Conveyance Seat Pad Back Face Member Molding
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Solution Overview
Problem
Conveyance seats with existing back face member configurations face issues of noise and reduced stiffness due to gaps between the seat pad and frame, leading to potential splitting under excessive loads, as the back face member is not consistently arranged, causing weak points without adequate reinforcement.
Innovation Solution
A manufacturing method that integrates the seat pad and back face member by arranging the back face member to cross over the parting line formed by sub elements of a molding die, ensuring overlap and continuous coverage to prevent gaps and enhance stiffness, allowing for smooth molding and bonding of the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the back face member is arranged at a portion receded by about 5 mm from the parting line, then resin leakage is prevented, but the back face member cannot be continuously arranged adjacent to the seat frame, causing gaps and noise
Solution Approach 1:
The back face member is preliminarily arranged to cross over the parting line position before molding, ensuring continuous coverage from the parting line toward the seat frame. This preliminary positioning prevents both resin leakage and gaps, eliminating noise sources while maintaining proper molding function.
Solution Approach 2:
The back face member is arranged with different positions relative to the parting line at different locations: crossing over the parting line at critical areas to prevent gaps and noise, while maintaining appropriate recession at other areas to prevent resin leakage, achieving localized optimization of both functions.
2Object-generated harmful factors
If the back face member is arranged at a portion receded by about 5 mm from the parting line, then resin leakage is prevented, but the stiffness of the seat is reduced due to non-continuous arrangement
Solution Approach 1:
The back face member is preliminarily positioned to cross over the parting line, ensuring continuous structural support is established before molding occurs. This continuous arrangement maintains seat stiffness while the molding process prevents resin leakage through the properly positioned member.
Solution Approach 2:
The back face member is merged continuously across the parting line region, combining the structural support function (stiffness) with the molding seal function (preventing resin leakage) into a single continuous component arrangement.
3Strength
If the back face member is arranged to cross over the parting line, then continuous coverage and stiffness are improved, but resin leakage may occur
Solution Approach 1:
The back face member is arranged to cross over the parting line at specific critical locations where continuous coverage is needed for stiffness, while maintaining appropriate recession at other locations to prevent resin leakage, achieving localized functional optimization.
Solution Approach 2:
The back face member is preliminarily arranged to cross the parting line in positions requiring structural continuity, and the molding process is controlled to prevent resin leakage at these crossed positions through proper die design and molding parameters.
Data Source
AI summary
A manufacturing method for a conveyance seat having a pad structure including a seat pad and a back face member includes integrally molding the seat pad with the back face member in a state where the back face member is arranged so as to cross over at least part of a parting line that is formed by laying a first sub element and a second sub element of a molding die on top of each other, the molding die being formed of at least the first sub element and the second sub element.