Foam Seat Back Assembly with Variable Density for Weight and Strength
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Solution Overview
Problem
Existing aircraft seat back assemblies are heavy, lack sufficient robustness, and do not adequately address comfort and support needs, particularly in extreme conditions and prolonged use scenarios.
Innovation Solution
A lightweight seat back assembly utilizing a foam support structure with adjustable density and firmness, optionally combined with a rigid frame, to provide structural support and customizable ergonomics, while incorporating fire-resistant materials and easy manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid support frame is used to provide structural support, then strength and robustness are improved, but weight increases
Solution Approach 1:
The patent employs composite foam structures combining different density regions - a higher density foam core provides structural strength while lower density foam regions reduce weight. This composite approach allows the seat back to achieve both strength and weight reduction simultaneously, resolving the contradiction between structural support and weight.
Solution Approach 2:
The foam support structure features varying density distribution throughout its volume, with higher density in regions requiring greater structural support and lower density in regions where weight reduction is prioritized. This local variation in material properties optimizes the strength-to-weight ratio, addressing both requirements of the contradiction.
2Strength
If foam density is increased to improve structural support, then strength is improved, but weight increases
Solution Approach 1:
The foam structure implements spatially varying density, with higher density foam strategically placed in load-bearing regions to provide structural support, while lower density foam is used in non-critical regions to minimize weight. This localized optimization resolves the contradiction between strength and weight by applying material properties only where needed.
Solution Approach 2:
The patent uses a composite foam construction with multiple density zones, combining high-density and low-density foam materials or regions within a single structure. This composite approach enables the foam to provide adequate structural support in critical areas while maintaining overall weight reduction, simultaneously achieving both strength and weight goals.
3Reliability
If a rigid frame is used to ensure robustness in extreme conditions, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent achieves robustness by optimizing foam material parameters including density, firmness, and compression characteristics rather than relying on complex rigid frame structures. The foam is engineered with specific physical properties (e.g., firmness greater than 200N, controlled compression between 2-10mm) that provide the necessary reliability under extreme conditions while maintaining structural simplicity.
Solution Approach 2:
The invention extracts and eliminates the traditional rigid support frame from the seat back assembly, relying instead on the engineered foam structure itself to provide both support and robustness. This removal of the frame component simplifies the overall device complexity while maintaining reliability through optimized foam material properties and configuration.
Data Source
Figure 1
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Figure 3a~3b
AI summary
The present application describes a seat back assembly for a vehicle such as an automobile or an aircraft. The seat back assembly comprise a foam support structure (4). The foam support structure panel is configured to provide a support structure against which the upper body and/or back of a user rests in use. The foam structure may comprise two or more regions having different foam density and/or firmness.