Padded Overlay Manufacturing via Pre-Formed Precursor
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Solution Overview
Problem
Current methods for producing upholstery elements, particularly for motor vehicle seats, are costly due to extensive processing steps like punching, grinding, and material waste, especially when using fiber composite materials.
Innovation Solution
A method where a precursor material is shaped in a mold to its final form, eliminating the need for further processing steps like punching and grinding, and using a filling collar to define the material's expansion and reduce waste, with the precursor material being pre-formed into a semi-finished product before molding, allowing for cost-effective production and reduced tooling needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber composite materials are used for upholstery elements, then seating comfort and seat climate are improved, but production costs increase due to extensive processing steps like punching and grinding
Solution Approach 1:
The invention applies preliminary action by pre-forming the precursor material to match the final upholstery element shape before molding. This pre-shaping eliminates the need for subsequent punching, cutting, and grinding operations, thereby reducing production costs while maintaining the comfort benefits of fiber composite materials
Solution Approach 2:
The invention merges the shaping and molding operations into a single integrated process. The precursor material is pre-formed to the final contour, and then directly molded in the mold without requiring separate punching or grinding tools, combining multiple processing steps into one efficient operation
2Productivity
If traditional molding methods are used without pre-formed precursor material, then material can be scattered directly into tools, but significant material waste occurs and additional processing steps are required
Solution Approach 1:
The precursor material is pre-formed into a semi-finished product with the desired final shape before being placed in the mold. This preliminary shaping ensures that material is precisely positioned and reduces spillage or excess material that would otherwise be wasted during the molding process
Solution Approach 2:
The precursor material is created as a copy or replica of the final upholstery element shape. This pre-formed precursor accurately replicates the target geometry, ensuring that when molded, the material fits perfectly without requiring trimming or removing excess material
3Manufacturing precision
If multiple processing steps like punching, cutting, and grinding are performed after molding, then the upholstery element can be finished, but production time and complexity increase
Solution Approach 1:
The precursor material is pre-formed to the exact final shape and edge contours before molding. This preliminary action ensures that the upholstery element emerges from the mold with precise edges already formed, eliminating the need for subsequent punching, cutting, or grinding operations and reducing tooling complexity
Solution Approach 2:
The invention merges the edge finishing operation into the molding process itself. By pre-forming the precursor material to the final shape, the molding operation simultaneously achieves both the basic form and the precise edge contours, combining multiple processing functions into one step
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 significantly reduces production costs and material waste, enabling the creation of high-quality, cost-effective upholstery elements with improved seating comfort and reduced tooling requirements.
Implementation Method 1
the precursor material is at least partially filled into a filling collar before the precursor material is introduced into the mold. This makes it possible for the lateral expansion of the filled-in material of the precursor material to be defined by the shape of the filling collar
Implementation Method 2
Air at a temperature of approx. 100°C is passed through the tools so that the latex/fiber mixture dries in the tool
Implementation Method 3
a precursor material is formed in a mold, the precursor material being adapted to the final shape of the upholstery element to be achieved
Data Source
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AI summary
A method for manufacturing a cushioning element, in particular a seat cushioning element for use in a motor vehicle, a cushioning element and a filling collar (2) for manufacturing the cushioning element is proposed, wherein a precursor material is formed in a molding tool, wherein the precursor material is adapted to the final shape of the cushioning element to be achieved before the molding tool is completely closed.