Vehicle Headrest Core Recess Layout for Easier Device Integration

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Solution Overview

Problem

The manufacturing process for existing headrests is complex and difficult due to the need to insert devices into a pouch-shaped skin material and then foam the material to form the headrest.

Innovation Solution

A headrest design featuring a pillar supported by a seat back, a core with receiving recesses for devices, and a skin material covering the core and devices, allowing for simple assembly by inserting devices into the recesses and covering them with the skin material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If devices are inserted into a pouch-shaped skin material and foaming material is injected to form a headrest, then a headrest with integrated devices can be manufactured, but the manufacturing process becomes complicated and difficult

Engineering Contradiction:

Improveintegration of devicesVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The headrest is divided into separate components: a core structure with pre-formed receiving recesses, devices, and a skin material. This segmentation allows each component to be manufactured and prepared independently, then assembled together, simplifying the overall manufacturing process while maintaining device integration capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receiving recesses are pre-formed in the core structure before device installation. This preliminary action eliminates the need to create recesses during the foaming process, allowing devices to be simply inserted into pre-prepared spaces, thereby simplifying the manufacturing workflow.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If devices are embedded within the headrest structure, then device integration is achieved, but the front surface becomes uneven reducing comfort

Engineering Contradiction:

Improvedevice integrationVSAvoidsurface comfort

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The receiving recesses are designed with specific local characteristics: they are positioned to accommodate devices while their openings are configured to allow device front surfaces to be flush with the core front surface. This local quality design ensures that devices are integrated functionally while maintaining a smooth, comfortable external surface.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If devices are placed in the headrest, then functionality is enhanced, but device stability under lateral load may be compromised

Engineering Contradiction:

Improvedevice functionalityVSAvoiddevice stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Devices are nested within receiving recesses that are formed in the core structure. This nesting arrangement provides mechanical support and positioning for the devices, ensuring they remain stable under lateral loads while maintaining their functional capabilities.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12337742B2Headrest for a passenger seat of a vehicle

Publication Date: 2025.06.24 TS TECH CO LTD

AI summary

Provided is a headrest in which devices can be placed and which is easy to manufacture. A headrest comprises a pillar supported by a seat back on which the headrest is provided; a core supported by the pillar and having one or more receiving recesses recessed inward from an outer surface of the core; one or more devices, each device received in a corresponding receiving recess; and a skin material covering the core and the devices.