Tool with integrated fluid lines to form a cushion assembly
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Solution Overview
Problem
Existing cushion assemblies for seating systems face challenges in efficiently forming nonrectangular shapes without material waste and ensuring uniform porosity and density, particularly in manufacturing processes involving thermoplastic resin meshes.
Innovation Solution
A manufacturing system utilizing a die plate, funnel, and water tank to extrude and consolidate thermoplastic resin filaments, followed by cooling and shaping with fluid lines to create a nonrectangular cushion with increased perimeter density and recesses, using tools with matching cross-sections and fluid cooling to maintain porosity and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional cushion manufacturing processes are used, then production is simpler, but material waste increases and uniform porosity/density cannot be achieved
Solution Approach 1:
The cushion is divided into regions with different densities: a first region with lower density and a second region with higher density. This segmentation allows material to be strategically placed only where needed, reducing overall material usage while achieving functional requirements for support and comfort in different areas.
Solution Approach 2:
Different regions of the cushion are given different material densities to match local functional requirements. The higher density second region provides enhanced support where needed, while the lower density first region provides comfort and reduces weight. This local differentiation eliminates material waste by not uniformly over-provisioning the entire cushion.
2Shape
If conventional forming processes are used, then manufacturing is easier, but nonrectangular shapes with recesses cannot be efficiently produced
Solution Approach 1:
A foam model of the desired cushion shape including recesses is created beforehand. This pre-formed model serves as a template that guides the placement and shaping of thermoplastic material, ensuring the final product achieves the complex nonrectangular geometry with recesses without requiring complex molding operations or post-manufacturing adjustments.
Solution Approach 2:
The foam model acts as an intermediary between the manufacturing process and the final cushion product. It provides the physical template that defines the recesses and nonrectangular shape, allowing thermoplastic material to be shaped around it. This intermediary approach simplifies manufacturing by avoiding the need for complex custom molds for each unique cushion shape.
3Manufacturing precision
If thermoplastic resin is used without controlled cooling, then processing is simpler, but uniform porosity and density cannot be maintained
Solution Approach 1:
A fluid cooling system using water circulation is implemented with channels positioned adjacent to the die plate. The water flow through these channels provides controlled cooling that maintains uniform temperature during thermoplastic resin processing, ensuring consistent porosity and density throughout the cushion material as it solidifies.
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 system enables efficient production of nonrectangular cushions with enhanced perimeter density and recesses, minimizing material waste and ensuring uniform porosity, suitable for various seating applications.
Implementation Method 1
a fluid line formed through the tool to cool the tool and the plurality of strands
Data Source
AI summary
A product is provided with a body with a nonrectangular cross section with a mesh of strands of expanded thermoplastic resin. A density of the mesh of strands about a perimeter of the nonrectangular cross section is greater than within the perimeter. The perimeter is provided with at least one recess formed therein.