Seat molded article and preparing method thereof
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Solution Overview
Problem
The challenge is to reduce the thickness of vehicle seat cushions while maintaining comfort performance, as conventional methods using urethane foam alone result in reduced support and increased irritation due to quicker compression under load, and replacing foam with stretch fabric limits mass production.
Innovation Solution
A seat molded article featuring a polyurethane foam upper pad with a thickness of 25 to 50 mm, combined with an elastic fabric underneath, where the elastic fabric is woven from thermoplastic polyester elastomer resin yarn, providing tensile elongation and flame retardancy, and is heat-treated to ensure optimal comfort and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of urethane foam cushion is reduced, then the volume of seat is reduced, but the comfort performance deteriorates due to quicker compression under load
Solution Approach 1:
The invention combines urethane foam with elastic fabric (stretch fabric) to create a composite cushion structure. The elastic fabric layer is integrated into the cushion, providing additional support and elasticity that compensates for the reduced foam thickness, thereby maintaining comfort performance while reducing overall volume.
Solution Approach 2:
The invention changes the physical parameters of the cushion by incorporating elastic fabric with specific tensile properties (20-40% elongation at 20kgf load). This parameter change allows the cushion to maintain support capabilities with less material volume, as the elastic fabric provides structural reinforcement and load distribution.
2Volume of moving object
If stretch fabric is used instead of urethane foam, then the seat volume is reduced, but the manufacturing capability is limited
Solution Approach 1:
The invention merges stretch fabric with conventional urethane foam manufacturing processes. The elastic fabric is positioned within the foam structure during molding, allowing the combined assembly to be produced as a single integrated component using existing foam injection molding technology, thus enabling mass production.
Solution Approach 2:
The elastic fabric is prepared and positioned in advance within the mold cavity before urethane foam injection. This preliminary arrangement of the fabric layer ensures proper integration during the molding process and facilitates automated mass production without requiring complex post-assembly operations.
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 reduced seat volume with maintained comfort performance, allowing for 40 to 70% sagging under a 55 kgf load compared to 100 kgf, preventing irritation and supporting passenger comfort, while enabling slim interior parts and improved vehicle efficiency.
Implementation Method 1
heat-treating the scoured elastic fabric at a temperature in a range of 150 to 165° C.
Implementation Method 2
a tensile elongation measured under a load of 20 kilogram-force (kgf) is in a range of 20 to 40% in the warp and weft directions
Data Source
AI summary
A seat molded article and a method of preparing a seat molded article are disclosed. The seat molded article includes: an upper pad formed of polyurethane foam having a thickness in a range of 25 to 50 mm; and an elastic fabric disposed under the upper pad, wherein, in the elastic fabric, a difference in tensile elongation between warp and weft directions is 5.0% or less, and a tensile elongation measured under a load of 20 kgf is in a range of 20 to 40% in the warp and weft directions.