Using foam for structural components of a seat assembly
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Solution Overview
Problem
Passenger vehicles face weight limitations due to the added weight of load-bearing structures and comfort cushioning in seat assemblies, restricting the use of other features, components, or payloads.
Innovation Solution
The use of load-bearing foam structural components in seat assemblies, which dissipate and disperse loads across frames, replacing traditional metallic supports and cushions, and incorporating a reinforcing grid for enhanced support and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metallic load-bearing structures and separate comfort cushioning are used in seat assemblies, then structural support and comfort are provided, but the overall weight of the seat assembly increases
Solution Approach 1:
The patent combines the load-bearing structure and comfort cushioning into a single integrated foam component. The foam material provides both structural support and comfort functions simultaneously, eliminating the need for separate metallic load-bearing structures and separate cushioning layers, thereby reducing overall weight while maintaining both support and comfort capabilities.
Solution Approach 2:
The patent employs foam material as a composite solution that integrates the functions of both structural support and comfort cushioning. This composite material approach replaces traditional metallic structures with a lighter foam-based system that maintains load-bearing capacity while providing inherent comfort properties.
2Device complexity
If traditional metallic load-bearing structures are used in seat assemblies, then structural support is provided, but the device complexity increases due to multiple components
Solution Approach 1:
The patent merges multiple components (load-bearing structure and comfort cushioning) into a single integrated foam component. This consolidation reduces the number of parts and assembly steps while maintaining the load-bearing capacity through the foam material's inherent structural properties.
3Weight of moving object
If load-bearing foam structural components are used to reduce weight, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes foam material properties and manufacturing parameters to achieve the desired structural performance. By adjusting foam density, composition, and molding parameters, the patent achieves both weight reduction and adequate manufacturing precision for structural components.
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 reduces the overall weight of seat assemblies by 10-20% while maintaining support and comfort, allowing for more efficient use of vehicle resources.
Implementation Method 1
The bottom support is coupled to the bottom frame for bearing at least half of a first load on the seat assembly and dispersing a portion of the first load across the bottom support to the bottom frame
Implementation Method 2
The bottom support, the back support, and the leg support include a load-bearing foam
Data Source
Figure 1
Figure 2
Figure 3A~4B
AI summary
Seat assemblies (200) including structural components (212, 222, 232) made of foam are described. A seat sub-assembly (210, 220, 230) can include a frame (214, 224, 234) and a foam support (212, 222, 232). The foam support (212, 222, 232) can be coupled to the frame (214, 224, 234) for receiving a load on the seat sub-assembly (210, 220, 230), dissipating at least half of the load, and dispersing the load through the frame (214, 224, 234).