Method for producing an adjusting device for a vehicle seat, and adjusting device
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Solution Overview
Problem
The manufacturing process for pneumatic adjusting devices in vehicle seats is complex, particularly when producing bladders with multiple chambers, as it involves welding multiple flexible films together, which increases complexity and reduces robustness due to the presence of weld seams.
Innovation Solution
A method involving the injection molding or deep-drawing of a single, flexible hollow body from thermoplastic plastic to create a one-piece pressure medium chamber with a connecting seam, reducing manufacturing complexity and improving robustness by eliminating weld seams, and optionally using a carrier film to integrate multiple hollow bodies for enhanced design freedom and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple flexible films are welded together to form multi-chamber bladders, then the bladder can have multiple pressure medium chambers, but the manufacturing complexity increases and robustness decreases due to weld seams
Solution Approach 1:
The patent merges multiple film welding operations into a single injection-molded hollow body structure. The hollow body is formed in one piece with multiple internal chambers, eliminating the need to weld multiple films together. This combining approach reduces manufacturing complexity while maintaining multi-chamber functionality.
Solution Approach 2:
The patent changes the manufacturing parameter from film welding to injection molding. By using injection molding to create the hollow body, the process achieves multi-chamber formation without weld seams, thereby improving robustness while maintaining manufacturing efficiency.
2Adaptability or versatility
If multiple flexible films are welded together to form multi-chamber bladders, then the bladder can have multiple pressure medium chambers, but the robustness decreases due to the presence of weld seams
Solution Approach 1:
The patent combines multiple welded films into a single injection-molded hollow body. This merging eliminates weld seams that compromise robustness, while the hollow body's internal structure maintains the multi-chamber capability through integrated design.
Solution Approach 2:
The patent uses a single thermoplastic material for the hollow body that integrates multiple chamber functions. This composite approach creates a unified structure with enhanced robustness compared to assembled welded films, while maintaining multi-chamber functionality through the material's molded geometry.
3Adaptability or versatility
If bladders are produced from two or more flexible films welded together, then the bladder can be formed with connecting seams, but the manufacturing process becomes very complex for multi-chamber bladders
Solution Approach 1:
The patent merges multiple film assembly and welding steps into a single injection molding operation. The hollow body with multiple chambers is formed in one piece, eliminating the need for separate film cutting, alignment, and welding operations, thereby greatly simplifying the manufacturing process.
Solution Approach 2:
The patent performs preliminary chamber formation during the injection molding process itself. The hollow body is pre-formed with integrated chambers and connecting structures, eliminating the need for subsequent assembly operations and simplifying the overall manufacturing workflow.
4Device complexity
If a hollow body is produced by injection molding from thermoplastic plastic, then the manufacturing complexity is reduced and design freedom is increased, but additional tooling is required
Solution Approach 1:
The patent changes the manufacturing parameter from film assembly to injection molding. Although injection molding requires specialized tooling, it eliminates the need for multiple welding operations and film handling equipment, resulting in net simplification of the manufacturing process and enhanced design freedom.
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 simplifies the manufacturing process, enhances the mechanical stability and robustness of the pneumatic adjusting device, and allows for complex designs with greater lift capabilities while minimizing tooling complexity, as the hollow body can be produced in a single step with improved quality and reduced mechanical stress.
Implementation Method 1
the hollow body is produced by an injection molding process of the thermoplastic plastic
Implementation Method 2
the flexible hollow body may be produced by a deep-drawing process from a second film
Data Source
AI summary
A method for producing an adjusting device for a vehicle seat has the following steps. A flexible hollow body is molded from a thermoplastic plastic by injection molding, wherein the hollow body forms a pressure medium chamber and has an opening which is surrounded by a connecting portion. Furthermore, a first film is arranged at the opening. In particular, a pressure medium line is inserted between the connecting portion or the opening and the first film. Finally, the first film is connected to the hollow body at the connecting portion of the opening at the connecting seam in order to thereby close off the pressure medium chamber. Because the flexible hollow body is formed in one step, in particular by an injection molding process, the manufacturing complexity is minimized and the robustness of the hollow body is increased.