Injection Mold Cavity Inserts for Adjustable Seat Shell Bolster Heights
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Solution Overview
Problem
Existing methods for producing seat shells for vehicle seats lack flexibility and cost-effectiveness in producing variants with different side bolster heights, as they require multiple tools or complex modifications to achieve varying designs.
Innovation Solution
A device with a changeable injection molding tool cavity, utilizing interchangeable inserts to adjust the side bolster height, allowing the same tool to produce seat shells with varying side bolster heights by altering the cavity shape, enabling the production of both sporty and basic variants with enhanced lateral support and ease of entry/exit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate injection molding tools are used to produce seat shells with different side bolster heights, then production flexibility and design versatility are improved, but device complexity and production cost increase
Solution Approach 1:
The injection molding tool is segmented into a fixed mold body and interchangeable insert elements. The insert elements can be removed and replaced to change the cavity shape, allowing different side bolster heights to be produced with a single base tool. This segmentation enables flexibility without requiring multiple complete tools.
Solution Approach 2:
The base injection molding tool is designed with universal functionality to accommodate multiple insert elements with different geometries. The same base tool can produce various seat shell variants by simply changing the inserts, making the tool multi-functional and eliminating the need for separate dedicated tools for each variant.
2Device complexity
If interchangeable inserts are used to modify the injection mold cavity, then production cost and tool complexity are reduced, but the reliability of secure attachment and consistent molding quality may worsen
Solution Approach 1:
The attachment system is segmented into separate locking components that are integrated into both the base tool and the inserts. This segmentation allows for dedicated locking mechanisms that ensure secure attachment while keeping the overall tool design relatively simple.
Solution Approach 2:
The locking mechanisms are pre-designed and pre-positioned in the base tool, so that when inserts are installed, the locking action occurs automatically through preliminary alignment features. This preliminary action ensures reliable attachment without requiring complex adjustment or verification procedures during operation.
Data Source
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AI summary
The invention relates to a device (7) for producing seat shells (2) for vehicle seats (1), comprising an injection molding tool (4), in which an injection molding compound, in particular of a plastic, particularly of a thermoplastic plastic, can be molded on a semi-finished product, in particular an organo-sheet, in order to form at least lateral cheeks (6) of the respective seat shell (2), wherein a cavity (K) in the injection molding tool can be modified in a forming region for the lateral cheeks (6). The invention further relates to a method for producing seat shells (2) for vehicle seats (1).