Vehicle Seat Cushion Molding with Air Permeable Fabric Segmentation
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Solution Overview
Problem
The existing method for manufacturing vehicle seat components with integrated cushion and upholstery members is not suitable for forming flow passages during molding, as the upholstery member can contact and interfere with the molding projections, making it difficult to maintain the original properties and flexibility of the upholstery while integrating the components.
Innovation Solution
A method that integrates the cushion and upholstery members during molding, forming a thin section on the back surface of the cushion member to facilitate the formation of flow passages, and using a backing member to reinforce the cushion while preventing intrusion of the molding material, allowing for efficient formation of air passages through the thin sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the upholstery member is disposed in the molding die before injecting molding material, then the upholstery member and cushion member are integrated together, but the upholstery member contacts with molding projections and its original properties and flexibility are compromised
Solution Approach 1:
The upholstery member is divided into two distinct portions: a first portion (air-permeable fabric layer) that contacts the cushion member and maintains flexibility, and a second portion (protective layer) that prevents intrusion of molding material. This segmentation allows each portion to serve its specific function without interfering with the other, resolving the contradiction between integration and quality preservation.
Solution Approach 2:
The second portion of the upholstery member acts as an intermediary protective layer between the molding material and the first portion (original upholstery). It prevents direct contact and damage from the molding material while allowing the first portion to maintain its original properties and flexibility during the molding process.
2Productivity
If flow passages are formed during molding of the cushion member, then manufacturing efficiency is improved, but the upholstery member interferes with the formation of flow passages
Solution Approach 1:
The second portion of the upholstery member is prepared in advance to cover the areas where flow passages need to be formed. This preliminary protective action prevents molding material from intruding into the upholstery member during the molding process, enabling flow passages to be formed efficiently without damaging the upholstery.
3Ease of operation
If the upholstery member is made air-permeable for comfort, then occupant comfort is improved, but molding material can intrude into the upholstery member during molding
Solution Approach 1:
The upholstery member is segmented into a first portion (air-permeable fabric) that provides comfort by allowing air flow, and a second portion (impermeable protective layer) that prevents intrusion of molding material. This segmentation resolves the contradiction by allowing the air-permeable portion to maintain comfort functionality while the protective portion ensures structural integrity during molding.
Data Source
AI summary
A method for manufacturing a vehicle seat component includes a first step of integrating a cushion member and an upholstery member together during molding of the cushion member, and a second step of forming a flow passage through which air passes from a back surface of the cushion member toward the upholstery member.