Vehicle Seat Polymer Layer for Integrated Wiring and Component Mounting
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Solution Overview
Problem
The increasing complexity of vehicle seat assemblies with electronic components poses challenges in efficiently attaching and organizing electrical components and their wire assemblies, leading to cumbersome logistics and space utilization issues under the seat.
Innovation Solution
Incorporating expanded polymer layers with defined cavities and channels to securely house and route electrical components, such as wire assemblies and motors, within the seat assembly, using negative draft angles, snap fits, and varying densities to simplify attachment and organization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are attached to the undercarriage using mechanical fasteners, then the components can be securely fixed, but the attachment process becomes cumbersome and time-consuming
Solution Approach 1:
The patent combines the mounting structure and electrical component housing into a single integrated polymer layer. The polymer layer simultaneously provides structural support, component mounting, and wire routing functions, eliminating the need for separate mechanical fasteners and reducing assembly steps.
Solution Approach 2:
The polymer layer is pre-formed with integrated cavities, channels, and mounting features during the molding process. This preliminary preparation of mounting structures eliminates the need for post-assembly fastening operations, significantly reducing attachment time while maintaining secure component fixation.
2Adaptability or versatility
If multiple electrical components are added to increase seat functionality, then the seat capabilities improve, but the space utilization under the seat becomes inefficient
Solution Approach 1:
The patent implements a nested arrangement where wire assemblies are routed through channels within the polymer layer, and electrical components are positioned in cavities that are integrated into the same polymer structure. This nesting approach maximizes space utilization by utilizing the three-dimensional space efficiently without requiring additional external mounting structures.
Solution Approach 2:
The polymer layer is designed as a three-dimensional structure with cavities and channels that utilize vertical and lateral spaces within the undercarriage volume. This dimensional approach allows multiple components to be arranged in space-efficient configurations, accommodating increased functionality without proportionally increasing the occupied volume.
3Ease of manufacture
If electrical components are loosely arranged under the seat, then assembly is simple, but the appearance becomes untidy and components are vulnerable to damage
Solution Approach 1:
The polymer layer acts as a flexible yet protective shell that encloses and organizes electrical components and wire assemblies. This shell structure provides physical protection against vibration and abrasion while maintaining an integrated, tidy appearance. The polymer material's inherent flexibility allows for easy assembly while the formed structure provides necessary protection.
Data Source
AI summary
A vehicle seat assembly has a seat bottom that is adapted for attachment to a vehicle. The seat bottom has a foam layer and an expanded polymer layer that defines a first cavity. The first cavity is configured to receive an electrical component.