Modular 3D Seat Trim Inserts for Custom Vehicle Seating
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Solution Overview
Problem
Existing seat trim elements for vehicle seats lack variability and flexibility, particularly in accommodating complex shapes and easy maintenance or personalization, with existing solutions often resulting in numerous seam lines and limited customization options.
Innovation Solution
A three-dimensionally shaped seat trim element featuring detachable and interchangeable 3D inserts produced through thermoforming, which can be pre-shaped to reduce seam lines and allow for complex designs, such as concave areas or storage features, using materials like non-woven plastics with fibers and low melting points, and can be made with decorative surfaces and integrated fastening elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional seat trim elements are used, then manufacturing is simpler, but variability and customization options are limited
Solution Approach 1:
The seat trim element is divided into a base structure and separate interchangeable inserts. Each insert can be independently designed, manufactured, and attached to the base structure, enabling multiple customization options without increasing overall structural complexity. The inserts can be removed and replaced with different designs.
Solution Approach 2:
The seat trim element transitions from a static, fixed design to a dynamic, reconfigurable system. The interchangeable inserts allow the trim element to change its appearance and functionality based on user needs, providing adaptability while maintaining a relatively simple base structure.
2Adaptability or versatility
If complex three-dimensional shapes are integrated into seat trim elements, then design flexibility improves, but manufacturing complexity increases
Solution Approach 1:
Complex three-dimensional shapes are segmented into separate insert components rather than being integrated into the main trim element. This allows each insert to be manufactured independently using appropriate processes, then attached to the base structure, reducing overall manufacturing complexity while maintaining design flexibility.
Solution Approach 2:
The complex three-dimensional shapes are pre-formed as separate inserts before being attached to the base structure. This preliminary formation allows for optimized manufacturing of each component and simplifies the final assembly process, reducing overall manufacturing complexity.
3Ease of repair
If interchangeable inserts are added to seat trim elements, then variability and ease of maintenance improve, but device complexity increases
Solution Approach 1:
The seat trim element is segmented into a base structure and removable inserts. This segmentation enables easy maintenance by allowing individual inserts to be removed and replaced without affecting the entire trim element, improving ease of repair while adding minimal structural complexity through simple attachment mechanisms.
Solution Approach 2:
The interchangeable inserts can be easily removed, replaced, or recovered when worn or damaged. This allows for simple maintenance operations where individual inserts are discarded or replaced without requiring complex disassembly or repair of the entire trim element.
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 provides a modular and customizable seat trim element with reduced seam lines, enabling easier maintenance and personalization, while offering enhanced design flexibility and storage options, such as built-in holders for devices, through the use of thermoformed 3D inserts that can be retrofitted to existing seat trim elements.
Implementation Method 1
A three-dimensionally shaped insert (132.1 to 132.6; 136), designed as a 3D add-on module or 3D insert or 3D trim module, produced by a thermoforming process
Implementation Method 2
The thermoforming process refers in particular to the thermoforming of materials, in particular plastics materials, for example plastics fiber materials, using pressure and heat
Implementation Method 3
The thermoforming process refers in particular to the thermoforming of materials, in particular plastics materials, for example plastics fiber materials, using pressure and heat
Implementation Method 4
The thermoforming process refers in particular to the thermoforming of materials, in particular plastics materials, for example plastics fiber materials, using pressure and heat and/or high-frequency welding (also known as HF welding)
Implementation Method 5
The material may also contain fibers with a low melting point
Data Source
AI summary
A seat trim element, formed as a three-dimensionally shaped seat covering element and/or three-dimensionally shaped seat cushion element of a vehicle seat, where at least one three-dimensionally shaped insert produced by a thermoforming process is provided and can be attached or is detachably or interchangeably attached to the seat trim element.