Modular Vehicle Seat Airbag Integration via Segmented Foam
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Solution Overview
Problem
Existing modular vehicle seat designs face challenges in integrating airbag modules into lateral upholstered elements due to limited installation space, often resulting in damage to the foam body and costly manufacturing processes, as well as issues with foam particles flying around during airbag deployment.
Innovation Solution
A modular vehicle seat design where lateral upholstered elements comprise an airbag module with an inflatable air cushion that unfolds through a predetermined opening between the foam part and the supporting body, minimizing foam damage and allowing for simple integration and manufacturing, using a tear seam or separating supporting body regions to guide the air cushion effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the airbag module is integrated into the lateral upholstered element with limited installation space, then side impact protection is achieved, but the foam body is damaged and manufacturing costs increase
Solution Approach 1:
The supporting body is divided into two separable parts: a first supporting body region and a second supporting body region. This segmentation allows the airbag module to be integrated into the lateral upholstered element without damaging the foam body, as the air cushion unfolds through the separation of these two regions rather than through the foam material itself.
Solution Approach 2:
The airbag module is extracted as a separate functional component that unfolds through a predetermined opening between the foam part and the supporting body. This extraction prevents the air cushion from directly interacting with and damaging the foam body during deployment, while still providing the necessary side impact protection.
2Speed
If the air cushion unfolds through the foam part, then deployment is achieved, but foam particles fly around and the foam body is damaged
Solution Approach 1:
A predetermined opening is introduced as an intermediary pathway between the airbag module and the external environment. This opening is positioned between the foam part and the supporting body, allowing the air cushion to unfold and deploy rapidly without directly interacting with the foam body, thereby preventing foam particles from being dispersed during deployment.
3Adaptability or versatility
If costly adaptations are made to the foam body and airbag module, then integration is achieved, but manufacturing complexity increases
Solution Approach 1:
The supporting body is designed with a universal structure that serves multiple functions: it provides structural support for the lateral upholstered element, contains the airbag module, and creates the predetermined opening through its two-segment design. This multi-functionality eliminates the need for costly and complex adaptations to either the foam body or airbag module, simplifying the manufacturing process while maintaining integration capability.
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
This design allows for the integration of airbag modules into vehicle seats with minimal foam damage and reduced manufacturing costs, ensuring effective side impact protection while maintaining the integrity of the foam parts and preventing foam particles from flying around during deployment.
Implementation Method 1
an airbag module (11) with an inflatable, unfolding air cushion (11a)
Data Source
AI summary
A vehicle seat comprises a seating portion and a back rest the angle of inclination is adjustable in relation to the seating portion, where at least the back rest is of modular design made of a plurality of upholstered elements, the upholstered elements each comprising a preformed foam part surrounded, at least in part, by a cushion cover, the upholstered elements made in this manner are put together via fasteners in modular fashion to form the back rest adjustable in inclination.