Overmolded Seat Suspension Holder for Simpler Module Assembly
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Solution Overview
Problem
Current seat suspension systems for vehicles are labor-intensive and costly due to the need for metal brackets and complex assembly processes, particularly when integrating control and sensing modules, and require additional steps for electrical insulation and wire joining.
Innovation Solution
A seat suspension system utilizing overmolded plastic-coated support wires with integral attachment clips and crossbars, allowing for easier assembly and electrical insulation, and eliminating the need for separate metal brackets and injection-molded parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal brackets and separate injection-molded parts are used to hold seat cushion modules, then secure attachment is achieved, but assembly complexity and labor costs increase
Solution Approach 1:
The patent combines multiple separate components (metal bracket, injection-molded parts, attachment mechanisms) into a single integrated plastic molding. The seat cushion module holder is formed as one piece that directly attaches to the seat frame, eliminating the need for separate metal brackets and multiple assembly steps. This merging of functions into a single component directly reduces assembly complexity while maintaining secure attachment.
2Ease of manufacture
If powder-coating is used to insulate suspension wires, then electrical insulation is achieved, but additional manufacturing steps and costs are added
Solution Approach 1:
The patent uses plastic-coated suspension wires where the plastic coating serves dual purposes: it provides electrical insulation to prevent contact with the conductive seat frame, and it acts as a bonding surface for the overmolded holder. This composite structure (metal wire + plastic coating) eliminates the need for separate powder-coating steps while maintaining reliable electrical insulation through the inherent insulating properties of the plastic material.
3Ease of manufacture
If multiple suspension wires are joined using twisted wires, then a unitary suspension structure is formed, but assembly labor and costs increase
Solution Approach 1:
The patent incorporates the suspension wires directly into the mold design during the overmolding process. The wires are positioned and secured within the mold cavity before the plastic material is injected, allowing the holder to be formed with pre-positioned wire attachments. This preliminary positioning of components during molding eliminates the need for separate wire joining and assembly operations, significantly reducing assembly time and labor costs.
4Strength
If separate metal brackets are used to support control modules, then structural strength is achieved, but weight increases
Solution Approach 1:
The patent transitions from metal brackets to plastic-molded holder structures, changing the material parameter from high-density metal to lower-density plastic. The overmolded plastic holder maintains sufficient structural strength to support control modules and withstand suspension forces while significantly reducing the weight of the seat assembly. The plastic material's strength-to-weight ratio provides adequate support without the excessive weight of metal 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
The solution reduces assembly costs and complexity, provides secure attachment for seat cushion modules, and enhances electrical insulation, while allowing for flexible support and reduced weight, thus improving the overall efficiency and cost-effectiveness of the suspension system.
Implementation Method 1
electrical insulation of the suspension wires so that the wires do not make electrical contact with the seat frame
Implementation Method 2
a coating of overmolded plastic applied to the first and second ends such that the first end second ends are held together by the coating
Data Source
AI summary
A suspension system for a vehicle seat comprising a support wire having a first end, a second end, and a middle portion between the first and second ends, such that the support wire is folded approximately in half at the middle portion. The suspension system further comprises a coating of overmolded plastic applied to the first and second ends such that the first end second ends are held together by the coating; a bend in the middle portion of the support wire to attach the support wire to a frame of the vehicle seat, wherein the bend is coated with overmolded plastic; a crossbar overmolded on the support wire; an integral attachment clip molded onto the crossbar; and a seat cushion module held adjacent the support wire using the integral attachment clip.