Resin Seat Back Structure With Integrated Adjustable Headrest Support
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Solution Overview
Problem
Existing seat back supports made from blow molding are limited by uniform thickness, complexity, and the need for additional materials like steel plates for attachment features, which restricts their shape and weight reduction while meeting safety standards.
Innovation Solution
A seat back support design featuring a first panel with a raised portion that is melted and re-solidified to bond with a second panel having a corrugated structure, eliminating the need for additional materials and allowing for integral attachment structures like adjustable headrest supports, armrest brackets, and seat back pivot brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If blow molding is used to manufacture seat back supports, then weight is reduced and cost is lowered, but component complexity is limited and additional materials like steel plates are required for attachment features
Solution Approach 1:
The patent combines polymer material with integrated attachment features, creating a composite structure that merges the seat back support with functional elements like headrest supports and armrest brackets. This integration eliminates the need for separate steel plates while maintaining structural complexity and strength.
Solution Approach 2:
The patent merges multiple functions into a single seat back support component. Attachment features such as headrest supports, armrest brackets, and pivot brackets are integrated directly into the seat back support structure, eliminating the need for separate components and additional materials like steel plates.
2Ease of manufacture
If blow molding is used to manufacture seat back supports, then manufacturing cost is reduced, but integral attachment structures cannot be incorporated
Solution Approach 1:
The patent merges attachment structures directly into the seat back support during the molding process. Features like headrest supports, armrest brackets, and pivot brackets are formed as integral parts of the polymer structure, enabling versatile functionality while maintaining cost-effective manufacturing.
Solution Approach 2:
The seat back support is designed with multi-functional capabilities, incorporating various attachment features that can accommodate different accessories and configurations. This universal design allows the same basic component to serve multiple purposes without requiring additional parts or materials.
3Ease of manufacture
If uniform thickness is used in blow molded components, then manufacturing is simplified, but structural strength and toughness are limited
Solution Approach 1:
The patent applies local quality by varying the thickness and density of the polymer material in specific areas of the seat back support. Thicker sections are placed where structural strength is needed, while thinner sections are used where less support is required. This localized variation optimizes both strength and manufacturing efficiency.
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 lightweight, strong seat back support that meets safety standards with reduced foam material requirements and integrated attachment features, enhancing structural strength and toughness without additional materials.
Implementation Method 1
at least part of the raised portion will have been melted and re-solidified
Implementation Method 2
the raised portion will have been melted and re-solidified
Data Source
AI summary
A seat back support for seat cushioning to be attached thereto and provide a seat component is disclosed. In addition, a process for making the seat back support is also disclosed. The seat back support can have first panel and a second panel. The first panel can have a base portion and a raised portion extending outwardly from the base portion, and the second panel can have a corrugated structure with a channel portion extending from a joining surface. The second panel is fixedly attached to the first panel by having at least part of the raised portion melt and re-solidified while in contact with the joining surface of the second panel.