Seat core material
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Solution Overview
Problem
The existing seat core materials for cars face issues with deformation and reduced dimensional accuracy due to molding shrinkage differences between foamed particle moldings and frame members, leading to a lack of unity and strength when integrated.
Innovation Solution
A seat core material design featuring a thermoplastic resin foamed particle molding with an annular frame member and strategically placed slits, where the first slit penetrates the molding from the upper to the lower surface, and a connection outside the slit, mitigates deformation by controlling shrinkage and maintaining strength and unity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the foamed particle molding and frame member are integrally molded, then the frame member is buried in the foamed particle molding as a reinforcing member, but shrinkage of the foamed particle molding causes deformation of the frame member and warpage of the seat core material
Solution Approach 1:
The foamed particle molding is divided into multiple independent shrinkage regions by providing pieces of divided space that expose portions of the frame member. This segmentation allows different regions to shrink independently, preventing cumulative shrinkage forces from causing warpage and deformation of the frame member while maintaining the overall strength of the integrated structure.
2Manufacturing precision
If pieces of divided space are provided in the foamed particle molding to allow independent shrinkage, then dimensional stability is improved, but the seat core material lacks overall sense of unity and is bent or deformed in handling
Solution Approach 1:
The pieces of divided space are strategically positioned at specific locations within the foamed particle molding where shrinkage control is most critical. This local application of divided spaces allows independent shrinkage in key areas while maintaining continuity and unity in other regions, preventing both warpage and loss of overall structural integrity.
3Adaptability or versatility
If the foamed particle molding has large difference between seat thickness at front and rear portion, then the molding can accommodate varying seat requirements, but shrinkage in front-back direction is not considered leading to deformation
Solution Approach 1:
The divided spaces are arranged to account for the varying thickness profile of the seat core material, with positioning that considers the front-back thickness differences. This segmentation strategy allows each region to shrink according to its local geometry, preventing deformation in areas with large thickness variations while maintaining the adaptive design.
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
The solution achieves excellent dimensional accuracy, strength, and a sense of unity by managing shrinkage forces and maintaining structural integrity, even when the frame member is buried within the foamed particle molding.
Implementation Method 1
a foamed particle molding is usually subject to molding shrinkage after molding in a mold and the shape of the foamed particle molding is thus stabilized with a dimension shrinked from the dimension of the mold
Data Source
AI summary
A seat core material having reduced deformation, extremely excellent dimensional accuracy, sense of unity, and strength is thus provided. The frame member and the foamed particle molding are integrated in the seat core material.