One-Piece Bending Joint Carrier for Headrest Assembly
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Solution Overview
Problem
Existing headrest systems are complex and time-consuming to assemble, with multiple components that increase material and assembly costs while reducing installation space, which limits the integration of additional features like audio, video, and storage components.
Innovation Solution
A one-piece bending joint carrier with integrated adjusting mechanism, formed from coupling links and bending joints, that simplifies the headrest system by reducing components, optimizing installation space, and allowing for convenient adjustment without compromising load-bearing strength or comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple individual components are used to form the headrest carrier and adjusting mechanism, then the system provides sufficient load-bearing strength and robustness, but the assembly process becomes complicated and time-consuming, and material and assembly costs increase
Solution Approach 1:
The patent combines multiple individual components (carrier elements and adjusting mechanism parts) into a single integrated carrier formed from one piece of sheet metal. This merging eliminates the need for separate assembly of multiple components, directly resolving the contradiction by simplifying the assembly process while maintaining the functional requirements through the integrated design of the bending joint carrier with its coupling links and bending joints.
2Area of stationary object
If multiple individual components are used to form the headrest carrier, then the system provides sufficient structural integrity, but installation space within the headrest and backrest is reduced
Solution Approach 1:
The integration of the carrier and adjusting mechanism into a single one-piece structure eliminates the space required for multiple separate components and their interconnections. The bending joint carrier's compact design with coupled links and joints achieves the same functional volume with fewer parts, directly increasing the available installation space in the headrest and backrest while maintaining structural integrity.
3Ease of manufacture
If multiple individual components are used, then the system allows for modular design, but material costs and assembly costs increase
Solution Approach 1:
The patent reduces the total quantity of parts by merging multiple components into a single one-piece carrier. This reduction in part count directly lowers material costs (fewer pieces of sheet metal required) and assembly costs (no assembly operations needed), while the integrated design maintains the modular functionality through the bending joint mechanism that allows relative movement between carrier regions.
4Area of stationary object
If a compact carrier design is used to maximize installation space, then package optimization is achieved, but load-bearing strength and robustness may be compromised
Solution Approach 1:
The bending joint carrier employs local quality by concentrating structural reinforcement at critical locations such as the coupling links and bending joints, while maintaining a compact overall form. The sheet metal is strategically shaped to provide local stiffness and strength where loads are applied, allowing the carrier to achieve both compact dimensions for space optimization and sufficient load-bearing capacity through localized structural features.
Data Source
AI summary
A support for a headrest may have a single-part bending joint support which may have two support regions. A first support region may be situated in a backrest, and a second support region may be designed to receive a headrest body. Also included is a headrest for a seat, including a vehicle seat, that may have at least one headrest body and a support mentioned above and a seat.