Deformable seat shell with motion control
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Solution Overview
Problem
Traditional seat assemblies face challenges in providing long-term comfort and preventing pelvis drift due to rigid structures and the environmental difficulties associated with thermoset foam materials, which are hard to dismantle and recycle.
Innovation Solution
A seat assembly featuring a deformable seat shell coupled with a support frame via motion control links that allow constrained relative movement, eliminating the need for traditional foam cushions by adjusting shape in response to occupant load distribution, thereby enhancing comfort and facilitating recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional foam cushions are used to provide comfort, then seating comfort is improved, but end-of-life dismantling and recycling become difficult
Solution Approach 1:
The patent removes the foam cushion layer entirely from the seat assembly, replacing it with a foamless design that uses a contoured seat pan and backrest structure to provide comfort. This extraction eliminates the material that causes recycling difficulties while maintaining the comfort function through structural design.
Solution Approach 2:
The patent changes the material parameters of the seat assembly by eliminating foam and using alternative materials such as molded plastics, metals, and fabric coverings. This parameter change transforms the seat from a foam-based comfort system to a foamless system that is easier to dismantle and recycle at end-of-life.
2Strength
If rigid seat structures are used to provide support, then structural strength is improved, but pelvis drift prevention deteriorates
Solution Approach 1:
The patent introduces dynamic elements to the seat structure, including movable lumbar support mechanisms, adjustable seat pans, and flexible backrest structures that can adapt to occupant movement. These dynamic features allow the rigid structure to respond to pelvis position changes, preventing drift while maintaining overall structural strength.
Solution Approach 2:
The seat design incorporates self-adjusting features such as elastic support elements and compliant structures that automatically respond to occupant position without requiring active control. The lumbar support and seat pan elements self-adjust to maintain proper pelvis alignment, preventing drift through passive mechanical response.
3Ease of operation
If foam cushions are used to absorb impact, then comfort is improved, but weight increases
Solution Approach 1:
The patent removes the heavy foam cushioning material from the seat assembly, replacing it with lighter alternative structures such as thin molded seat pans, metal or plastic frames, and fabric coverings. This extraction eliminates the primary source of seat weight while maintaining comfort through structural design.
Solution Approach 2:
The patent uses thin, flexible shell structures and film-like materials to replace bulky foam cushions. The seat pan and backrest utilize thin molded plastics or metals that provide necessary support and comfort with minimal weight, eliminating the need for heavy foam layers.
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 seat assembly provides a self-adjusting, comfortable seating experience that prevents pelvis drift and reduces environmental impact by eliminating the need for foam cushions, while allowing for easier recycling and minimizing weight and cost.
Implementation Method 1
the motion control link is a spring that undergoes elastic deformation when the joints undergo relative movement
Data Source
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AI summary
A seat assembly includes a seat bottom with a deformable seat shell. The deformable seat shell is configured to change shape with a changing occupant load distribution. The seat shell is coupled with a support frame via a shell motion controller having one or more motion control links. Each motion control link is coupled with the seat shell at a fixed location relative to the seat shell and with the support frame at a fixed location relative to the support frame. The shell motion controller allows these fixed locations to move relative to each other and also constrains their relative movement. The combined seat shell deformation and controlled movement relative to the support frame can provide the seat occupant with a comfortable seating experience while preventing pelvis drift and potentially eliminating traditional foam seat cushions.