Seat pad and method for manufacturing seat pad

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional vehicle seat cushions made of urethane foam suffer from poor air permeability and inadequate cushion durability, leading to stuffiness and collapse during long-distance driving.

Innovation Solution

A method involving the placement of an air permeable member within a metallic mold cavity, compressed by the mold, and filled with foamed resin material to create a seat pad with improved air permeability and durability, utilizing a covering member made of cloth material to project the air permeable member and enhance ventilation and cushioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If an air permeable member is installed on an upper portion of the cavity of a metallic mold and combined with urethane foam, then air permeability is improved, but the member moves to the back surface side of the elastic body during use, causing ventilation performance to be lost

Engineering Contradiction:

Improveair permeabilityVSAvoidventilation performance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The air permeable member is embedded within the urethane foam elastic body, with its both ends fixed at the front and rear surfaces of the foam. This nesting structure ensures the member remains in its proper position during use and maintains ventilation performance, resolving the issue of the member moving to the back surface side.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The air permeable member is pre-positioned and fixed within the urethane foam before the foam is molded. This preliminary positioning ensures the member maintains its correct orientation and position during subsequent use, preventing it from moving to the back surface side where ventilation would be lost.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If a non-foaming urethane is used with an air permeable member on its lower surface, then air permeability is provided, but the elastic body performance is inferior

Engineering Contradiction:

Improveair permeabilityVSAvoidelastic body performance

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The invention combines a foaming urethane elastic body with an air permeable member to create a composite structure. The foaming urethane provides superior elastic body performance while the integrated air permeable member maintains ventilation functionality, overcoming the limitations of non-foaming urethane.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If an air flow passage is disposed by covering one side of the urethane foam with another member, then air permeability is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveair permeabilityVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The air permeable member is integrated directly into the urethane foam during the molding process itself, combining the elastic body formation and air permeability features in a single manufacturing step. This eliminates the need for separate covering or assembly operations, reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Object-affected harmful factors

If a front released C-shaped three-dimensional net-shaped elastic body is arranged inside the polyurethane foam, then air permeability is improved, but the elastic modulus becomes higher than polyurethane foam, causing cushion collapse during long-distance driving

Engineering Contradiction:

Improveair permeabilityVSAvoidcushion durability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The air permeable member is positioned specifically at the front and rear portions of the urethane foam, allowing these areas to provide ventilation while the central seating area maintains the appropriate cushioning characteristics of the foaming urethane. This localized approach preserves cushion durability while achieving air permeability.

Inventive Principle:

Principle #3Local quality

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 results in a seat pad with enhanced comfort and durability, providing better air permeability and maintaining cushion performance during extended use.

Implementation Method 1

a urethane foam that is made by a foamed resin material being foamed in a cavity of a metallic mold

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

an air permeable member that is arranged inside the urethane foam in a state where the both ends of the air permeable member are fixed to front and rear surfaces of the urethane foam

Methodology Applied

Scientific EffectAir permeability: Permeation

Data Source

PatentEP3235404B1Seat pad and method for manufacturing seat pad

Publication Date: 2020.10.14 TACHI S CO LTD

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

It is provided a seat pad having excellent comfort in seating with improved air permeability and cushion durability in a seat pad of the vehicle seat. The seat pad includes an air permeable member having a ventilation n function with an outside. The seat pad is integrally foam molded using a foamed resin material in a state where the air permeable member is introduced. The seat pad has a surface of the air permeable member projecting with respect to a surface of the seat pad located at a closest position to the air permeable member.