Seat Cushion Molding With Direct Heating for Faster Mold Release
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Solution Overview
Problem
Conventional methods for forming three-dimensional netted structures, such as those used in cushion production, face inefficiencies in mold release times and require complex secondary formations, particularly for applications like aircraft seat cushions, which hinder production efficiency.
Innovation Solution
The method involves directly heating the three-dimensional netted structure made from tangled continuous filaments with voids, using steam, hot blast, or hot water, and cooling with liquid or cold air to accelerate the curing process, allowing for faster mold release and improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the three-dimensional netted structure is heated using conventional mold heating methods, then the cushion can be formed, but the mold release time becomes extremely long due to the large size of the mold
Solution Approach 1:
The patent extracts the heating function from the mold and applies it directly to the three-dimensional netted structure. By using a heating device that contacts the cushion material directly rather than heating the mold indirectly, the heating process is decoupled from the large mold mass, enabling faster thermal response and shorter cycle times
Solution Approach 2:
The patent introduces a heating device as an intermediary between the heat source and the three-dimensional netted structure. This intermediary device can be heated quickly and then transfer heat directly to the cushion material, avoiding the thermal inertia of the large mold and enabling rapid heating and cooling cycles
2Manufacturing precision
If conventional four-face forming method is used, then the three-dimensional netted structure can be formed, but secondary formation processes are required which complicate the manufacturing process
Solution Approach 1:
The patent combines the forming and finishing operations into a single integrated process. By using a heating device that can apply localized heat while the material is in the mold, the cushion achieves its final shape and density in one step, eliminating the need for separate secondary formation processes
Solution Approach 2:
The patent utilizes changes in temperature and pressure parameters during the heating process to achieve both formation and finishing. By controlling the thermal and mechanical parameters dynamically, the cushion material transforms from a loose three-dimensional structure to a densely packed finished product in a single continuous process
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 mold release time, enhances production efficiency, and allows for the formation of cushions with tailored properties suitable for various applications, including aircraft seats, by optimizing the thermal softening and compression steps.
Implementation Method 1
heating a male die or a female die, or a female die and/or the three-dimensional structure to a temperature sufficiently high to soften the three-dimensional structure
Implementation Method 2
cooling down the mold, e.g., with water to cure the three-dimensional netted structure
Data Source
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AI summary
A method for forming seat cushions reduces the mold release time. A structure (2) is formed when three or four surfaces of four surfaces, excluding the two end surfaces in the extrusion direction thereof, cure. Normally, the density of the structure (2) is higher than other regions, and the structure (2) is provided with a total of six surfaces: a top surface, a bottom surface, a left surface and a right surface (see fig. 9 and 10), and two end surfaces that have been cut (see fig. 11). The structure (2) is formed according to a formation method comprising the following steps. (1) A compression step in which the structure (2) is compressed in a mold (3). (2) A thermal softening step in which the structure (2) is thermally softened by means of a heating medium. (3) A curing step in which the structure (2) directly undergoes forced cooling in a cooling medium, and is then cured. (4) A mold release step in which the structure (2) is released from the mold (3).