eliminating waste material formation
Solution Approach 2:
The magnetic holding mechanism converts the potential harmful effect of resin intrusion into a beneficial outcome by completely preventing the intrusion from occurring in the first place, eliminating the need for any post-processing removal operations and ensuring all poured material forms useful product
3Ease of manufacture
If mechanical fitting or magnetic force is used to hold the back layer, then the pad can be manufactured, but the number of working steps increases when attempting to remove intruded foam
Solution Approach 1:
The magnetic holding mechanism converts the potential problem of resin intrusion into a complete prevention solution, where the magnetic field continuously secures the back layer throughout the entire foaming process, eliminating the need for any subsequent foam removal steps and reducing total working time
Solution Approach 2:
The back layer is preliminarily secured to the upper die cavity surface using magnetic force before the foaming process begins. This preliminary magnetic attachment ensures complete contact and prevents any resin intrusion during molding, eliminating the need for post-molding removal operations and reducing the total number of working steps
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 ensures proper contact between the seating surface and back layer, suppresses unnecessary foam formation, and simplifies the demolding process by preventing foamed resin from intruding between die surfaces, thus maintaining design specifications and improving workability.
Implementation Method 1
a plurality of protrusions which is configured to be brought into contact with the seating surface side of the back layer part and is configured to press the back layer part against the upper cavity surface
Implementation Method 2
in the process of foaming and curing the foamed polyurethane resin raw material
Implementation Method 3
in the process of foaming and curing the foamed polyurethane resin raw material
Data Source
AI summary
A method for manufacturing a seat cushion material, the seat cushion material including a front layer part and a back layer part having a back side surface, the method including: preparing for molding the seat cushion by attaching the back layer part to an upper die having an upper cavity surface; molding the seat cushion material by adding foamed resin raw material forming on a lower cavity surface of a lower die and then by closing the upper die to which the back layer part is attached, the lower cavity surface being provided with a plurality of protrusions which is configured to be brought into contact with a seating surface side of the back layer part and press the back layer part against the upper cavity surface when the upper die to which the back layer part is attached is closed; and demolding the molded seat cushion material.