Seat Foam Sensor Mat Anchoring for Precise, Durable Positioning
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Solution Overview
Problem
Traditional methods for fixing sensor mats to seat foam, such as double-sided tape or barbed members, face issues like chemical aggression from oil films, loss of flexibility, and damage from repeated loading, leading to insecure and imprecise positioning.
Innovation Solution
The use of incisions in the seat foam with anchor tabs and retaining elements, such as foam lobes, to securely hold the sensor mat in place without adhesives, allowing for precise positioning and easy replacement, while preventing rotational movement and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-sided tape or Velcro is used to fix the sensor mat to the seat foam, then the sensor mat can be easily attached, but the fixation becomes insecure due to chemical aggression from oil films and anti-adhesive properties
Solution Approach 1:
The patent replaces chemical fixation methods (double-sided tape, Velcro) with a mechanical fixation system consisting of anchor tabs integrated into the sensor mat and corresponding cavities formed in the seat foam. The anchor tabs are inserted into the cavities and secured with adhesive, creating a mechanical interlock that is not affected by oil films or anti-adhesive properties on the foam surface.
2Strength
If barbed members or tabs are forced into cavities to secure the sensor, then fixation strength is improved, but the plastic material loses flexibility and becomes brittle when ageing
Solution Approach 1:
The patent changes the material parameter from rigid plastic with barbed members to a more flexible material composition for the anchor tabs. The cavities in the foam are designed with smooth walls rather than requiring barbed engagement, allowing the use of materials that maintain flexibility and durability over time while still providing strong fixation when combined with adhesive.
3Strength
If tabs are strongly deformed or compressed during engagement, then initial fixation is achieved, but repeated loading and relief cause additional bending and creasing leading to damage or breakage
Solution Approach 1:
The patent designs the cavity geometry and anchor tab configuration to distribute loads evenly during insertion and service. The cavities are formed with appropriate dimensions and smooth transitions that prevent stress concentration, and the adhesive layer provides cushioning that absorbs repeated loading and relief cycles, preventing damage or breakage of the anchor tabs during the service life of the seat.
4Ease of manufacture
If traditional fixation methods are used, then the sensor mat can be attached, but precise positioning is difficult to achieve
Solution Approach 1:
The patent divides the sensor mat into multiple sections with individually positioned anchor tabs. Each anchor tab is precisely positioned at predetermined locations that correspond to cavities formed in the seat foam during manufacturing. This segmentation allows for precise positioning of the sensor mat relative to the foam, ensuring correct alignment while maintaining ease of attachment through the modular anchor tab design.
Data Source
AI summary
In an assembly of a seat foam and a sensor mat, the seat foam has at least one incision and the sensor mat has at least one anchor tab adapted to be inserted into the at least one incision, thereby securely holding the sensor mat on a surface of the seat foam, where the seat foam includes at least one retaining element at the incision for retaining the anchor tab in the incision.