Insert for integration into trim layer and providing conditioning
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Solution Overview
Problem
Existing vehicle seat conditioning systems require separate installation of inserts and trim layers, which can be cumbersome and may not provide a seamless integration, potentially allowing the insert's profile to be felt by occupants.
Innovation Solution
A conditioning system where an insert, including a cover layer, a heater, and a spacer layer, is integrally connected to the trim layer of a vehicle seat, forming a unitary piece that is applied simultaneously, with the insert being self-contained and having a profile that cannot be felt by the occupant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insert is separately installed from the trim layer, then the installation process becomes complex and time-consuming, but the integration quality may be compromised
Solution Approach 1:
The insert is integrally connected to the trim layer to form a unitary piece, combining two separate components (insert and trim layer) into one integrated assembly. This eliminates the need for separate installation steps while ensuring consistent integration quality throughout the seat structure.
Solution Approach 2:
The insert and trim layer are pre-assembled into a unitary piece before installation into the seat. This preliminary integration ensures proper alignment and connection quality is achieved during manufacturing rather than during vehicle assembly, improving both ease of installation and integration reliability.
2Ease of operation
If the insert profile is reduced to be imperceptible, then occupant comfort is improved, but the structural integrity or functionality may be compromised
Solution Approach 1:
The insert uses a flexible spacer material that can be compressed to a very thin profile when not in use, making it imperceptible to occupants. When activated, the flexible material expands to provide the necessary structural support and thermal insulation, maintaining structural integrity while minimizing the resting profile.
3Device complexity
If the insert is made self-contained with integrated heater and spacer, then the system complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The heater element, spacer material, and trim layer are merged into a single unitary insert assembly. This integration reduces the number of separate components and connection points, thereby reducing overall system complexity while the precision is maintained through pre-assembly during manufacturing.
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
This solution provides a seamless and efficient integration of the conditioning system into the vehicle seat, ensuring that the insert is securely fastened and its components, such as heaters and blowers, are effectively distributed without being noticeable to the occupant, enhancing comfort and functionality.
Implementation Method 1
a heater located under the cover layer
Implementation Method 2
a blower that is located on a bottom of the seat such that air is moved from a remote location to the insert to distribute the air
Data Source
AI summary
An insert comprising: (a) a cover layer; (b) a spacer layer located below the cover layer; (c) a connection material that is adapted to extend between and connect the cover layer to a trim layer so that the insert is fixed to the trim layer.