Foamless Seat Cushion Structure for Ergonomic Vehicle Support
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Solution Overview
Problem
Existing seat cushions for vehicle seats are often bulky and uncomfortable due to the use of foam, which can lead to long-term hollow formations and lack of ergonomic support.
Innovation Solution
A foamless seat cushion designed with elastic cover units made of polypropylene, featuring flexible surfaces connected by lever elements and fastening elements that allow for detachable attachment to the seat unit, providing ergonomic deformation and resettable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam is used in seat cushions, then cushioning and comfort are provided, but hollow formations occur during long-term use and ergonomic support is lost
Solution Approach 1:
The seat cushion is divided into multiple cover units (first cover unit, second cover unit, etc.) that can independently deform and provide support. Each cover unit is formed from separate flexible surfaces connected by lever elements, creating a segmented structure that prevents the hollow formations seen in monolithic foam cushions while maintaining overall cushioning function.
Solution Approach 2:
The seat cushion transitions from a static foam structure to a dynamic mechanism where flexible surfaces and lever elements can move relative to each other. The lever elements act as kinematic connections that allow the cover units to adapt their shape in real-time based on user weight distribution, providing continuous ergonomic support without the degradation that occurs in foam over time.
2Ease of operation
If foam is used in seat cushions, then cushioning is provided, but the cushion becomes bulky and loses ergonomic deformability
Solution Approach 1:
The cushion is segmented into multiple thin cover units rather than using a single thick foam block. This segmentation allows the cushion to achieve the required ergonomic deformability through the coordinated movement of multiple thin layers connected by lever elements, reducing overall bulk while maintaining functionality.
Solution Approach 2:
The invention replaces the mechanical compression behavior of foam with a mechanical linkage system consisting of lever elements and flexible surfaces. This substitution enables controlled deformability through geometric mechanisms rather than relying on the viscoelastic properties of foam, achieving ergonomic adaptation with reduced material volume.
3Ease of repair
If foam is used in seat cushions, then support is provided, but the cushion cannot be easily replaced or retrofitted
Solution Approach 1:
The seat cushion is segmented into discrete cover units that can be independently removed and replaced. Each cover unit has its own fastening elements that attach to the seat unit, allowing individual components to be serviced or replaced without affecting the entire cushion assembly, significantly improving maintainability.
Solution Approach 2:
The fastening elements are designed with universal attachment capabilities that can interface with standard seat unit mounting points. This universal design allows the same cover units to be used across different seat models and enables easy retrofitting of the foamless cushion system into existing vehicle seats.
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 foamless design offers improved comfort and ergonomic support, preventing lateral movement and allowing the cushion to adapt to the user's shape, while maintaining pressure stability and ease of replacement or retrofitting.
Implementation Method 1
an elastic seat cover which is formed from a plurality of elastic cover units, wherein the elastic cover units each comprise two opposite and spaced apart flexible surfaces and a number of lever elements which movably connect the flexible surfaces to each other
Implementation Method 2
the respective cover unit comprises at least one associated fastening element for releasable fastening to the seat unit
Data Source
AI summary
A seat cushion for a seat unit of a vehicle seat is disclosed. The seat cushion may be formed as a foamless seat cushion and may be characterized by an elastic seat support which is formed from a plurality of elastic cover units. The elastic cover units may each have two opposing and spaced apart flexible surfaces and a number of lever elements which movably connect the flexible surfaces to each other. The respective cover unit may have at least one associated fastening element for releasable fastening to the seat unit.