Motor Vehicle Seat Back Panel With Variable Stiffness Foam

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Solution Overview

Problem

Existing motor vehicle seat back panels are typically made of rigid plastic and lack variability in stiffness, failing to provide optimal comfort and functionality.

Innovation Solution

A back panel comprising a single piece with at least two areas of different stiffness, achieved through the stacking of a non-expanded foam layer and an expanded foam layer, each with distinct formulations and hardness ranges, and optionally including a paint layer and assembly elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid plastic material is used for the back panel, then structural integrity is improved, but comfort and ease of installation deteriorate due to lack of flexibility

Engineering Contradiction:

Improvestructural integrityVSAvoidease of installation

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The back panel is divided into multiple zones with different foam densities and stiffness characteristics. The first area has a first foam density while the second area has a second foam density, creating local variations in mechanical properties. This allows different regions to serve different functions: rigid areas for structural support and flexible areas for comfort and ease of installation.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If a single stiffness back panel is used, then manufacturing simplicity is improved, but comfort and functionality deteriorate due to lack of stiffness variability

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstiffness variability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The back panel is segmented into multiple areas with different foam densities. The panel comprises a first area with a first foam density and a second area with a second foam density, creating distinct functional zones within a single integrated structure. This segmentation enables stiffness variability while maintaining the panel as a single manufacturable component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The back panel uses composite foam structures with varying densities. By combining foams of different densities in specific patterns, the panel achieves multiple stiffness characteristics in a single piece, providing both comfort and structural support without requiring assembly of multiple separate components.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple separate components are used to achieve varying stiffness, then stiffness variability is improved, but device complexity and assembly difficulty increase

Engineering Contradiction:

Improvestiffness variabilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple foam areas with different densities are merged into a single integrated back panel structure. The first area with first foam density and the second area with second foam density are combined in one piece, eliminating the need for separate components and complex assembly procedures while maintaining stiffness variability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11325344B2Back panel of a seat element

Publication Date: 2022.05.10 FAURECIA SIEGES D AUTOMOBILE SA

AI summary

A back panel of a motor vehicle seat element includes at least a first foam layer with at least two areas of different stiffness.