Vehicle Seat Back Synthetic Resin Foam Supports
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Solution Overview
Problem
Conventional seat back designs for vehicles face challenges in weight reduction, recyclability, and maintaining optimal cushioning and comfort due to the limitations of urethane foam, which lacks sufficient rigidity and flexibility, leading to inadequate support during vehicle movements and discomfort.
Innovation Solution
The use of synthetic resin foam with specific bending deflection and load properties, integrated into a seat back design with independent supporting bodies and a structured interspace, allows for bending deformation to support occupants effectively while promoting weight reduction and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If urethane foam is used as cushioning material to achieve high cushioning properties and comfort, then cushioning performance is improved, but recyclability deteriorates and weight reduction is limited
Solution Approach 1:
The patent changes the material parameter from conventional urethane foam to synthetic resin foam with specific physical properties (density 20-80 kg/m³, bending deflection ≥20mm, load 2-100N). This material substitution maintains cushioning performance while improving recyclability and enabling weight reduction.
Solution Approach 2:
The patent uses composite structure combining synthetic resin foam with a net material layer. The synthetic resin foam provides base cushioning and structural support, while the net material enhances surface comfort and fit, creating a composite system that achieves both comfort and recyclability goals.
2Strength
If urethane foam density is increased to obtain sufficient rigidity for supporting occupant body at optimal position, then support function is improved, but weight increases
Solution Approach 1:
The patent optimizes the density parameter of synthetic resin foam to a specific range (20-80 kg/m³) that provides sufficient rigidity for body support while maintaining lightweight characteristics. This parameter optimization allows achieving both strength and weight reduction goals simultaneously.
Solution Approach 2:
The patent divides the cushioning function into multiple components: synthetic resin foam for structural support and rigidity, and net material for surface comfort. This segmentation allows each component to be optimized independently, achieving sufficient rigidity without excessive weight.
3Weight of moving object
If net material is used as cushion material to achieve light weight, then weight is reduced, but seat frame strength must be increased leading to weight increase
Solution Approach 1:
The patent creates a composite system where synthetic resin foam provides structural support and distributes loads, reducing the burden on the seat frame. The net material layer provides additional support and comfort. This composite approach maintains lightweight design while ensuring sufficient overall strength.
Solution Approach 2:
The synthetic resin foam acts as an intermediary between the seat frame and the net material, distributing forces and reducing the load on the seat frame. This intermediary function allows the use of lighter seat frame structures while maintaining overall strength requirements.
4Device complexity
If conventional cushion materials are used to achieve basic cushioning, then simple structure is maintained, but fitting feeling and three-dimensional support are insufficient
Solution Approach 1:
The patent employs a composite structure combining synthetic resin foam and net material, where each layer contributes different functions. The foam provides three-dimensional support and structural integrity, while the net material enhances surface fitting and comfort, achieving superior fitting feeling without excessive complexity.
Solution Approach 2:
The patent applies different material properties to different layers: the synthetic resin foam provides bulk support and structural support in the three-dimensional space, while the net material provides localized surface comfort and fitting. This local quality differentiation achieves excellent fitting feeling with a relatively simple two-layer structure.
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 synthetic resin foam provides enhanced cushioning and comfort, improved marketability through creep resistance, and reduced processing costs, while achieving weight reduction and superior support during vehicle movements.
Implementation Method 1
each of the plurality of supporting bodies 3 is made of a synthetic resin foam having larger than or equal to 20 mm in bending deflection amount and 2 to 100 N in load when deflected by 20 mm
Implementation Method 2
the synthetic resin foam is indicative of a synthetic resin foam molding that is flexible to be bending-deformed and excellent in restoration properties
Implementation Method 3
the synthetic resin foam is indicative of a synthetic resin foam molding that is flexible to be bending-deformed and excellent in restoration properties
Data Source
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AI summary
The present invention relates to a vehicle seat back which comprises a seat back pad. An opening portion is disposed at a front portion of the seat back pad where a backrest surface is formed for a seated person. A plurality of independent rod-like or plate-like supports, which are formed of a synthetic resin foam having a bending deflection measured according to a method described in JIS K7221-2:2006 of at least 20 mm and having a load at a 20 mm deflection of between 2 N and 100 N, are fixed to a seat frame or a circumferential edge portion of the opening portion, or integrally molded with the circumferential edge portion of the opening portion, in a bridging direction between opposing edge portions forming the opening portion and in the form of a single-point support or multi-point support. The seat pad is a structure which has a shape in which the plurality of supports are arrayed at predetermined intervals. The vehicle seat back of the present invention comprises a void portion which enables bending deformation of the support toward a rear portion of the support, and therefore weight can be reduced, and cushioning properties, fit, and recyclability can be improved.