Unitary Headrest Support Plate Assembly
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Solution Overview
Problem
Existing seat assemblies with headrests often require complex assembly processes and additional components like clips or hinges, which can increase manufacturing costs and reduce structural integrity.
Innovation Solution
A seat assembly design featuring a support post with a U-shaped configuration and a headrest with a unitary support plate, where the support post extends through elliptical holes in the plate, allowing for direct assembly without intervening coupling components, and enabling pivotal movement of the headrest.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional headrest assembly methods are used with clips or hinges, then the headrest can be attached to the seat back, but the assembly process becomes complex and manufacturing costs increase
Solution Approach 1:
The support plate integrates multiple functions into a single component: it provides structural support, contains built-in mounting features (holes and recesses) for direct attachment, and enables pivotal movement. This merging eliminates the need for separate clips, hinges, or other coupling components, thereby simplifying the assembly process and reducing manufacturing complexity.
2Strength
If additional coupling components like clips or hinges are used, then the headrest can be mounted, but structural integrity is reduced
Solution Approach 1:
The mounting features are integrated directly into the support plate structure itself. The holes and recesses are formed as part of the unitary support plate, creating a direct structural connection between the headrest and support post without introducing separate fasteners or coupling components that would compromise structural integrity.
3Ease of manufacture
If a unitary support plate with integrated mounting features is used, then component costs are reduced, but the ability to adjust headrest position may be limited
Solution Approach 1:
The support plate incorporates pivotal movement capability through its integrated mounting features. The headrest can rotate or pivot relative to the support post while maintaining a secure connection, enabling position adjustment without requiring complex mechanical mechanisms. This dynamic capability is achieved through the geometric design of the holes and recesses in the unitary support plate.
Data Source
AI summary
A seat assembly having a headrest and a method of assembly. The headrest may be pivotally disposed on a support post and may have a support plate. The support plate may have first and second walls that have first and second holes, respectively, that may be disposed along the axis and that may receive the support post.