Vehicle Seat Padding Attachment Support for Easier Recycling
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Solution Overview
Problem
Existing padding elements for vehicle seats with metal rods or rigid plastic parts for attachment complicate recycling due to their complex configurations.
Innovation Solution
A padding element with an attachment support formed from unexpanded plastic material, integrated with a foam block, using a manufacturing method that molds the attachment support and overmolds the foam block to secure the contact surface, facilitating recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rods or rigid plastic parts are used for attachment supports, then attachment strength is improved, but device complexity and recycling difficulty increase
Solution Approach 1:
The attachment support is merged with the foam block by integrating it into the foam matrix during the molding process. The support consists of a contact surface integral with the bottom of the groove and a rib arranged opposite the contact surface, both formed as part of the foam structure itself, eliminating the need for separate metal or rigid plastic components.
Solution Approach 2:
The attachment support is formed from unexpanded plastic material that is subsequently molded into the final configuration. This parameter change from unexpanded to expanded/molded state allows the material to achieve the required structural strength while maintaining compatibility with the foam block for recycling purposes.
2Strength
If metal rods or rigid plastic parts are used for attachment supports, then attachment strength is improved, but ease of manufacture for recycling deteriorates
Solution Approach 1:
The attachment support and the foam block are both made from polyurethane material, creating a homogeneous structure. The support is formed from unexpanded plastic material that is compatible with the foam block material, allowing both components to be processed together during recycling without requiring separation of dissimilar materials like metal and foam.
Solution Approach 2:
The manufacturing process merges the formation of the attachment support and the foam block into a single overmolding operation. The support is first molded, then the foam block is overmolded over it to secure the contact surface to the bottom of the groove, creating an integrated structure that simplifies recycling.
3Ease of manufacture
If attachment supports are integrated into the foam block, then recycling ease is improved, but attachment strength may deteriorate
Solution Approach 1:
The attachment support is segmented into two functional parts: a contact surface integral with the bottom of the groove for bonding to the foam block, and a rib arranged opposite the contact surface for attachment of the seat covering. This segmentation allows each part to be optimized for its specific function while maintaining overall integration with the foam block.
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 provides a padding element with good mechanical strength and facilitates recycling by using similar polyurethane materials for both the foam and attachment support, eliminating the need for metal inserts.
Implementation Method 1
a step of manufacturing the foam block via overmolding over said attachment support, so as to secure the contact surface of said attachment support to the bottom of the groove of the foam block
Data Source
AI summary
A padding element for a vehicle seat includes a block of foam, the block having an outer surface and a groove, the groove having a bottom and side walls opening onto the outer surface. The padding element further includes an attachment support, arranged at the bottom of the groove. The attachment support includes: a contact surface, integral with the bottom of the groove; and a rib, arranged opposite the contact surface, in the direction of the outer surface of the foam block.