Vehicle Headrest Connector Unit Resin Coating and Alignment
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Solution Overview
Problem
Conventional connector units for vehicles risk damaging internal components due to edge collisions and suffer from dust ingress and structural instability due to mismatched diameters, leading to potential dislocation and noise issues.
Innovation Solution
A connector unit design featuring a tubular metallic holder with projections and matching holes, and engaging members that ensure secure connection and alignment, with the connector's tip extending beyond the holder's end to prevent edge collisions and minimize gap size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the second holder is made of metal and inserted into the holder, then the connector unit provides structural strength, but the edge at the top end of the second holder may strike the inner surface of the holder to injure other components
Solution Approach 1:
A resin coating layer is applied on the outer surface of the metallic second holder, serving as an intermediary between the metal holder and other components. This coating prevents direct contact and potential damage while maintaining the structural strength of the metal holder.
Solution Approach 2:
The resin coating forms a protective thin film on the holder surface that can absorb impact energy and prevent edge strikes from damaging internal components, while the underlying metal holder maintains its structural integrity.
2Reliability
If the connectors are fixed securely to the holders to prevent dislocation, then connection reliability is improved, but the assembly process becomes more complex
Solution Approach 1:
The connector and holder are designed as integrated components where the connector is built-in to the holder structure. This merging ensures secure connection while simplifying the assembly process, as the connector and holder are assembled together as a single unit.
Solution Approach 2:
The connector is nested within the holder structure, with the holder providing both mechanical support and connection functionality. This nested design ensures reliable connection while reducing the number of separate components that need to be assembled.
3Ease of operation
If the inner diameter of the holder is slightly larger than the outer diameter of the second holder for insertion, then assembly is facilitated, but a gap is created that allows dust to enter and causes the headrest to become rickety
Solution Approach 1:
A resin coating is applied on the outer surface of the second holder, creating a protective film that extends slightly beyond the holder's outer diameter. This coating fills the gap between the holder and second holder, preventing dust ingress while maintaining ease of assembly.
Solution Approach 2:
The resin coating acts as an intermediary material that bridges the gap between the holder and second holder. It provides a dust-tight seal while allowing the components to be assembled with minimal interference.
4Object-affected harmful factors
If the connector tip extends beyond the holder end to prevent edge collisions, then protection of internal components is improved, but the overall length of the connector unit increases
Solution Approach 1:
The resin coating on the second holder extends beyond the holder end, providing protective coverage without requiring the connector tip to extend significantly. This intermediary coating protects internal components from edge collisions while minimizing the increase in overall length.
Data Source
AI summary
A headrest side connector unit mounted on a headrest of a vehicle includes a stay as a holder and a connector. The connector includes a projection 430 to be received in a projection insertion hole formed on the stay. A tip part of the second connector at a side to be connected to the mating connector is disposed further outside of the stay than an end of the stay near a seat. An outer surface of the tip part is arranged on the same plane as an outer surface of the end of the stay.