Vehicle Seat Cushion Molding With Integrated Polyurethane Surface Layer
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Solution Overview
Problem
Existing processes for manufacturing cushions for motor vehicle seats result in padding blocks with fragile and irregular surfaces, leading to discomfort for passengers, and the addition of protective layers increases costs.
Innovation Solution
A process involving a mold with a tank and lid, mixing elastically compressible foam particles and/or recycling fibers with a precursor mixture of flexible polyurethane resin, coating the mixture with a film based on the same resin, and compressing it to form a padding block with a smooth, robust surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a protective layer is added to the padding block surface, then comfort is improved, but manufacturing cost increases significantly
Solution Approach 1:
The invention merges the protective layer with the padding block by using the same flexible polyurethane resin precursor mixture for both. The resin forms a continuous matrix that binds foam particles and fibers together, creating an integrated structure where the protective function is inherent to the material composition rather than an added layer, thereby eliminating the need for separate protective materials and reducing manufacturing costs
Solution Approach 2:
The invention changes the physical and chemical parameters of the resin mixture to achieve both structural integrity and surface protection. By adjusting the resin formulation, cross-linking properties, and foam particle characteristics, the material develops a surface that is naturally robust and comfortable without requiring additional protective coatings
2Ease of manufacture
If the padding block is made with foam particles and recycled fibers bound by resin, then manufacturing cost is reduced, but surface quality becomes fragile and irregular
Solution Approach 1:
The invention modifies the resin parameters including flexibility, cross-linking density, and bonding strength to create a matrix that binds foam particles and fibers while producing a smooth, robust surface. The resin formulation is optimized to fill gaps between particles and create a uniform surface structure that maintains both cost-effectiveness and high surface quality
Solution Approach 2:
The invention creates a composite material system where flexible polyurethane resin, foam particles, and recycled fibers work together synergistically. The resin matrix provides structural continuity and surface smoothness, while the foam particles and fibers provide cushioning properties, achieving both economical manufacturing and high surface quality through material composition
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 process produces a cushion with improved robustness and comfort, achieved at a lower cost by integrating the smoothing layer directly into the manufacturing process, which also prevents the penetration of comfort foam into the padding block.
Implementation Method 1
after cross-linking said resin, demold said padding block obtained
Implementation Method 2
coat the walls of said cavity with a film based on a precursor mixture of flexible polyurethane resin
Implementation Method 3
fill said mold with said mixture and compress it to give it the shape of said molding cavity
Data Source
Figure 1~2a
Figure 2b~3a
Figure 3b
AI summary
The invention relates to a method for making a cushion for a seat element of a motor vehicle, said method comprising the following steps: mixing elastically compressible foam particles (16) and/or recycled fibers with a precursor mixture of flexible polyurethane resin for bonding said particles and/or fibers together, so as to obtain a mixture (4) to form a padding block of said cushion; coating the walls (6) of a molding cavity with a film based on a precursor mixture of flexible polyurethane resin (19); filling the mold with said mixture and compressing it to give it the shape of said cavity; after cross-linking said resins, demolding said padding block obtained.