Seat Backrest Outer Airbag Module With Reduced Foam Structure

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Solution Overview

Problem

Conventional seat backrests require a large amount of material, especially foam, to encapsulate the airbag module, increasing size, mass, and manufacturing costs, and necessitate special arrangements for airbag deployment, which complicates the design and material usage.

Innovation Solution

The seat backrest design features a cover directly in contact with the frame, reducing the need for foam in the attachment area and allowing the airbag module to deploy externally without additional cover arrangements, using a housing attached through the cover and a single attachment element, such as a rod, to simplify deployment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a foam layer is used to encapsulate the airbag module housing, then the airbag module is seamlessly integrated into the seat and not visible under the cover, but the amount of material increases, backrest size and mass increase, and manufacturing costs increase

Engineering Contradiction:

Improveseamless integration of airbag moduleVSAvoidamount of foam material

Core Design Contradiction:

ShapeVSQuantity of substance

Solution Approach 1:

The invention extracts the foam layer from the attachment area where the airbag module is mounted, eliminating the need for foam encapsulation in this specific zone. The cover is configured to extend directly over the frame and contact the housing, allowing the airbag module to be seamlessly integrated without requiring foam material in the attachment area.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention applies different structural configurations to different areas of the backrest. In the attachment area, the cover contacts the housing directly without foam, while in other areas, foam may still be used for comfort or structural purposes. This localized approach optimizes material usage while maintaining seamless integration where needed.

Inventive Principle:

Principle #3Local quality

2Shape

If a foam layer is used to encapsulate the airbag module housing, then the airbag module is seamlessly integrated into the seat, but the backrest mass increases

Engineering Contradiction:

Improveseamless integration of airbag moduleVSAvoidbackrest mass

Core Design Contradiction:

ShapeVSWeight of stationary object

Solution Approach 1:

The foam layer is extracted from the attachment area, eliminating unnecessary foam material that would increase backrest mass. The cover structure is modified to extend directly over the frame and contact the housing, achieving seamless integration without the added weight of foam encapsulation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If special measures are taken to allow the airbag to deploy outwards from the seat, then the airbag can deploy, but the design complexity increases and additional material is required

Engineering Contradiction:

Improveairbag deployment capabilityVSAvoiddesign complexity of cover arrangement

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of creating openings or breakage zones in the cover to allow airbag deployment, the invention inverts the approach by positioning the housing to extend entirely to the side of the outer surface of the backrest. The airbag deploys outward through the side opening of the housing, eliminating the need for special cover arrangements or breakage zones.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts the need for special deployment arrangements from the cover design. By extending the housing to the side of the outer surface, the airbag can deploy outward directly through the housing opening without requiring any modifications to the cover structure.

Inventive Principle:

Principle #2Taking out (Extraction)

4Shape

If a foam layer is used to encapsulate the airbag module housing, then the airbag module is integrated into the seat, but manufacturing costs increase

Engineering Contradiction:

Improveintegration of airbag moduleVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The foam layer is extracted from the attachment area, reducing material costs and simplifying the manufacturing process. The cover is configured to extend directly over the frame and contact the housing, achieving seamless integration without the need for foam encapsulation in the attachment area.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11738707B2Seat backrest comprising an outer airbag module

Publication Date: 2023.08.29 FAURECIA SIEGES D AUTOMOBILE SA

AI summary

A seat backrest having a frame and a cover extending around at least part of the frame, the cover defining at least part of the outer surface of the backrest. The seat backrest includes an airbag module, having a housing receiving an airbag, that is attached to the frame in an attachment area. At least in the attachment area, the cover is in direct contact with the frame and extends between the frame and the housing of the airbag module. The housing is attached to the frame through the cover and extends entirely to the side of the outer surface of the backrest.