Plastic Headrest Frame with Flexible Support Elements
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Solution Overview
Problem
Conventional headrests for vehicles are costly and lack optimal support and safety features, particularly in the event of a rear-end collision, due to their reliance on foamed materials and complex manufacturing processes.
Innovation Solution
A headrest body designed with a frame and flexible support elements made from plastic materials, such as thermoplastic or fiber composite materials, which provides a concave support surface without foamed materials, enhancing both comfort and safety by reducing head movement during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foamed materials are used for cushioning in headrests, then comfort is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent removes the foamed material layer from the headrest structure, extracting the problematic element that caused manufacturing complexity while retaining the essential cushioning function through alternative means (the plastic material itself provides sufficient support without requiring separate foam layers)
Solution Approach 2:
The patent combines the structural frame and cushioning function into a single integrated plastic component. The thermoplastic or thermosetting plastic material serves both structural and comfort functions, eliminating the need for separate foam materials and reducing manufacturing steps
2Ease of operation
If foamed materials are used for cushioning in headrests, then comfort is improved, but production cost increases
Solution Approach 1:
The patent employs inexpensive thermoplastic or thermosetting plastic materials that can be mass-produced through injection molding or compression molding. These materials provide adequate comfort for the intended service life of the headrest while being significantly cheaper than traditional foam materials
Solution Approach 2:
The patent changes the material parameters by using plastics with specific mechanical properties (flexibility, density, elasticity) that provide comfort equivalent to or better than foam. The material parameters are optimized through formulation and processing conditions to achieve the desired comfort at lower cost
3Ease of operation
If conventional headrest design with padding is used, then comfort is provided, but head movement during collisions is not sufficiently minimized
Solution Approach 1:
The patent applies different material properties to different regions of the headrest. The plastic material is formulated with specific local characteristics - firmer in areas requiring head stabilization during collision, and sufficiently flexible in contact areas for comfort. This spatial variation in material quality addresses both comfort and safety requirements
Solution Approach 2:
The patent uses composite plastic formulations or multi-layer plastic structures that combine materials with different mechanical properties. This allows the headrest to provide comfort through flexible contact surfaces while maintaining structural rigidity for collision safety, achieving both comfort and protective function in a single material system
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 results in a cost-effective, ergonomic, and safer headrest design that limits head impact in collisions, while maintaining comfort through reduced padding and improved structural integrity.
Implementation Method 1
The headrest body is formed by injection molding a material free from foamed plastic materials or by multi-component injection molding from a number of plastic materials
Implementation Method 2
a headrest body (1) designed as at least one frame (1.1) with one or more flexible support elements (1.4) lying on the inside and forming a support surface (1.3)
Implementation Method 3
The headrest body is made of an impact-resistant elastoplastic or thermoplastic material, for example a thermoplastic material, in particular polypropylene, urethane, polyurethane, polyethylene or polycarbonate-acrylonitrile-butadiene-styrene (PC-ABS)
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3C
AI summary
The invention relates to a headrest body (1) for a headrest (3), formed as at least one frame (1.1) having one or more supporting elements (1.4) located on the inside and forming a supporting surface (1.3), and formed by primary forming from a plastics material, in particular a material free of foam materials, or a composite material.