Cushion Mat Deflection Stopper for Automotive Seat Comfort
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cushion mats for automotive seats face challenges in providing optimal comfort and preventing collisions with the floor or other seat elements due to varying passenger weights, requiring complex modifications to the seat frame and cumbersome mounting procedures.
Innovation Solution
A cushion mat design featuring a set of metal wire springs with S-shaped windings and plastic connectors, integrated with deflection stoppers made of flexible cables or metal bands, which limit deflection without affecting initial suspension properties until a predetermined value is reached, allowing easy attachment to a standard seat frame without modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the deflection of the cushion mat is increased to improve suspension comfort, then the suspension comfort is improved, but the cushion mat may collide with the floor or other seat elements
Solution Approach 1:
A deflection stopper is introduced as an intermediary component between the cushion mat and the floor/seat elements. This stopper limits the maximum deflection of the cushion mat, preventing collision with the floor or other seat elements while allowing sufficient deflection for suspension comfort. The stopper acts as a mechanical intermediary that controls the deflection range without affecting the elastic behavior within the normal operating range.
2Reliability
If a deflection controller is added to limit deflection, then the collision prevention is improved, but the device complexity and mounting complexity increase
Solution Approach 1:
The deflection stopper is merged with the existing cushion mat structure and seat frame components. Instead of being a separate complex device requiring special mounting, the stopper utilizes the existing seat frame structure and is integrated into the cushion mat assembly. This merging approach simplifies the overall device complexity and allows for easy mounting using existing attachment points on the seat frame.
3Reliability
If separate spring elements and deflection controllers are used, then the deflection control is improved, but the manufacturing time and mounting time increase
Solution Approach 1:
The cushion mat is segmented into modular components: metal wire springs, plastic connectors, and deflection stoppers. Each component can be manufactured independently and then assembled into the complete cushion mat. This segmentation allows for parallel manufacturing of components, reducing overall manufacturing time. The modular design also enables quick assembly and installation, as the pre-assembled cushion mat unit can be mounted as a single component rather than installing multiple separate elements individually.
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 solution provides enhanced suspension comfort, prevents collisions by limiting deflection, and simplifies the manufacturing and mounting process, ensuring reliable performance under heavy loads without compromising the seat's comfort or requiring additional frame modifications.
Implementation Method 1
Usually such deflection has a pure elastic behavior. Then the amount of deflection in general is proportional to the normal force of the weight of the passenger.
Implementation Method 2
at least one deflection stopper arranged for limiting the deflection of the cushion mat, when a predetermined deflection value is exceeded
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
The present invention relates to a cushion mat 1 for integration into an automotive seat, comprising a set of springs 10, each spring 10 extending across the cushion mat, connectors 20, connecting the springs 10 with each other to form the cushion mat 1 and at least one deflection stopper 30, 40, 50, 60 arranged for limiting the deflection of the cushion mat 1, when a predetermined deflection value d1 is exceeded. Further a method for the production of a cushion mat with a deflection stopper 30, 40, 50, 60 is claimed.