Lumbar support system
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Solution Overview
Problem
Existing lumbar support systems in vehicle seats often suffer from poor efficiency, noise, and require numerous heavy components due to the use of Bowden cables and electromechanical actuators.
Innovation Solution
A lumbar support system utilizing a reversible DC motor, worm gear, and spindle mechanism with oppositely threaded ends to translate sliders along a spindle rail, coupled with flexible cables and hinges for smooth, adjustable lumbar support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a Bowden cable and electromechanical actuator are used to move the lumbar support, then the lumbar support can be adjusted, but the system becomes noisy and requires large, heavy motors
Solution Approach 1:
The patent replaces the traditional electromechanical actuator with a manual crank mechanism. The user directly operates the lumbar support adjustment through a hand crank that winds a cable, eliminating the need for electric motors and reducing noise generation to minimal mechanical friction sounds only.
Solution Approach 2:
The patent removes the electromechanical actuator and motor components from the system entirely. By extracting these noisy components and replacing them with a simple manual cable-winding mechanism, the system achieves quiet operation while maintaining full adjustability functionality.
2Ease of operation
If a Bowden cable and electromechanical actuator are used to move the lumbar support, then the lumbar support can be adjusted, but the system requires large, heavy motors
Solution Approach 1:
The patent removes the heavy electromechanical actuator and motor components from the system. By extracting these weighty components and replacing them with a lightweight manual crank and cable mechanism, the overall system weight is significantly reduced while maintaining full adjustability functionality.
Solution Approach 2:
The patent employs simple, inexpensive manual components (crank, cable, pulleys) instead of expensive, heavy electromechanical systems. These simple mechanical parts are lightweight and sufficient for the adjustment function, eliminating the need for large motors.
3Ease of operation
If a Bowden cable system is used for lumbar support actuation, then the lumbar support can be moved, but the total system efficiency becomes poor
Solution Approach 1:
The patent replaces the inefficient Bowden cable system with a direct cable-winding mechanism. Instead of using a Bowden cable with internal friction and mechanical disadvantage, the user directly winds the cable onto a drum, creating a more efficient mechanical system with fewer energy losses and better force transmission.
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
Provides efficient, quiet, and adjustable lumbar support with reduced component complexity, enhancing occupant comfort and reducing noise and weight.
Implementation Method 1
a reversible DC motor
Implementation Method 2
worm gear
Implementation Method 3
worm gear
Implementation Method 4
spindle mechanism with oppositely threaded ends to translate sliders along a spindle rail
Implementation Method 5
spindle mechanism
Data Source
Figure 1
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AI summary
A lumbar support system for a seat backrest includes a fixed frame and a flexmat coupled to the fixed frame. The flexmat includes first and second outer wires and a plurality of transverse wires extending between the outer wires. A support element is coupled to a lower portion of the flexmat below the plurality of transverse wires for concurrent movement with the flexmat from a first position to a second position. The support element is anatomically contoured for lumbar and pelvic support, and the support element is constructed of a more rigid material than the flexmat.