Headrest Speaker Megaphone Tube and Ring Seal
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Solution Overview
Problem
In headrests with integrated speakers, the foaming material used in skin integral foam molding can leak into the side support member due to an unsecured end portion of the opening in the skin material, compromising the structural integrity and sound quality.
Innovation Solution
A headrest design featuring a megaphone-shaped tube and ring-shaped member that secures the end portion of the skin material, preventing foaming material leakage during molding and ensuring hermeticity, while maintaining sound transmission through the speaker grill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the skin material is provided with an opening portion for sound transmission, then sound quality is improved, but the end portion of the opening is not secured causing foaming material leakage
Solution Approach 1:
The opening in the skin material is segmented into two functional zones: an inner circular opening portion that remains open for sound transmission, and an outer end portion that is secured by the ring-shaped member to prevent foaming material leakage. This segmentation allows simultaneous achievement of sound quality and leakage prevention.
Solution Approach 2:
The ring-shaped member acts as an intermediary component between the skin material and the megaphone-shaped tube. It secures the end portion of the skin material while allowing the inner opening to remain accessible for sound transmission, thus mediating between the conflicting requirements of sealing and sound output.
2Reliability
If the opening in the skin material is left open for sound transmission, then acoustic performance is improved, but structural integrity is compromised due to foaming material leakage
Solution Approach 1:
The opening structure is divided into an inner acoustic opening and an outer sealed portion. The ring-shaped member secures the outer portion to maintain structural integrity during molding, while the inner opening remains open for acoustic performance.
Solution Approach 2:
Different portions of the skin material opening have different functional qualities: the inner circular region maintains openness for sound transmission, while the outer end portion is secured by the ring-shaped member to prevent leakage and maintain structural integrity during the molding process.
3Manufacturing precision
If the skin material is secured tightly to prevent leakage, then manufacturing reliability is improved, but sound transmission is blocked
Solution Approach 1:
The skin material opening is segmented into a secured outer portion for leakage prevention and an unsecured inner portion for sound transmission. The ring-shaped member applies securing force only to the outer end portion, leaving the inner opening free for acoustic functionality.
Solution Approach 2:
The ring-shaped member provides localized securing at the end portion of the skin material opening, creating a gradient of constraint: tightly secured at the outer edge for leakage prevention, progressively more open toward the center for sound transmission.
4Object-affected harmful factors
If a securing mechanism is added to the opening, then foaming material leakage is prevented, but device complexity increases
Solution Approach 1:
The ring-shaped member and megaphone-shaped tube are merged into an integrated assembly. The ring-shaped member is fitted onto the megaphone-shaped tube, combining the securing function with the existing acoustic structure, thereby minimizing additional complexity while effectively preventing foaming material leakage.
Data Source
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AI summary
A headrest includes: (a) a headrest frame 40, (b) a speaker unit 50 supported by the headrest frame 40 and having a speaker box 51, a speaker 52L,R attached to the speaker box 51, and a megaphone-shaped tube 54L,R attached to the speaker box 51, (c) a cushion material 60, (d) a skin material 70 having an opening, sewed into a pouch shape, and covering the headrest frame 40, the speaker unit 50, and the cushion material 60, and (e) a ring-shaped member 55L,R securing the entire opening-side end portion of the skin material 70 sandwiched between the ring-shaped member 55L,R and the megaphone-shaped tube 54L,R.