Osmosis-Membrane Cushion Structure for Foam-Network Bonding

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Solution Overview

Problem

The existing cushion structures for automobile seats face challenges in achieving sufficient connection strength between the three-dimensional network structure section and the foam section, leading to inadequate bonding and increased production costs due to adhesion methods.

Innovation Solution

A cushion structure is designed where the three-dimensional network structure section is impregnated with a liquid foam material, which is then solidified, enhancing the connection strength between the two components, and an osmosis membrane is used to control the permeation and solidification of the foam material, improving productivity and breathability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive or double-sided adhesive tape is used to connect the three-dimensional network structure section and the foam section, then the connection strength is improved, but the production cost increases and productivity decreases

Engineering Contradiction:

Improveconnection strengthVSAvoidproductivity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The foam material serves dual purposes: it forms the foam section and simultaneously acts as adhesive to bond the three-dimensional network structure section. The liquid foam material is applied to the network structure, allowed to solidify, and naturally bonds both components together without requiring separate adhesive materials or additional bonding steps, thereby improving productivity while maintaining connection strength

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent combines the foam material with the bonding function by using the same liquid foam material both to create the foam section and to serve as the bonding agent. This merging of functions eliminates the need for separate adhesive materials and bonding processes, resolving the contradiction between connection strength and productivity

Inventive Principle:

Principle #5Merging (Combining)

2Strength

Engineering Contradiction:

Improveconnection strengthVSAvoidprocessing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The liquid foam material performs multiple functions: it forms the foam section structure and simultaneously serves as the bonding adhesive. This multi-functionality eliminates the need for separate adhesive materials, reducing processing costs while maintaining the required connection strength between components

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The foam material self-bonds the components together during the natural solidification process without requiring additional bonding operations or materials. This self-service approach eliminates extra processing steps and material costs, resolving the contradiction between connection strength and processing cost

Inventive Principle:

Principle #25Self-service

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 configuration provides a cushion structure with improved connection strength and reduced production costs, while maintaining breathability and flexibility, enhancing the seating experience and durability.

Implementation Method 1

an osmosis membrane disposed at a boundary between the three-dimensional network structure section and the foam section, the osmosis membrane allows the liquid foam material to permeate

Methodology Applied

Scientific EffectOsmosis: Osmosis

Implementation Method 2

the three-dimensional network structure section is impregnated with the liquid foam material and subsequently solidified, which connects the three-dimensional network structure section and the foam section to each other

Methodology Applied

Scientific EffectSolidification: Phase Change

Data Source

PatentUS10632881B2Cushion structure, cushion structure component and cushion structure manufacturing method

Publication Date: 2020.04.28 NAGASE & CO LTD

AI summary

An osmosis membrane is disposed at the boundary between a three-dimensional network structure section and a foam section. The osmosis membrane allows a liquid foam material to permeate. The three-dimensional network structure section is impregnated with the foam material through the osmosis membrane, and subsequently the foam material is solidified, thereby connecting the three-dimensional network structure section and the foam section to each other. The bonded body of the three-dimensional network structure section and the foam section is completed only by disposing the cushion structure component in between the upper mold and the lower mold, and performing a foaming step.