Modular Seat Cushion with Mechanical Interface for Simplified Assembly

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Solution Overview

Problem

Existing vehicle seat designs require complex assembly of multiple components, which is economically inefficient, especially when assembly occurs at high-cost workforce sites. Additionally, these designs do not allow for the easy addition of comfort features like heating, ventilation, or massage without disassembling the seat from the vehicle.

Innovation Solution

A modular seat cushion system that includes a support base with a mechanical interface system, allowing for easy fixation to a seat structure with two lateral flanges and transverse front and rear tubes. The system includes a rear mechanical interface with a U-shaped housing for the rear tube and a front mechanical interface for the front tube, enabling secure locking and allowing for the addition of comfort features without full disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional seat assembly methods are used with multiple components assembled at the final vehicle assembly site, then the seat structure can be securely assembled, but the assembly process becomes complex and economically inefficient due to high labor costs

Engineering Contradiction:

Improveassembly simplicityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The seat cushion is divided into modular components: a base with integrated mechanical interface system, padding, and covering. This segmentation allows the cushion to be assembled from separate parts while maintaining overall simplicity, resolving the contradiction between assembly simplicity and component integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical interface system is merged into the base structure itself, combining the attachment mechanism with the cushion base. This integration reduces the number of separate components needed while maintaining secure assembly, addressing the contradiction between component reduction and assembly simplicity.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If the seat is designed as a fixed integrated structure, then the assembly is stable and secure, but additional comfort features cannot be added without removing the seat from the vehicle

Engineering Contradiction:

Improveability to add comfort featuresVSAvoidseat assembly stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The seat cushion is segmented into a removable base module with integrated mechanical interfaces and a padding/covering module. This segmentation allows the base to be detached and reattached, enabling addition of comfort features like heating or ventilation elements to the base without removing the entire seat from the vehicle, while maintaining stability through the mechanical interface system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical interface system provides a dynamic connection that allows the base to be easily attached and detached. This dynamic capability enables adaptability for adding comfort features while maintaining stable connection during normal use, resolving the contradiction between versatility and stability.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If a modular cushion design is implemented with a single-piece plastic base, then manufacturing complexity is reduced and assembly is simplified, but the mechanical interface for secure attachment becomes more challenging

Engineering Contradiction:

Improvenumber of molded partsVSAvoidattachment security

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The mechanical interface system is merged into the single-piece plastic base through injection molding. The housing elements and locking features are integrated directly into the base structure, reducing the number of separate molded parts while maintaining secure attachment capability. This resolves the contradiction between manufacturing simplicity and attachment reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical interface incorporates elastomeric material integrated into the plastic base structure. This composite approach provides both the structural integrity of plastic and the flexible locking capability of elastomers, ensuring secure attachment while maintaining the simplicity of a single-piece molded base.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4530127A1Modular cushion for seating, and seat assembly comprising such a cushion

Publication Date: 2025.04.02 FAURECIA SIEGES D AUTOMOBILE SA

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AI summary

This disclosure relates to a modular seat cushion (CM), configured to be attached to a seat structure (2) having a seat structure comprising two side flanges (20) braced by a transverse front tube (23) and a transverse rear tube (22), said modular seat cushion comprising in the assembled state: - a support, - a padding resting on a top surface of the support, e.- a covering covering the padding, and in which said mechanical interface system comprises: - a rear mechanical interface (16), on a rear portion of the support (S), comprising a first housing (LG1), open, configured to house the rear tube (22) in a manner mechanically lockable by a locking system, - a front mechanical interface (17), on a front portion of said support comprising a second housing (LG2), open, configured to house the front tube (23) in a manner pivotable around said front tube (23).