Headrest Stay Stopper Structure for Exit Prevention
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Solution Overview
Problem
Conventional headrest structures require complex machining operations and multiple components to prevent the headrest stay from unintentionally exiting the seatback, leading to increased complexity and assembly steps.
Innovation Solution
A headrest structure featuring an integral stopper member with a claw portion that deforms to fit into a tube-shaped support, preventing exit by catching on the support's edge when attempting to move out, and a simple anchor projection system for fixation, reducing machining and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotational stopper and shaft are used to prevent headrest stay from exiting, then the headrest stay can be prevented from unintentionally exiting the seatback, but the number of components increases and assembly steps become more numerous
Solution Approach 1:
The stopper member integrates multiple functions into a single component: the claw portion prevents headrest stay exit by catching on the support portion edge, the fixing portion anchors the stopper member to the headrest stay, and the stopper portion interfaces with the support portion. This eliminates the need for separate rotational stopper and shaft components, reducing part count while maintaining reliability
2Reliability
If slits and holes are machined in the headrest stay to accommodate the stopper, then the stopper mechanism can be installed, but machining operations become more complex and time-consuming
Solution Approach 1:
The invention extracts the complex machining requirements from the headrest stay by designing the stopper member to attach without requiring slits or holes in the headrest stay itself. The stopper member's fixing portion anchors to the headrest stay through simpler means, eliminating the need for complex machining operations on the headrest stay while maintaining the exit prevention function
3Reliability
If the claw portion has a large outer diameter to prevent exit, then the headrest stay cannot exit the support portion, but the stopper portion cannot be completely inserted into the support portion
Solution Approach 1:
The claw portion is designed with elastic deformability, allowing its outer diameter to dynamically adjust. During insertion, the claw portion elastically deforms to a smaller diameter enabling complete insertion of the stopper portion into the support portion. Once inserted, the claw portion returns to its larger original diameter, ensuring it can catch on the support portion edge to prevent headrest stay exit
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 minimizes machining and component count while effectively preventing the headrest stay from exiting the seatback, enhancing ease of assembly and maintenance while maintaining design aesthetics.
Implementation Method 1
the claw portion resiliently deforming such that an outer diameter of the claw portion corresponds to an inner diameter of the support portion or smaller, when the stopper portion has been completely inserted into the support portion, the claw portion resiliently rebounding such that the outer diameter of the claw portion exceeds the inner diameter of the support portion
Data Source
AI summary
A headrest structure is equipped with a headrest main body; a headrest stay that supports the headrest main body; and a stopper member, a first end portion of the stopper member configuring a fixing portion fixed to the bottom end portion of the headrest stay, a second end portion of the stopper member configuring a stopper portion that is inserted into a support portion and is formed with a claw portion, when the stopper portion is inserted into the support portion, the claw portion resiliently deforming, when the stopper portion has been completely inserted into the support portion, the claw portion resiliently rebounding such that the outer diameter of the claw portion exceeds the inner diameter of the support portion, and when the stopper portion moves in a direction of exiting from the support portion, the claw portion catches on an end portion of the support portion.