Elastomeric Panel Seat Support to Reduce Foam Bulk and Cost
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Solution Overview
Problem
Conventional seat cushions for vehicles are bulky due to excessive foam, leading to increased manufacturing costs and inefficient use of space, as they do not effectively conform to the occupant's contour.
Innovation Solution
A thin seat cushion structure featuring a one-piece elastomeric panel made of thermoplastic elastomer, which is constrained on both sides and includes lateral portions that deflect torsionally to support the occupant during ingress and egress, distributing pressure and providing support without the need for extensive foam, allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional foam is used in seat cushions, then support and comfort are provided, but the seat becomes bulky and manufacturing costs increase
Solution Approach 1:
The patent replaces conventional foam with a thin elastomeric panel that functions as a flexible shell. The panel is constrained at its periphery and utilizes elastic deformation to provide support, achieving the same comfort function with significantly reduced thickness. The elastomeric material's ability to deflect and recover provides the necessary support without requiring bulky foam structure.
Solution Approach 2:
The invention changes the material parameter from foam (compressible cellular structure) to elastomer (elastically deformable continuous material). This parameter change allows the seat cushion to achieve equivalent support performance with reduced thickness, as the elastomeric panel utilizes elastic strain energy storage rather than foam compression.
2Strength
If conventional foam is used in seat cushions, then occupant support is provided, but manufacturing costs increase due to excessive material usage
Solution Approach 1:
The elastomeric panel acts as a thin flexible shell that provides occupant support through elastic deformation rather than material volume. This approach dramatically reduces the quantity of material needed compared to conventional foam, lowering manufacturing costs while maintaining support functionality.
Solution Approach 2:
The invention extracts the essential support function from the foam material and implements it through a different mechanism - the elastic deformation of a thin constrained panel. By taking out the core functionality (support) and separating it from the bulky foam structure, the design achieves support with minimal material quantity.
3Volume of stationary object
If a thin elastomeric panel is used, then seat thickness is reduced, but the panel must effectively conform to occupant contour
Solution Approach 1:
The constrained elastomeric panel functions as a flexible shell that conforms to occupant contour through elastic deformation. The peripheral constraints provide a stable base while allowing the panel surface to deflect and adapt to the occupant's shape, achieving contour conformity without requiring thick foam.
Solution Approach 2:
The seat cushion transitions from a static foam structure to a dynamic elastomeric panel that actively deflects and adapts to the occupant's shape. The panel's ability to dynamically deform under load and recover provides continuous contour conformity, enhancing comfort while maintaining thin profile.
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 elastomeric panel effectively supports occupants by distributing pressure and conforming to their shape, reducing the need for foam and resulting in a thinner, more cost-effective seat cushion system that manages loads through tension and distributed beam principles.
Implementation Method 1
The elastomeric panel positions and supports a seated occupant. The elastomeric panel comprises an elastomeric portion, a first lateral elastomeric portion and a second lateral elastomeric portion. The at least one of the first lateral elastomeric portion and the second lateral elastomeric portion deflect in a torsional manner to support the occupant.
Implementation Method 2
The at least one of the first lateral elastomeric portion and the second lateral elastomeric portion deflect in a torsional manner to support the occupant during ingress and egress.
Data Source
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AI summary
A seat support structure including an elastomeric panel. The elastomeric panel positions and supports a seated occupant. The panel is constrained on a forward side and a rearward side.