Headrest Frame Segmentation for Rigidity and Foam Sealing

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Solution Overview

Problem

Conventional headrests with integrated frames face challenges in improving rigidity without compromising sitting comfort, and they often experience leakage of foaming agents during integral foam formation.

Innovation Solution

A headrest design featuring a headrest frame with a retaining portion for a headrest stay guide, where the headrest skin is sandwiched between the headrest stay guide and the frame, utilizing a configuration of two members – a metal rear frame and a resin front frame – with an annularly formed insertion opening to enhance rigidity and prevent foaming agent leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the headrest frame is made thicker to improve rigidity, then the rigidity of the headrest frame is improved, but the sitting comfort of the occupant deteriorates

Engineering Contradiction:

Improverigidity of the headrest frameVSAvoidsitting comfort of the occupant

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The headrest frame is divided into two separate members: a rear frame made from metal and a front frame made from resin. This segmentation allows each member to contribute different properties - the metal rear frame provides rigidity while the resin front frame maintains comfort, resolving the contradiction between strength and ease of operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The headrest frame uses composite construction with two different materials (metal and resin) joined together. The metal rear frame member provides the necessary rigidity and structural support, while the resin front frame member provides comfort and flexibility, allowing both contradictory requirements to be satisfied simultaneously.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If integral foam formation is performed to create a unified structure, then the headrest skin, pad member, and headrest frame are integrated, but leakage of the foaming agent occurs

Engineering Contradiction:

Improveintegration of headrest skin, pad member, and headrest frameVSAvoidsealing to prevent foaming agent leakage

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The headrest skin is pre-positioned and sandwiched between the headrest stay guide and the headrest frame before the foaming process begins. This preliminary arrangement ensures that the skin is already in place to act as a seal, preventing foaming agent leakage during the subsequent integral foam formation process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The headrest skin serves as an intermediary sealing element between the headrest stay guide and the headrest frame. By positioning the skin in this intermediate location, it creates a barrier that prevents the foaming agent from leaking out during the integration process, while still allowing the three components to be formed into a unified structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9713973B2Headrest

Publication Date: 2017.07.25 TS TECH CO LTD

AI summary

Provided is a headrest that is capable of improving the rigidity of a headrest frame and preventing the leakage of a foaming agent upon integral foam formation of the headrest. The headrest, which is disposed on the upper part of a seatback and includes a headrest frame inside the headrest, includes a retaining portion of a headrest stay guide in the headrest frame. Further, the headrest is configured in a manner that a headrest skin is sandwiched between the headrest stay guide and the headrest frame.