Four-Component Armrest Assembly with Integrated Fabric Matrix
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Solution Overview
Problem
The existing armrest assembly manufacturing process is inefficient due to the need for separate molding and assembly of multiple components, leading to increased production costs and time.
Innovation Solution
A new armrest assembly design that integrates a fabric layer directly into the support substrate using a matrix interface, eliminating the need for a separate fabric frame and reducing the number of components from five to four, with a method involving molding and resin injection to form a bonded subassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate fabric frame is used in the armrest assembly, then the fabric layer can be properly supported and mounted, but the number of components increases to five parts requiring separate molding and assembly steps
Solution Approach 1:
The patent combines the fabric frame and support substrate into a single integrated component. The fabric layer is directly attached to the support substrate without requiring a separate fabric frame, reducing the component count from five parts to four parts while maintaining the structural support function.
2Adaptability or versatility
If five component parts are used in the armrest assembly, then each component can be optimized for its specific function, but the manufacturing process becomes more complex with separate molding and assembly steps
Solution Approach 1:
The fabric frame and support substrate are merged into a single molded component, eliminating the need for separate molding operations and assembly steps. This integration simplifies the manufacturing process while the design still allows for optimization of the combined structure's functions.
3Productivity
If five component parts are assembled separately, then each part can be manufactured independently, but production time and costs increase
Solution Approach 1:
By integrating the fabric frame and support substrate into a single component, the patent eliminates multiple assembly operations and reduces production time. The combined component can be manufactured in fewer steps, directly improving productivity and reducing manufacturing costs.
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 simplifies the manufacturing process, reducing production costs and time by eliminating unnecessary steps and creating a more efficient production method for the armrest assembly.
Implementation Method 1
The matrix interface may comprise a portion of the fabric layer impregnated with a resin of the support substrate
Data Source
AI summary
An armrest assembly includes a support substrate, a fabric layer stretching across a receiver of the support substrate and a matrix interface connecting the fabric layer to the support substrate. A cushion overlies the fabric layer and the receiver and a coverstock conceals the cushion and the fabric layer while closing the receiver. A method of producing the armrest assembly is also disclosed.