Headrest Insert With Corrugated Web For Rod Misalignment
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Solution Overview
Problem
Existing headrest inserts in automobiles face difficulties in accommodating skewing or misalignment of support rods relative to the seat back sleeves, leading to binding and difficult operation, especially due to the long and narrow design of the rods and rigid sleeves.
Innovation Solution
A headrest insert with first and second rod holders connected by a web featuring a corrugated structure with flex portions that allow for accordion-like movement, accommodating angular and twisting movements between the rods and providing a compressible and extendable structure to facilitate smooth operation and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the headrest support rods are made long and narrow to extend deep into the seat back for adequate support, then the structural support is improved, but the rods become susceptible to skewing and misalignment relative to the sleeves
Solution Approach 1:
The patent applies a flexible web structure with corrugated portions that can bend and deform to accommodate misalignment between the support rods and sleeves. The web acts as a flexible connector that absorbs angular deviations and skewing, allowing the rigid support rods to maintain their structural function while the flexible web compensates for positioning errors.
Solution Approach 2:
The patent changes the physical state of the web material from rigid to flexible, allowing it to deform under load. The corrugated structure enables the web to change its shape and absorb misalignment, transforming the system from one requiring precise alignment to one that tolerates variation through material deformation.
2Stability of the object's composition
If the sleeves are rigidly secured between frame members to provide stable mounting, then the mounting stability is improved, but any misalignment or non-parallel positioning causes binding against the support rods
Solution Approach 1:
The flexible web with corrugated portions serves as a compliant element that absorbs misalignment between the rigid sleeves and support rods. When the headrest is adjusted, the web deforms to accommodate slight variations in sleeve positioning, preventing binding while the rigid sleeves maintain their stable mounting function.
Solution Approach 2:
The web acts as an intermediary element between the rigid sleeves and support rods. It mediates the connection by absorbing misalignment and skewing, allowing the rigid components to maintain their structural integrity while the flexible web compensates for positioning errors that would otherwise cause binding.
3Strength
If the headrest insert is made rigid to provide adequate support during crashes, then the safety support is improved, but it cannot accommodate skewing of the support rods one relative to the other
Solution Approach 1:
The corrugated web provides a flexible connection that can skew and deform during normal operation to accommodate rod misalignment, while the overall insert structure maintains rigidity for crash support. The flexible web acts as a shock-absorbing element that allows controlled deformation during adjustment while preventing excessive movement during impact.
Solution Approach 2:
The headrest insert is segmented into rigid support structures and flexible web portions. The rigid portions provide crash support while the flexible corrugated web segments allow for skewing accommodation. This segmentation enables different parts of the structure to perform different functions - rigidity where needed for safety and flexibility where needed for adjustment tolerance.
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 solution enables easy operation and adequate support of the headrest, accommodating minor skewing and misalignment, ensuring smooth adjustment and maintaining structural integrity during crashes.
Implementation Method 1
A flex portion in the web accommodates relative angular movement between the first rod holder and the second rod holder
Implementation Method 2
At least one region in the web has a compressible and extendable structure disposed from the top edge to the bottom edge, and enabling accordion-like movement
Data Source
Figure 1~2
Figure 3~5
AI summary
A headrest insert for an automobile headrest has first and second rod holders for engaging support rods of the headrest. A web interconnects the first and second rod holders and includes a corrugated section accommodating twisting or skewing of the rod holders relative to one another. The insert can be formed as a monolithic body of plastic.