Seat Backrest Cover Layout for External Airbag Integration
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Solution Overview
Problem
Conventional seat backrests require a large quantity of foam and materials, increasing size, mass, and manufacturing costs, and complicate airbag deployment, necessitating additional structural modifications.
Innovation Solution
The seat backrest design features a cover directly contacting the frame and extending between the frame and the airbag module housing, reducing foam usage and simplifying airbag deployment by allowing direct external deployment without additional structural arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a layer of foam is used to cover the housing and extend between the housing and headrest, then the airbag module is harmoniously integrated into the seat and the feel of the seat is maintained, but the quantity of material increases, increasing size, mass, manufacturing costs, and CO2 consumption
Solution Approach 1:
The patent removes the foam layer from the fixing zone area, extracting only the necessary portion of foam while maintaining it in other areas. This allows the airbag module to be fixed directly to the frame without requiring foam coverage in the deployment region, thereby reducing overall material consumption while preserving seat comfort in non-critical areas.
Solution Approach 2:
The patent applies different structural solutions to different zones of the seat backrest. In the fixing zone, the cover contacts the frame directly without foam, while in other areas, foam may still be present. This localized differentiation optimizes material usage by applying foam only where structurally necessary rather than uniformly across the entire seat.
2Ease of operation
If a layer of foam is used to cover the housing, then the airbag module is harmoniously integrated into the seat, but special measures must be taken to allow deployment of the airbag towards the outside of the seat, such as the addition of a break zone in the foam layer and a tear zone in the cap
Solution Approach 1:
The patent extracts the foam layer from the fixing zone entirely, eliminating the need for break zones in foam and tear zones in the cap cover. By fixing the airbag module directly to the frame in this area, the deployment path is cleared of obstacles, simplifying the deployment mechanism and removing the need for complex structural modifications.
Solution Approach 2:
Instead of modifying the foam layer and cap cover to accommodate airbag deployment (as in conventional designs), the patent inverts the approach by placing the airbag module housing directly against the frame where no foam interference exists. This reverses the conventional logic of 'modifying the cover for deployment' to 'positioning the module where deployment is naturally possible'.
3Ease of operation
If the housing is fixed to the frame through the cover with foam, then the airbag module is integrated into the seat, but the quantity of material increases and manufacturing costs increase
Solution Approach 1:
The patent removes the foam layer from the fixing zone, extracting unnecessary material that would otherwise be required for housing coverage in this specific area. This reduction in material quantity directly lowers manufacturing costs and simplifies the assembly process while maintaining adequate integration of the airbag module through direct frame fixation.
4Ease of operation
If foam is used to coat the frame, then the airbag module can be fixed to the frame, but the size and mass of the backrest increase
Solution Approach 1:
The patent extracts the foam layer from the fixing zone where the airbag module is mounted, eliminating unnecessary material that contributes to backrest mass. The airbag housing is fixed directly to the frame structure in this area, achieving secure fixation without the added weight of foam coating.
Data Source
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AI summary
The seat back (2) comprises a frame (4) and a cover (6) extending around at least a portion of the frame (4), said cover (6) defining at least a portion of the outer surface of the seat back, an airbag module (10), comprising a housing (22) for receiving an airbag (24), being attached to said frame (4) in an attachment zone. At least in the attachment zone, the cover (6) is in direct contact with the frame (4) and extends between said frame (4) and the housing (22) of the airbag module (10), said housing (22) being attached to the frame (4) through the cover (6) and extending entirely along the outer surface of the seat back.