Vehicle Headrest Assembly with Integrated Molded Plastic Interface

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Solution Overview

Problem

Existing vehicle headrest assemblies are costly and complex to manufacture, requiring multiple parts and adjustments to fit standard backrests, which increases production costs and complexity.

Innovation Solution

A headrest assembly with two pins, each extending from a lower mounting part to an upper adjustment part, featuring a molded plastic interface connecting the intermediate parts, allowing for adjustable height and simplified manufacturing, while maintaining aesthetic appeal and safety standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-pin headrest assembly is used, then the manufacturing cost is reduced and the structure is simplified, but the compatibility with standard backrests is lost

Engineering Contradiction:

Improvemanufacturing costVSAvoidcompatibility with standard backrests

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent merges two separate pins into a single integrated pin structure that combines both mounting functions. The single pin includes a mounting portion with two mounting sections that can be fixed to standard backrests, eliminating the need for separate pins while maintaining compatibility with existing backrest designs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single pin is segmented into functional portions: a mounting portion with two mounting sections for attaching to the backrest, an intermediate portion for structural connection, and an adjustment portion for height adjustment. This segmentation allows the single pin to perform multiple functions that traditionally required separate components.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple parts are used in headrest assembly, then the adaptability to standard backrests is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvefit with standard backrestsVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate parts (two pins, plastic plate, mounting brackets) into a single integrated pin assembly. The single pin structure inherently includes the mounting functionality that previously required separate components, reducing the total part count while maintaining adaptability to standard backrests.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single pin is designed as a multi-functional component that simultaneously provides mounting attachment, structural support, and height adjustment capabilities. The mounting portion with two mounting sections can interface with standard backrest configurations, making the headrest universal across different vehicle models without requiring additional parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Shape

If a plastic plate is added to improve rendering, then the aesthetic appearance is enhanced, but the assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidassembly steps

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The aesthetic rendering function is merged into the single pin structure itself. The pin is designed with smooth surfaces and appropriate geometries that provide both structural function and aesthetic appearance, eliminating the need for separate decorative plastic plates while maintaining visual appeal.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces manufacturing costs and complexity by integrating multiple components into a single piece, enhancing the headrest's appearance and usability without increasing production costs or compromising safety, and allows for easy assembly onto standard backrests.

Implementation Method 1

an interface made of molded plastic material and interconnecting the intermediate parts of the two pins

Methodology Applied

Scientific EffectMolding:

Data Source

PatentEP3293044B1Headrest assembly for vehicle seat and vehicle seat comprising such an assembly

Publication Date: 2020.01.08 FAURECIA SIEGES D AUTOMOBILE SA

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AI summary

Headrest assembly (6) for vehicle seat (1) comprising: - two pins (9a, 9b) each extending substantially in an adjustment direction (Z) between a lower end (26a, 26b) and an upper end (25a, 25b), each of the two pins having a mounting portion (14a, 14b) including the lower end and intended to be fixed to a seat back (3) (1), an adjustment portion (16a, 16b) including the upper end, and an intermediate portion (20a, 20b) included between the mounting portion and the adjustment portion, - a support structure (17) adapted to support the head of a user, and - an interface (15) made of overmolded plastic material and connecting the intermediate portions (20a, 20b) of the two pins (9a, 9b).