Seat Support Element Lamination in a Single Forming Tool
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method for producing seat support elements is tedious, time-consuming, and requires multiple workstations, making it inefficient for producing elements with both comfort and appealing appearance.
Innovation Solution
A method involving a single forming tool that applies a paint layer, a water-free synthetic skin, and a foam layer with a foaming catalyst to create a seat support element, allowing for a reduced number of steps and integration of a cover element for enhanced appearance and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the support element is formed by separately making the shell and padding by molding and then attaching them, then the support element has sufficient comfort and appealing appearance, but the production method is tedious and time-consuming and requires a number of workstations
Solution Approach 1:
The patent merges the previously separate shell and padding manufacturing processes into a single integrated forming operation. The shell (outer layer with skin) and padding (foam layer) are formed simultaneously in one workstation using a forming tool that applies paint, synthetic skin, and foam in sequence, eliminating the need for multiple workstations and reducing production time while maintaining both appearance quality and comfort
2Ease of manufacture
If the shell and padding are made separately by molding and then attached, then each component can be optimized for its function, but the production process requires multiple workstations and is time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-applying the synthetic skin to the painted outer layer before the foam layer is applied. This sequencing ensures that when the foam expands and cures, the skin is already in position, allowing the shell and padding to be formed together in one operation without requiring separate attachment steps, thereby simplifying the process and reducing production time
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
This method enables the production of seat support elements with satisfactory appearance and comfort in a single operation cycle using fewer workstations, improving efficiency and reducing production time.
Implementation Method 1
a first layer of foam extending over the skin of synthetic material, the first foam layer having a formulation containing water and a foaming catalyst at the time of its application to the skin of synthetic material
Data Source
AI summary
A seat support element having an outer layer that includes an outer surface and an inner surface, a synthetic skin extending over the inner surface of the outer layer, and a first foam layer extending over the synthetic skin. A method of forming the seat support element includes the following steps: forming the outer layer by applying at least one layer of paint against a first forming surface of a forming tool, applying the synthetic skin against the inner surface of the outer layer, and applying the first foam layer against an inner surface of the synthetic skin.