Vented Mold B-Surface Inversion for Ribbon Elimination
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Solution Overview
Problem
Conventional mold venting techniques result in material wastage and visibility of ribbons through trim covers in complex seat designs, as they typically vent on the A-surface, leading to inefficiencies and additional labor in removing excess material.
Innovation Solution
The novel mold design incorporates a second part line on the B-surface, with vents placed interiorly to allow partial curing of material within the passageway, preventing ribbons from forming on the A-surface and ensuring they are entirely on the B-surface, which can be sealed to prevent material ingress and minimize waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vents are positioned on the A-surface of the mold, then air and gas can escape during foaming, but raw material is extruded onto the A-surface requiring removal and creating visible ribbons through trim covers
Solution Approach 1:
The patent inverts the conventional vent positioning by placing vents on the B-surface instead of the A-surface. This inversion causes raw material to be extruded onto the B-surface rather than the A-surface, eliminating the need for material removal and preventing visible ribbons through trim covers while maintaining effective venting function
2Reliability
If vents are positioned on the A-surface, then gas can escape during polymerization, but additional labor is required to remove extruded material before applying trim covers
Solution Approach 1:
By inverting vent positioning to the B-surface, the patent eliminates the post-foaming material removal step. The extruded material now appears on the B-surface which is sealed off, automatically removing the need for additional labor to trim ribbons before applying finish covers, thereby improving manufacturing efficiency
3Reliability
If vents are positioned on the A-surface, then air can exit the mold during foaming, but ribbons become visible through thin trim covers in complex seat designs
Solution Approach 1:
The patent positions vents on the B-surface instead of the A-surface, causing ribbons to form on the B-surface rather than the A-surface. Since the B-surface is sealed off and positioned beneath the trim cover, the ribbons are hidden from view, eliminating the harmful visual defect while maintaining effective air exit during foaming
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 approach minimizes material wastage and ensures that ribbons are hidden beneath the trim cover, reducing labor costs and improving the aesthetic quality of finished products by eliminating visible ribbons.
Implementation Method 1
the at least one vent comprising a passageway configured to permit liquid foamable polymeric composition in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the liquid foamable polymeric composition in the passageway
Implementation Method 2
As the composition expands in the mold, polymerization occurs and the polymer so formed becomes solidified
Implementation Method 3
polymerization occurs and the polymer so formed becomes solidified
Implementation Method 4
it is essential during this process that the mold be adequately vented to allow the air present in the mold to exit the mold as the foamable composition expands. Further, it is essential to allow a portion of the gases (typically CO2 in the production of polyurethane) generated during polymerization to exit the mold
Data Source
AI summary
A mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.