Vehicle Seat Assembly With Concealed Brackets for Continuous Cushioning
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Solution Overview
Problem
The existing method of installing vehicle seat assemblies prevents the use of a continuous cushion pillow top over the bolsters and armrests, impacting the aesthetics of the installed seat.
Innovation Solution
The vehicle seat assembly includes a seat main frame with left and right side members that define outboard bolsters and armrests, with forward attachment brackets for attachment to the seat main frame, and corner cover members that conceal the attachments, allowing for a continuous cushion cover beneath the seat base and main frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If seat components are mounted to the vehicle body first, then the installation process is complete, but the continuous cushion pillow top cannot be used over bolsters and armrests
Solution Approach 1:
The seat assembly is divided into separate components: side members with bolsters and armrests are attached to the seat base frame, and the cushion cover is then stretched over these components. This segmentation allows the cushion to be continuously formed across all surfaces while maintaining structural integrity of individual components.
Solution Approach 2:
The cushion cover is designed to continuously cover the bolsters and armrests, merging these separate structural elements into a unified aesthetic appearance. The cover integrates over all protruding components to create a smooth, continuous surface that eliminates visual discontinuities.
2Reliability
If multiple separate components are used for side members and covers, then the seat assembly is complete, but the number of parts increases
Solution Approach 1:
The corner cover members serve multiple functions: they cover the forward attachment brackets, conceal the attachment of side members to the seat main frame, and provide structural support at the corners. This multi-functionality reduces the need for separate components for each function.
Solution Approach 2:
The corner cover members are positioned to nest around and conceal the attachment brackets and joint areas. This nesting arrangement allows multiple components to be integrated in a space-efficient manner, reducing overall complexity while maintaining completeness.
3Strength
If attachment brackets are exposed, then the structural connections are visible, but the exterior appearance is disrupted
Solution Approach 1:
The corner cover members act as intermediary elements that cover the attachment brackets and structural connections. These covers maintain the structural integrity of the connections while providing an aesthetic overlay that creates a smooth, continuous exterior surface.
Solution Approach 2:
The cushion cover and corner covers function as flexible shells that conform to the underlying structural components. These thin film-like covers encapsulate the rigid attachment brackets, transforming the appearance from exposed mechanical connections to smooth continuous surfaces.
Data Source
AI summary
A vehicle seat assembly includes a seat main frame including a seat back attached to the seat main frame. The vehicle seat assembly also includes left and right side members in which each side member defines an outboard seat back bolster and an armrest. The armrest has a forward attachment bracket for attachment to the seat main frame. The vehicle seat assembly also includes a seat base including a seat base frame attached to the seat main frame and left and right corner cover members separate from the respective left and right side members and the seat base. Each corner cover member is adapted to cover the forward attachment bracket of the corresponding side member. Further, the left and right corner cover members conceal the attachment of the left and right side members to the seat main frame.