EPP Passenger Seat Structure for Multi-Direction Impact Absorption
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Solution Overview
Problem
Current passenger seat constructions in double cabin light commercial vehicles of N category are heavy, costly, and lack adequate safety protection in side or rear impact collisions, failing to meet M safety regulations for transporting multiple passengers while having a high carbon footprint due to non-recyclable materials.
Innovation Solution
A polymer passenger seat construction primarily composed of expanded polypropylene (EPP) that absorbs impact forces, offering lightweight, high energy absorption, and recyclable properties, replacing traditional metal and hard plastic components with a simplified design that meets M category safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal and hard plastic materials are used for seat construction, then strength and robustness are improved, but weight increases and safety protection in side or rear impact collisions deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional metal and hard plastic to expanded polypropylene (EPP) foam. This material parameter change achieves a paradigm shift where the foam provides both lightweight properties and unexpected impact absorption capabilities, resolving the contradiction between strength and weight by fundamentally altering the material's density and energy absorption characteristics.
Solution Approach 2:
The patent employs composite material construction by combining EPP foam with strategic metal reinforcement elements only where absolutely necessary for structural integrity. This composite approach allows the majority of the seat construction to be lightweight foam while maintaining adequate strength through targeted reinforcement, thus resolving the weight-strength contradiction.
2Strength
If traditional metal and hard plastic materials are used for seat construction, then strength is improved, but safety protection in side or rear impact collisions deteriorates
Solution Approach 1:
The patent converts the previously harmful characteristic of foam (perceived as too soft for structural applications) into a beneficial feature. The EPP foam's ability to compress and absorb energy during side and rear impacts transforms what was considered a weakness into the primary safety mechanism, exceeding M-category safety requirements while traditional rigid materials failed to provide adequate protection.
Solution Approach 2:
The patent changes the material parameter from traditional metal and hard plastic to expanded polypropylene (EPP) foam. This material parameter change achieves a paradigm shift where the foam provides both lightweight properties and unexpected impact absorption capabilities, resolving the contradiction between strength and weight by fundamentally altering the material's density and energy absorption characteristics.
3Strength
If multiple types of hard plastics and metals are used for seat construction, then strength is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple previously separate components (seat cushion, backrest, armrests, and structural elements) into a unified EPP foam construction. This consolidation eliminates the need for multiple different hard plastics and metals, reducing the number of parts from 25+ to a much smaller number while maintaining or improving strength through the foam's inherent properties.
Solution Approach 2:
The patent applies homogeneity by using a single primary material (EPP foam) throughout the majority of the seat construction, replacing the heterogeneous mix of 25+ different materials. This material unification simplifies the construction while the foam's consistent energy absorption properties provide uniform protection across all impact scenarios.
4Strength
If traditional materials are used for seat construction, then strength is improved, but recyclability deteriorates
Solution Approach 1:
The patent enables full recovery and recycling of the seat construction materials. The EPP foam can be completely recycled at the end of the vehicle's lifecycle, unlike traditional metal and plastic composites that are difficult or impossible to recycle. This recovering principle eliminates the carbon footprint issue while the foam's structural properties maintain the necessary strength.
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 EPP-based seat construction provides enhanced safety in all impact directions, maintains vehicle integrity during crashes, reduces production energy and waste, and meets stringent safety regulations, while being lightweight and cost-effective, with improved recyclability and reduced carbon footprint.
Implementation Method 1
the seat construction is capable of absorbing rear, front and side impact forces exerted on the passenger seat construction during a collision
Data Source
Figure 1A~1F
Figure 2A
Figure 2B
AI summary
The present invention relates to a polymer passenger seat construction for a double cabin light commercial vehicle of N category, wherein said seat construction is comprised of a backrest part, a seating part and a support part comprised of polymer material, and wherein the seat construction is capable of absorbing rear, front and side impact forces exerted on the passenger seat construction during a collision. The present invention further relates to a double cabin light commercial vehicle comprising said passenger seat assembly.