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Seat_Foam_Design_Guidelines.pdf

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SEAT_FOAM_DESIGN_GUIDELINES
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Foam Design at foam pad wing area. Foam Design Best Practice / Guidelines● Purpose: Strip fastener at bottom slot. ● Explanation / Guidelines: The strip fasteners are cross-located at seat back. Foam Design Best Practice / GuidelinesFoam Design Best Practice / Guidelines ● Purpose: Minimum spacing for strip fasteners when used with trim slot applications ● Explanation / Guidelines: A preferred minimum distance of 2 inches between trim slots is recommended for foam flow.● Purpose: As a general rule all internal vertical surfaces require a minimum draft angle which is utilized between mold manufacturing and foam shrinkage ● Explanation / Guidelines: Recommended angle based on reduction of tearing conditions during removal of pad from tool. Foam Design Best Practice / Guidelines● Purpose: The ideal condition for foam flow is a surface that is foam free of obstruction while containing generous radii. ● Explanation / Guidelines: : A 6mm minimum radius is recommended where pad design lines Intersect at 90 ? corners and a 12mm minimum radius for all corners and edges where a larger radius is not previously specified. Coordinate radii on bottom of pad with known undersurface radii. (Woodbridge suggests 15mm radius on B surface and preferred 30mm. Foam Design Best Practice / Guidelines SECTION A-AIssue: Gaps between the trim cover and the headrest guides after assembly process is completed. Root Cause: With the variances in trim, foam, and assembly process, the trim cover can be built forward, rearward, or pulled down too far leaving a gap. Lesson Learned: By overbuilding the foam (doughnut) around or under, the headrest guide fills in pushing the cover up leaving no gap. Best Practice: Apply overbuild to all front and rear backs that utilize headrests. BEFORE AFTER FOAMRoot Cause: With no overbuild, the cover does not have enough support causing it to collapse, leaving wrinkles and puckers in the trim. Lesson Learned: By putting an overbuild (4 to 5mm) in the corners or the radius of the inserts, the cover has support and does not show wrinkles or puckers. Best Practice: Over build the corners and radius on insert corners and intersections. BEFORE AFTER Issue: Puckers and wrinkles in insert corners and intersections. FOAMRoot Cause: With the wider trenches the trim bridges more giving a washed out appearance. Lesson Learned: By utilizing the narrow trench there is more support for the trim cover. This also gives it more definition and an overall better appearance. Best Practice: Utilize narrower 16mm trenches for all Velcro trench applications. BEFORE AFTER Issue: Trim cover has washed out bridging appearance in and around the trenches. FOAMRoot Cause: During assembly the trim cover attaches to the Velcro in the Pad, the seam can roll during this process making the seam appear wavy. Lesson Learned: By having an attachment point that applies equal pressure to the join seam and controls the salvage the appearance of the seam is crisp. Best Practice: Start early in the development stage utilizing the CLIP attachment in the Pad. BEFORE AFTER Issue: Wavy appearance in the trench area of trim cover after assembly is completed. FOAMRoot Cause: With no wire to support the foam, the foam collapses or roll over leaving a poor appearance. Lesson Learned: Adding a support wire supports the foam and the trim. Best Practice: Add a support wire to all high bolsters and armrest openings. BEFORE AFTER Issue: The foam collapses not supporting the trim cover FOAMRoot Cause: Having trenches that run straight through a pad does not leave support for the trim cover. Lesson Learned: Ramping out of the trench and into a salvage trench give a more crafted appearance with less chance of bite line gaps. Best Practice: Ramp out of trenches, and into a salvage trench if applicable. Issue: Bite line gaps at the rear of cushions and bulky wavy seams coming over the front of cushions. This also applies to backs at the top and bottom. FOAM● Purpose: To insure that the occupant does not feel the frame, border wire. Tie-down wire or any other hard point through the foam pad. ● Explanation / Guidelines: Minimum distance between hard point and surface of foam pad. Foam Design Best Practice / Guidelines Type of Pad Minimum Strike- Preferred StrikeThrough Distance Through DistanceCushions 38mm (1.5in) 57mm (2.25in)Backs 32mm (1.25in) 51mm (2 in)● Purpose: To insure that the foam pad density and hardness is optimized for Cost, Durability / comfort performance ● Explanation / Guidelines: ? Follow OEM specific material specification / classification per seat application. Following are the starting targets for densities. ? FSC can be class “A” with a Density of 48Kg/m^3 +/-2 ? FSB can be class “C” with a Density of 32Kg/m^3 +/-2 ? Rear seat cushion and backs are Class “C” of 32Kg/m^3 ? For foam system best performance it is critical to have a optimal combination of density and IFD. Foam Design Best Practice / Guidelines● Define Trim Attachment Method ? Hook / Loop Fastener ? Trench design optimized for tooling and process conditions. ? Lear Proprietary Trim Clips ? Follow established trench design guidelines ? Hogg Ring ● B-Surface Cloth Design ? Optimized for durability and comfort ● Border Wire Design (If required) ? Bolster support for durability and comfort ● Communize Program Components ? Within design limitations ● Foam Free Conditions ? Essential to trim attachment integrity ? No visible read-through or trim attachment interference Foam Design Best Practice / Guidelines1) Current density 2) Current hardness 3) Thickness - center of IFD circle 4) Type of support mechanism - ie. deadpan, flexolator, sinuous wire or hammock 5) Type of trim Acura MDX or BMW X5 etc. 9) Are you off on benchmark performance?- ie. deflection, hysteresis loss, seat hardness distribution, vibration characteristics (resonant frequency / transmissibility) 10) What kind of design performance are we looking at? a) Optimized density - low cost, min. durability b) Optimized density - optimal durability c) Optimized density - optimal complete comfort d) Optimized density - matched benchmark hysteresis Foam Design Best Practice / Guidelines
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