Vehicle Seat Occupancy Detector Layout to Prevent Foam Preload
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Solution Overview
Problem
Existing occupant detection systems (ODS) in vehicle seats face challenges such as reduced sensitivity and reliability due to integration with foam-in-place seat manufacturing processes, which can lead to foam creeping over sensor pads and preload issues.
Innovation Solution
The proposed solution involves embedding an ODS between the seat foam and the outer membrane, and manufacturing the seat using a foam-in-place process where a plug or insert with the ODS is embedded in a recess within the seat, creating a gap that helps maintain sensor reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an occupant detection system is integrated into a foam-in-place seat manufacturing process, then the seat can be manufactured efficiently, but the sensor pads are compromised by foam creeping over them and preload issues, reducing detection reliability
Solution Approach 1:
The seat is divided into distinct components: an outer membrane, foam material, and a separate sensor assembly. The sensor assembly is positioned in a recess that isolates it from direct foam contact, preventing foam creep while maintaining manufacturing efficiency. This segmentation allows each component to perform its function without interfering with others.
Solution Approach 2:
A recess structure acts as an intermediary barrier between the foam material and the sensor pads. This recess prevents the foam from directly contacting and compromising the sensor pads, while still allowing the sensor assembly to be integrated into the seat during the foam-in-place manufacturing process.
2Ease of manufacture
If sensor pads are embedded directly in the foam during manufacturing, then the occupant detection system can be integrated seamlessly, but the foam creep and preload issues reduce measurement precision
Solution Approach 1:
The sensor assembly is separated from the foam material by positioning it in a dedicated recess. This segmentation prevents foam from contacting the sensor pads, eliminating preload issues and maintaining measurement precision while keeping the manufacturing process simple and integrated.
Solution Approach 2:
The recess structure is prepared in advance during mold preparation, creating a pre-defined space that will house the sensor assembly. This preliminary action ensures that when the foam is injected, it cannot creep over the sensor pads, thereby preserving measurement accuracy from the outset.
3Reliability
If highly sensitive occupant detection systems are used, then vehicle safety functionalities can be optimized, but the complexity and cost of the detection system increases
Solution Approach 1:
By using a simple recess structure and basic sensor assembly that is resistant to foam creep, the system achieves reliable detection without requiring complex, expensive sensors. The straightforward mechanical design allows for the use of more economical sensor technologies while maintaining adequate detection capability for safety functions.
Data Source
AI summary
A vehicle seat with an embedded occupancy detector system and manufacturing method for same, and an occupant protection system including an occupancy detector system embedded in a vehicle seat as described herein. Examples include a molded vehicle seat with one or more inserts including an occupant detection system with one or more sensor pads. A gap housing one or more sensor pads of an occupant detection system may be provided between a surface of an insert and a recessed surface of the molded vehicle seat.