Vehicle Headrest Core Member Bent Pouring Passage
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Solution Overview
Problem
Existing vehicle seat headrest designs face challenges in achieving even filling of polyurethane foam due to narrow gaps between the outer and inner surfaces, and issues with foaming raw material distribution when the pouring passage is straight or misaligned.
Innovation Solution
A vehicle seat headrest design featuring a core member with a pouring passage that extends from one end to the other, including a bent part to promote foaming raw material diffusion evenly across the gap between the core member and the cover, ensuring uniform filling of the cushion member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight pouring passage is used in the core member, then the structure is simple and manufacturing is easier, but the foaming raw material does not diffuse evenly and filling becomes insufficient in certain areas
Solution Approach 1:
The pouring passage is designed with a bent shape instead of a straight configuration. Specifically, the pouring passage extends upward from the lower end, bends in the front-rear direction at a predetermined height, and then extends upward again. This curvature enables the foaming raw material to diffuse more evenly in the front-rear direction, ensuring uniform filling of the cushion member while maintaining manufacturing feasibility.
2Volume of moving object
If the gap between the outer surface of the core member and the inner surface of the cover is narrow, then the headrest structure is compact, but the foaming raw material takes time to reach the lower side and filling becomes insufficient
Solution Approach 1:
The bent pouring passage design allows the foaming raw material to be distributed more effectively throughout the narrow gap. By extending the passage upward, bending it in the front-rear direction, and then extending it upward again, the system ensures that the foaming raw material reaches all areas including the lower side and front-rear extremes, achieving sufficient filling even in compact configurations.
3Ease of manufacture
If the pouring passage is positioned centrally, then the structure is symmetric and manufacturing is simpler, but the foaming raw material does not reach the side opposite to the top part evenly when positions are shifted
Solution Approach 1:
The bent pouring passage design compensates for positional shifts between the pouring passage and the top part of the headrest. By incorporating a bend in the front-rear direction, the passage ensures that the foaming raw material diffuses evenly to both sides, including the side opposite to the top part, thereby achieving uniform distribution even when central positioning is not perfectly maintained.
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
This design ensures more even filling of the cushion member by controlling the pouring allocation of foaming raw material, preventing insufficient filling and improving the distribution of polyurethane foam within the headrest.
Implementation Method 1
the foaming raw material that forms the pad layer is poured through the foaming raw material pouring passage. To be more specific, a foamed molded product that is the pouring passage forming member is formed into a generally rectangular parallelepiped shape having a width to be accommodated between the left and right side support members, and the foaming raw material pouring passage penetrating in the vertical direction is formed at the generally center part in the width direction. The foaming raw material poured from the pouring nozzle passes through the foaming raw material pouring passage, flows in to the top part side of the headrest, and is diffused so as to flow through the gap between the outer surface of the foamed molded product and the inner surface of the surface skin member from the top part side to the lower side.
Data Source
AI summary
A vehicle seat includes a headrest, a seat back to which the headrest is attached, and a seat cushion connected to the seat back. The headrest includes pillar frames attached to the seat back, a core member that includes a pouring passage penetrating from one end to the other end, a cover that covers the core member and a part of the pillar frames, and a cushion member that is formed in a gap between the outer surface of the core member and the inner surface of the cover and inside the pouring passage. The pouring passage extends in a first direction from the one end of the core member to reach a predetermined position, extends in a second direction from the predetermined position to reach the other end, and includes a bent part at the predetermined position.