Foam Structural Components for Lightweight Seat Assemblies
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Solution Overview
Problem
Passenger vehicles face weight limitations due to the added weight of load-bearing structures and comfort cushioning in seat assemblies, restricting the use of other features, components, or passengers.
Innovation Solution
Implementing a foam support system within the seat assembly, comprising a foam structural layer and a comfort layer, which dissipates at least half of the passenger load and disperses it through the frame, replacing traditional metal load-bearing components to reduce overall weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal load-bearing structures and separate comfort cushioning are used in seat assemblies, then structural support and comfort are provided, but the weight of the seat assembly increases
Solution Approach 1:
The patent combines the load-bearing structure and comfort cushioning into a single integrated foam component. The foam material is formulated with specific density and elasticity ranges (0.5-1.2 g/cm³ density, 30-80% elasticity) to simultaneously provide structural support and comfort functions that were previously separated into distinct metal frames and cushion layers, thereby reducing overall weight while maintaining both support and comfort performance
Solution Approach 2:
The patent employs composite foam materials with specific physical properties (density: 0.5-1.2 g/cm³, elasticity: 30-80%) that combine the load-bearing capabilities traditionally associated with metal structures and the comfort properties of soft cushioning materials. This single composite foam component replaces both the metal load-bearing structure and separate comfort cushioning, achieving weight reduction while maintaining dual functionality
2Stability of the object's composition
If traditional metal load-bearing structures are used in seat assemblies, then structural integrity is maintained, but device complexity increases
Solution Approach 1:
The patent merges the load-bearing structure and comfort cushioning into a single integrated foam component, eliminating the need for separate metal frames and cushion assemblies. This integration simplifies the overall seat assembly structure while maintaining structural integrity through the foam's engineered density (0.5-1.2 g/cm³) and elasticity (30-80%) properties that provide both support and comfort in one element
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 foam support system effectively reduces the weight of seat assemblies by 10-20% while maintaining support and comfort, allowing for more efficient use of resources and space within vehicles.
Implementation Method 1
The foam support can dissipate at least half of the load
Implementation Method 2
foam support... dissipating at least half of the load and dispersing a portion of the load
Implementation Method 3
dispersing a portion of the load through the frame
Data Source
AI summary
Seat assemblies (200) including structural components (212, 222, 232) made of foam are described. A seat sub-assembly (210, 220, 230) can include a frame (214, 224, 234) and a foam support (212, 222, 232). The foam support (212, 222, 232) can be coupled to the frame (214, 224, 234) for receiving a load on the seat sub-assembly (210, 220, 230), dissipating at least half of the load, and dispersing the load through the frame (214, 224, 234).