Elastic Backing Material for Vehicle Seat Cushion Crease Elimination
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Solution Overview
Problem
Existing seat back cushion manufacturing methods using stiff backing materials result in crease lines and uneven surfaces due to mismatched stretch characteristics with leather, leading to suboptimal fit and finish, and rectangular shapes that complicate attachment to seat frames.
Innovation Solution
A method involving longitudinally oriented sewing lines to secure foam padding between outer and backing materials, with additional zig-zag and laterally oriented sewing lines to create a tiered structure, using a more flexible backing material that stretches like a wrist watch strap, ensuring better fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stiff backing material is used to facilitate manufacturing and assembly, then manufacturing ease is improved, but the seat back cushion surface develops crease lines due to mismatched stretch characteristics with leather
Solution Approach 1:
The patent changes the physical parameter of the backing material from stiff to elastic/stretchable, allowing it to match the stretch characteristics of the leather outer material. This eliminates crease lines while maintaining ease of manufacturing through the use of elastic materials that can be easily attached and stretched during assembly.
Solution Approach 2:
The patent uses a composite structure consisting of an elastic backing material combined with foam padding and leather outer material. The elastic backing material serves as an intermediary that combines the manufacturing advantages of stiff materials with the stretch characteristics needed to prevent creasing, creating a multi-layer composite that resolves the contradiction.
2Strength
If a thick multi-layer seat trim cover panel is used, then structural support is improved, but the seat back cushion becomes difficult to attach and creates an undulating rear surface
Solution Approach 1:
The patent changes the physical properties of the backing material to be elastic and stretchable rather than stiff and thick. This allows the material to conform to the seat frame contours during attachment, eliminating undulations on the rear surface while maintaining sufficient structural support through the elastic properties and foam padding integration.
3Ease of manufacture
If a generally rectangular perimeter is used for the seat cushion, then manufacturing simplicity is improved, but the fit and finish becomes suboptimal
Solution Approach 1:
The patent introduces dynamic, curved sewing lines (including zig-zag and tiered patterns) that allow the cushion perimeter to be adjusted and contoured to match the specific geometry of the seat frame. This maintains manufacturing simplicity through standardized elastic materials while achieving optimal fit and finish through flexible, non-rigid sewing patterns that can adapt to various shapes.
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 method produces a seat back cushion with improved fit and finish, reducing crease lines and undulations, providing enhanced comfort and aesthetic appeal by utilizing a flexible backing material that matches the stretch characteristics of the outer material.
Implementation Method 1
utilizing an elastic backing material that stretches more than the outer material
Data Source
AI summary
A method for manufacturing a vehicle seat cushion assembly includes providing an outer material to define an outer seating surface. A backing material is sewn to the outer material using a first sewing line against which a wadding material is placed in a central region of the cushion. To secure the wadding material, a second sewing line is run. Left and right wadding materials are placed between the sewing lines and the edges of the cushion. Additional sewing lines laterally cross the longitudinal sewing lines to imbue the cushion with a wrist watch-like appearance.