Seat Pad Ventilation Structure to Prevent Fastener Voids

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Solution Overview

Problem

Existing seat pad manufacturing methods often result in voids (air gaps) near fastener members due to trapped gas, with previous countermeasures either causing clogging, requiring large insert reinforce members that deteriorate the pad quality, or compromising the strength of the fastener detachment.

Innovation Solution

Incorporating a ventilation member with one end near the fastener and the other extending on the rear surface, allowing gas to escape through a gas discharging hole, and using breathable materials to prevent gas entrapment while maintaining the strength of the fastener integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the fastener member is placed on the front surface side of the pad body in the cavity, then the fastener member can be securely integrated into the pad body, but gas is trapped in the vicinity of the fastener member causing voids

Engineering Contradiction:

Improvefastener integration strengthVSAvoidvoid formation near fastener

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The cavity is divided into multiple regions with different functions: a first region for receiving the fastener member and a second region for receiving the supporter member. This segmentation allows the fastener to be positioned optimally for strength while providing separate pathways for gas evacuation, preventing void formation near the fastener.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A ventilation member is introduced as an intermediary element between the fastener member and the resin raw material. This ventilation member provides a dedicated gas discharge pathway, allowing trapped gas to escape during foaming without compromising the fastener's integration strength or creating voids in critical areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If gas discharge grooves are provided in the cavity, then gas can be discharged during foaming, but the grooves become clogged with resin requiring maintenance

Engineering Contradiction:

Improvegas entrapmentVSAvoidmaintenance work for clogging

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The ventilation member acts as an intermediary gas discharge pathway that is less prone to clogging. It provides a controlled channel for gas evacuation during foaming, reducing resin intrusion compared to open grooves, thereby minimizing maintenance requirements while effectively preventing gas entrapment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The ventilation member can be designed as a disposable or easily replaceable component. If it becomes clogged or degraded, it can be replaced without requiring complex maintenance procedures, making the system more economical and easier to maintain in the long term.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If a large insert reinforce member is used to discharge gas, then gas can be discharged from the lower portion cavity, but the insert reinforce member falls upon the seat pad causing quality deterioration

Engineering Contradiction:

Improvegas discharge from lower cavityVSAvoidseat pad quality

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The cavity is segmented into distinct regions with dedicated functions. The first region handles fastener integration, the second region receives the supporter member, and gas discharge pathways are integrated into these regions. This eliminates the need for large insert reinforce members that could fall and damage the seat pad, as gas discharge is achieved through properly positioned ventilation members in segmented zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Ventilation members serve as intermediary structures that provide gas discharge pathways without requiring large, heavy insert reinforce members. These ventilation members are strategically positioned to discharge gas from lower cavity regions without compromising seat pad quality or causing damage during the molding process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Effectively prevents voids near fastener members without clogging issues or quality deterioration, enhances detachment strength, and ensures the seat pad's comfort and durability.

Implementation Method 1

one end portion of the ventilation member being located in the vicinity of the fastener member, and the other end portion of the ventilation member extending on a rear surface side of the pad body

Methodology Applied

Scientific EffectGas discharge through ventilation member:

Implementation Method 2

a resin raw material such as raw solution of urethane foam is foamed and solidified in the cavity, whereby the pad body is foamed and shaped

Methodology Applied

Scientific EffectFoaming and solidifying: Phase Change

Data Source

PatentUS8864238B2Seat pad

Publication Date: 2014.10.21 ARCHEM INC

AI summary

Provided is a seat pad 1 having a fastener member 4 on a front surface side of a pad body 2 made of a foaming resin, which includes: a ventilation member 5, one end portion of the ventilation member being located in the vicinity of the fastener member 4, and the other end portion of the ventilation member extending on a rear surface side of the pad body 2.