Layered Vehicle Seat Pad Structure Without Hardness Steps
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Solution Overview
Problem
Existing vehicle seat designs often cause discomfort due to the step formed between pad portions of different hardness and require additional components like metal wires for shape retention, which can increase weight and complexity.
Innovation Solution
A vehicle seat with a layered structure comprising a soft, high-density surface layer pad and a hard, low-density back layer pad, where the back layer pad is fitted into recesses in the surface layer pad, eliminating the need for metal wires and providing adjustable hardness for comfort and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If pad portions of different hardness are arranged next to each other, then weight reduction is achieved, but discomfort is caused due to steps formed between pad portions
Solution Approach 1:
The patent transitions from horizontal arrangement of different hardness pads to a vertical layered structure. The softer pad is positioned as the surface layer while the harder pad forms the back layer, eliminating horizontal steps that cause discomfort while maintaining weight reduction benefits through the harder, lower-density back layer.
Solution Approach 2:
The patent applies different material properties to different layers of the pad structure. The surface layer uses softer material for comfort where the user directly contacts, while the back layer uses harder, lower-density material for structural support and weight reduction, creating localized quality differentiation that resolves the contradiction.
2Stability of the object's composition
If metal wires are added for shape retention, then shape stability is improved, but weight and device complexity increase
Solution Approach 1:
The patent removes metal wires from the pad structure entirely. Instead of adding external shape-retention components, the shape stability function is integrated into the back layer pad itself through the use of harder, low-density material that inherently maintains the pad's shape without requiring additional weight-bearing elements.
Solution Approach 2:
The patent uses composite material construction with two distinct pad layers having different hardness and density properties. This composite structure provides both shape retention and comfort functions through material selection alone, eliminating the need for metal wire reinforcement and reducing overall weight.
3Weight of moving object
If back layer pad is made of low density material, then weight is reduced, but hardness may be insufficient for stability
Solution Approach 1:
The patent divides the pad into two functional segments: a surface layer pad for comfort and a back layer pad for structural support. The back layer uses low-density material optimized for weight reduction while maintaining sufficient hardness for stability, as its primary function is structural rather than direct contact comfort.
Solution Approach 2:
The patent applies different material properties to different layers based on their specific functions. The back layer uses harder, low-density material where structural support is needed, while the surface layer uses softer material where comfort is prioritized, creating localized quality differentiation that resolves the hardness-density contradiction.
Data Source
AI summary
A vehicle seat includes a pad that is made of resin foam, and that forms a seat cushion or a seatback. The pad has a layered structure formed of a surface layer pad that forms a seating surface-side portion of the pad and a back layer pad that is provided on the back side of the surface layer pad. The back layer pad is higher in hardness and lower in density than the surface layer pad.