Vehicle Seat Cushion Molding With Recyclable Reinforcing Layer
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Solution Overview
Problem
The presence of a reinforcing layer with a different chemical nature from the foam block complicates the recycling of padding elements, compromising their environmental sustainability.
Innovation Solution
A manufacturing method involving a mold with a base and cover that allows for the integration of a reinforcing layer and foam block using polyurethane-based fluid compositions, which are expanded together to form a unified padding element, facilitating recycling and enhancing abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing layer of different chemical nature is added to the foam block, then abrasion resistance is improved, but recyclability deteriorates
Solution Approach 1:
The patent applies homogeneity by making both the foam block and reinforcing layer consist of the same chemical material (polyurethane). This allows the entire padding element to be recycled as a single material type, eliminating the recyclability problem caused by mixed materials while maintaining the abrasion resistance benefit of the reinforcing layer.
Solution Approach 2:
The patent merges the foam block and reinforcing layer into a unified structure where both components are made of polyurethane. The layers are bonded together through chemical bonding during the expansion process, creating an integrated component that can be recycled together as a single material system.
2Strength
If a reinforcing layer is added to the foam block, then abrasion resistance is improved, but structural complexity increases
Solution Approach 1:
The patent uses composite materials by combining a foam block and a reinforcing layer into a single padding element. The reinforcing layer, made of polyurethane open-cell foam, is chemically bonded to the foam block, creating a composite structure that provides enhanced abrasion resistance while maintaining a relatively simple two-layer configuration.
3Ease of manufacture
If polyurethane-based fluid compositions are used for both foam block and reinforcing layer, then recyclability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by controlling the polyurethane content in each layer within specific ranges (foam block: at least 50% by mass, reinforcing layer: at least 50% by mass). These parameter specifications ensure both layers are sufficiently polyurethane-based for recyclability while allowing flexibility in the exact composition to accommodate manufacturing variations.
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 method results in a padding element with improved strength and recyclability, particularly when both the foam block and reinforcing layer consist of high polyurethane content, simplifying recycling and maintaining good abrasion resistance.
Implementation Method 1
expanding the first fluid composition
Implementation Method 2
each of the first and second compositions comprises polyurethane
Data Source
Figure 1
Figure 2
AI summary
The method comprises the following steps: - providing a mold (32) comprising a mold base (40) and a cover (44), capable of being assembled in a removable manner to form an enclosure (48); - the mold base and the cover being dissociated, depositing in the mold base (40) a first fluid composition (50), precursor of a foam block of a padding element, said first fluid composition comprising an expansion agent; and depositing in the cover a layer of second fluid composition (52), precursor of a reinforcing layer of the padding element; - expanding the first fluid composition; and assembling the mold base and the cover during said expansion, so as to secure the foam block and the reinforcing layer.