EPP Foam Integrated Seat Shell to Reduce Vehicle Seat Weight
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Solution Overview
Problem
Existing vehicle seats are heavy due to the use of multiple structural components and materials, which complicates manufacturing and increases weight, despite efforts towards weight reduction and maintaining functionality and comfort.
Innovation Solution
A lightweight vehicle seat is designed using expanded polypropylene particle foam (EPP) as the primary material, which provides structural stability and integrates multiple functions into a single, ergonomically shaped seat shell, eliminating the need for additional support structures and allowing for tool-free attachment of a flexible foam overlay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If multiple structural components and materials are used to provide structural stability and functionality, then the seat achieves adequate support and durability, but the weight increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple structural components (seat frame, backrest, armrests, and foam padding) into a single integrated EPP foam carrier part. This merging eliminates the need for separate metal frames and multiple assembly steps, achieving weight reduction while maintaining structural stability and support functionality.
Solution Approach 2:
The EPP foam carrier part serves multiple functions simultaneously: it provides the structural frame, forms the backrest and armrests, offers cushioning support, and enables tool-free attachment of upholstery. This multi-functionality reduces the number of components needed while achieving comprehensive seat functionality.
2Ease of manufacture
If traditional metal frames and multiple components are used, then structural strength and stability are achieved, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent merges the seat frame, backrest, armrests, and cushioning into a single EPP foam carrier part that can be produced in one molding operation. This eliminates complex assembly processes involving multiple metal components and fasteners, significantly simplifying manufacturing while maintaining structural integrity through the foam's inherent properties.
Solution Approach 2:
The patent uses expanded polypropylene (EPP) foam as a composite material that combines the structural properties traditionally provided by metal frames with the cushioning properties of foam. This single material achieves both strength and comfort functions, simplifying manufacturing while maintaining structural strength.
3Weight of moving object
If conventional foam and separate upholstery layers are used, then comfort and cushioning are achieved, but weight and production complexity increase
Solution Approach 1:
The patent merges the carrier part and upholstery into an integrated design where the EPP foam carrier part includes built-in attachment features for the upholstery layer. This eliminates the need for separate fastening mechanisms and reduces overall weight while maintaining comfort through the combined cushioning and support functions.
Solution Approach 2:
The patent applies different densities or properties of EPP foam in different regions of the carrier part to optimize both weight and comfort. By varying the foam characteristics locally, the design achieves adequate cushioning in contact areas while minimizing weight in non-critical regions.
Data Source
Figure 1
AI summary
The invention relates to a lightweight seat (1) for vehicles, in particular for rear seats of motor vehicles, consisting of a carrier part (2), wherein the carrier part (2) is produced from a dimensionally stable material and integrally comprises at least one seat shell (3) for a seat user.