Vehicle Headrest Foam Connecting Part Design
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Solution Overview
Problem
Existing vehicle headrests have high mass, lower mechanical stability, and reduced restraining effect due to prefabricated connecting parts surrounded by foam, requiring complex production processes and increased labor and costs.
Innovation Solution
A headrest design featuring a connecting part formed from a first foam material with high strength and hardness, produced in an 'on-site foaming process' within the cover, combined with a support element from a softer foam material, allowing for low mass, high mechanical stability, and a complex external shape with a soft feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a preformed foam body is used to fill the headrest body, then the production process is simplified, but the mass increases and mechanical stability decreases
Solution Approach 1:
The patent changes the density parameter of the foam material by using two different foam materials with different densities. The first foam material has lower density for weight reduction, while the second foam material has higher density for structural stability. This parameter change resolves the contradiction between reducing mass and maintaining mechanical stability.
Solution Approach 2:
The patent uses a composite structure with two different foam materials. The first foam material (lower density) forms the main filling, while the second foam material (higher density) creates reinforcing elements. This composite approach allows the headrest to achieve both reduced mass and high mechanical stability simultaneously.
2Ease of manufacture
If a preformed foam body is used to fill the headrest body, then the production process is simplified, but the restraining effect is reduced
Solution Approach 1:
The patent employs composite foam materials where the second foam material with higher density and better mechanical properties forms reinforcing elements within the first foam material. This composite structure enhances the restraining effect during collisions while maintaining production simplicity through the injection molding process.
Solution Approach 2:
The patent applies local quality by placing the second foam material specifically in regions requiring enhanced restraining effect. The reinforcing elements are positioned strategically within the headrest body to provide localized structural support and improved collision resistance where most needed.
3Strength
If the headrest is designed with standard thickness, then mechanical stability is sufficient, but the mass increases
Solution Approach 1:
The patent uses composite foam materials to achieve high mechanical stability with reduced thickness. The combination of low-density first foam material and high-density second foam material creating reinforcing elements allows the headrest to maintain sufficient strength at smaller thickness, thereby reducing overall mass.
Solution Approach 2:
The patent changes the structural parameters by introducing reinforcing elements made of second foam material that increase the moment of inertia and structural rigidity without significantly increasing thickness. This allows the headrest to achieve required mechanical stability with reduced overall dimensions and mass.
4Shape
If a complex external shape is desired, then design flexibility is improved, but production complexity increases
Solution Approach 1:
The patent applies self-service by allowing the foam material to automatically form complex shapes through the injection molding process. The liquid foam material flows into the mold cavity and solidifies into the desired complex external shape without requiring additional forming operations, manual assembly, or complex tooling.
Solution Approach 2:
The patent utilizes the phase change parameter of the foam material from liquid to solid state. The liquid foam is injected into the mold in a controllable state, allowing it to conform to complex shapes, and then solidifies to maintain the complex external form, simplifying the production of complex geometries.
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 achieves a headrest with low mass, high mechanical stability, and enhanced restraining effect, simplifying production, reducing costs, and enabling a smaller thickness while maintaining long-term dimensional stability and comfort.
Implementation Method 1
The connecting part is formed from a first foam material produced within the cover in an 'on-site foaming process' or 'pour-in-place process'
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a headrest (1) for a vehicle, comprising a headrest body (2), a headrest mounting (3), and a fitting (4) provided on an outer face of the headrest body (2). A connecting part (5) is provided within the headrest body (2) in order to connect the headrest mounting (3) to the headrest body (2). According to the invention, the connecting part (5) is made of a first foam material produced within the fitting (4) in a pour-in-place method. A support element (8) which is made of a second foam material is arranged on an inner face of the fitting (4) in a supporting region (SB), which is provided for supporting the head of a passenger, between the connecting part (5) and the fitting (4). Furthermore, the first foam material has a greater strength, in particular a greater compressive strength, and a greater indentation hardness than the second foam material. The invention further relates to a method for producing a headrest (1) for a vehicle.