Polyurethane Vehicle Saddle Casting Process
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Solution Overview
Problem
Existing bicycle saddle manufacturing processes are complex, expensive, and not environmentally friendly, leading to high production costs and storage challenges due to the use of traditional molds and materials.
Innovation Solution
A saddle manufacturing process using a polyurethane-based composite material for the base component, produced through a casting or injection process within an aluminum mold, which allows for the introduction of fillers for enhanced mechanical properties and simplifies production, while the padding component can be made of polyurethane foam or EVA for comfort, with a cover element made of polyurethane, PVC, or leather.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molds and manufacturing processes are used, then the saddle can be produced, but the manufacturing process becomes complex, expensive, and not environmentally friendly
Solution Approach 1:
The patent combines the shell and padding into a single integrated component manufactured in one molding process. The mold cavity is divided into a shell molding cavity and a padding molding cavity, allowing both components to be formed simultaneously from a single material mixture, eliminating the need for separate manufacturing processes and reducing overall complexity
Solution Approach 2:
The patent uses composite materials consisting of a shell material (such as thermoplastic polymer) and a padding material (such as foam material) combined in a single mixture. This composite approach allows both structural and comfort functions to be achieved in one manufacturing step, simplifying the overall process while maintaining performance
2Quantity of substance
If traditional molds are used, then the saddle can be manufactured, but high storage costs are incurred for separate shell components
Solution Approach 1:
The patent eliminates the need for separate shell storage by integrating the shell and padding into a single molded component. The unified structure removes the intermediate storage step for shell components, allowing direct progression from manufacturing to final assembly, thereby reducing storage space requirements and improving production efficiency
3Productivity
If separate shell and padding components are used, then the saddle can be assembled, but the process becomes complex and time-consuming
Solution Approach 1:
The patent merges the shell and padding into a single integrated component that is molded and cured as one piece. This eliminates the need for separate assembly operations, reducing both the time required for manufacturing and the complexity of the assembly process, thereby significantly improving productivity
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 reduces manufacturing costs and time, enhances the stability and comfort of the saddle, and minimizes environmental impact by using eco-friendly materials and eliminating the need for storage of separate shells, allowing for customization and improved adhesion between components.
Implementation Method 1
a base component (2), made of a polyurethane or of a polyurethane material, obtained by a casting or injection process
Implementation Method 2
The polyol/isocyanate mixing ratio is chosen according to the isocyanate/polyol compositions and the filler to be used... the base component (2) is made of polyurethane or of a polyurethane material
Data Source
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Figure 3~4
Figure 5~6
AI summary
Saddle (1) for vehicles, for example for bicycles or motorcycles, comprising a base component (2), set to be constrained to a frame of a vehicle such as a bicycle or a motorcycle, a padding component (3), arranged on said base component (2), and a cover element or covering (4), wherein the base component (2) comprises an upper surface (2a) and a lower surface (2b) and the padding component (3) comprises an upper surface (3a) and a lower surface (3b) intended to come into contact and/or be constrained with the upper surface (2a) of the base component (2), therein the base component (2) is made at least partly or entirely of polyurethane or of a polyurethane material.