Lumbar Mat Spring Element Design to Reduce Backrest Rattling Noise
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Solution Overview
Problem
Lumbar mats in vehicle seats often suffer from permanent deformation and reduced elasticity over time, leading to a loss of firm clamping between the lumbar support structure and backrest cushion, resulting in undesirable rattling noises due to movement during vehicle vibrations.
Innovation Solution
A lumbar mat with a combination of first and second spring elements, where the stiffness of the first spring elements is greater than the second, and the second spring elements extend further to maintain contact with the backrest cushion, reducing pressure points and ensuring the mat remains firmly positioned between the lumbar support and backrest cushion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible lumbar mat is used to transmit supporting force, then comfort and force distribution are improved, but the mat loses elasticity and firm clamping over time due to permanent deformation
Solution Approach 1:
The patent changes the physical state of the lumbar mat from a purely flexible material to a structured assembly with spring elements. The spring elements provide reversible elastic deformation, maintaining firm clamping force while distributing pressure comfortably. This parameter change from flexible material alone to spring-based mechanical structure resolves the contradiction between comfort and reliability.
Solution Approach 2:
The lumbar mat combines flexible material with metal or plastic spring elements to create a composite structure. The flexible material provides comfort and pressure distribution, while the spring elements maintain structural integrity and firm clamping over time. This composite approach resolves the contradiction by combining the advantages of both materials.
2Adaptability or versatility
If the lumbar mat is freely supported to allow deformation, then adaptability to user preference is improved, but movement during vehicle vibrations causes rattling noises
Solution Approach 1:
The lumbar mat is segmented into multiple spring elements distributed across its surface. Each spring element can independently deform to adapt to user preference while the collective array of springs provides structural stability. This segmentation allows local adaptability while preventing overall movement that causes rattling noises.
Solution Approach 2:
The spring elements provide dynamic response to user weight and position, automatically adjusting to maintain optimal lumbar support. The springs absorb vibrations from vehicle movement, converting harmful vibrations into controlled elastic deformation of individual spring elements, thereby preventing rattling noises while maintaining adaptability.
3Reliability
If spring elements are added to maintain contact, then firm clamping and stability are improved, but device complexity increases
Solution Approach 1:
The spring elements are integrated directly into the lumbar mat structure, merging the support function with the mat itself. The springs are attached to the rear surface of the mat, combining the mat and support mechanism into a single unified component. This merging approach maintains firm clamping while minimizing device complexity by avoiding separate support structures.
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 effectively minimizes rattling noises by maintaining contact and reducing pressure points, ensuring a stable and quiet vehicle seat experience even with deformation of the backrest cushion over time.
Implementation Method 1
each of the first spring elements adapted to apply a first elastic force towards the backrest cushion via a first contact area of the first spring element
Implementation Method 2
each of the second spring elements adapted to apply a second elastic force towards the backrest cushion via a second contact area of the second spring element
Data Source
AI summary
A lumbar mat for a backrest structure for use in a vehicle seat, the lumbar mat adapted to be arranged between a lumbar support structure and a backrest cushion of the backrest structure, including a front surface adapted to face towards a backrest cushion of a backrest structure, when the lumbar mat is arranged in the backrest structure, a plurality of first spring elements arranged at the front surface of the lumbar mat, each of the first spring elements adapted to apply a first elastic force towards the backrest cushion via a first contact area of the first spring element, respectively, and a plurality of second spring elements, each of the second spring elements associated with a respective one of the plurality of first spring elements and adapted to apply a second elastic force towards the backrest cushion via a second contact area of the second spring element, respectively.