Seat Panel Structure With Integrated Airflow and Reduced Foam Bulk
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Solution Overview
Problem
Conventional vehicle seats are bulky, heavy, and costly due to excessive foam material and complex ventilation systems, which consume valuable space and increase manufacturing complexity.
Innovation Solution
A seat panel design featuring a one-piece, unitary structure with integrated air flow channels and a flexible thermoplastic elastomer material that reduces thickness, weight, and cost while maintaining comfort through a combination of recessed seat cover grooves and air permeable cushioning, eliminating the need for thick cushioning materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excessive foam material is used to provide cushioning and comfort, then comfort level is improved, but weight and volume increase
Solution Approach 1:
The patent employs a foam material with controlled porosity and cell structure to provide cushioning and comfort while reducing density. The foam's cellular structure allows it to maintain comfort properties with less material, directly addressing the contradiction between comfort and weight.
Solution Approach 2:
The seat assembly uses a composite construction combining foam material with a fabric cover and structural components. This composite approach allows optimization of each layer's function, providing comfort through the foam while using lighter materials for the cover and frame, reducing overall weight.
2Reliability
If excessive foam material is used to provide cushioning and comfort, then comfort level is improved, but volume and space consumption increase
Solution Approach 1:
The foam material's porous structure provides high comfort performance per unit volume. The cellular structure delivers cushioning and support while occupying less space compared to solid materials, resolving the contradiction between comfort and volume.
Solution Approach 2:
The patent modifies the foam material parameters including density, thickness, and cell structure to achieve optimal comfort with reduced volume. By changing these parameters, the seat provides desired comfort levels while minimizing space consumption in the vehicle cabin.
3Adaptability or versatility
If separate ductwork and blowers are added for ventilation, then ventilation function is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The ventilation system merges the blower motor and ductwork into an integrated assembly that combines with the seat structure. This consolidation reduces the number of separate components, simplifying the overall system while maintaining ventilation functionality.
Solution Approach 2:
The ventilation system is designed to serve multiple functions: providing airflow to the occupant, integrating with the seat structure for support, and incorporating the blower motor within the same assembly. This multi-functionality reduces the need for separate dedicated components.
4Adaptability or versatility
If separate ductwork and blowers are added for ventilation, then ventilation function is improved, but weight increases
Solution Approach 1:
By merging the blower motor, ductwork, and seat structure into a single integrated assembly, the patent eliminates redundant structural elements and fasteners that would add weight. The combined design allows shared components and optimized material usage.
Solution Approach 2:
The ventilation ducts utilize thin-walled structures and flexible materials that provide adequate airflow channels with minimal material mass, reducing the weight contribution of the ventilation system while maintaining its functional integrity.
Data Source
AI summary
A panel for a seat may have a retention portion with a recessed seat cover groove. The groove may have at least one tooth adapted to selectively retain a seat cover in the groove. The panel may also have a plurality of recessed air flow channels. The panel may also have a rear bolster. The rear bolster may have a leading wall, a connecting wall and a trailing wall. The leading wall may have a first clamp portion and the trailing wall may have a second clamp portion. The clamp portions may be adapted to selectively receive a frame connection member. A seat having a seat base panel and a seat back panel may have seat cover grooves and air flow channels.