Vehicle Seat Back Cover Structure Without Adhesive Odor
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Solution Overview
Problem
Vehicle seats with foam pads and rigid plastic back covers create a hard, uncomfortable surface that passengers find unmarketable, and existing solutions using flexible materials still result in unpleasant odors and environmental contamination due to adhesives.
Innovation Solution
A vehicle seat design featuring a flexible rear cover made of thermoplastic composites with glass fibers, integrated with a bracket and outer cover, where the components are formed by press molding without adhesives, providing a soft touch and luxurious feel while maintaining structural integrity and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid plastic material is used for back cover, then structural strength is improved, but comfort and softness deteriorate
Solution Approach 1:
The back cover uses a composite structure combining rigid plastic material for structural strength and soft cushioning material (foam or fabric) for comfort. The rigid frame provides support while the soft layers contact the passenger, resolving the contradiction between strength and comfort.
Solution Approach 2:
Different parts of the back cover have different material properties - the structural frame uses rigid plastic while the surface layers use soft materials. This local differentiation allows each region to perform its specific function optimally.
2Ease of manufacture
If adhesive is used to manufacture back cover, then manufacturing ease is improved, but environmental contamination and unpleasant smell worsen
Solution Approach 1:
The invention removes the adhesive component from the manufacturing process entirely. The back cover components are assembled using mechanical fastening methods such as clips, snaps, or interlocking structures, eliminating the source of unpleasant smells and environmental contamination while maintaining ease of manufacture.
Solution Approach 2:
Mechanical fastening elements act as intermediaries between back cover components, replacing adhesive as the joining mechanism. These fasteners provide strong bonds without introducing harmful chemicals into the vehicle interior.
3Adaptability or versatility
If integrated pocket structure is used in back cover, then functionality is improved, but manufacturing complexity worsens
Solution Approach 1:
The back cover is divided into separate functional modules - the main back cover structure and the pocket as a separate component. The pocket can be attached using mechanical fasteners, allowing independent manufacturing and assembly, thus reducing overall manufacturing complexity while maintaining functionality.
Data Source
AI summary
A vehicle seat includes: a seat back pad of a vehicle; a rear cover coupled with the seat back pad on the rear side and made of flexible material; and a bracket formed along the periphery of the rear cover, the bracket being coupled with the seat back pad so that its front is supported by the seat back pad.