Vehicle Seat Resilient Insert for Impact Protection
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Solution Overview
Problem
Existing vehicle seat structures lack an effective energy-absorbing safety feature that maintains appearance and provides adequate cushioning to prevent occupant impact with the rigid seat frame during sudden stops.
Innovation Solution
Incorporating a resilient insert made of injection molded expanded polypropylene within the occupant support, which is overmolded with polyurethane foam and positioned between the seat frame and the B-surface, to dissipate energy and maintain the seat's appearance by compressing more than the foam under impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cushioning or padding is added to the seat back portion to protect occupants during sudden stops, then occupant safety is improved, but the appearance and structural integrity of the seat may deteriorate
Solution Approach 1:
The resilient insert is nested within the occupant support structure, with the foam material overmolded around it. This nesting approach allows the safety feature to be integrated inside the existing seat structure, protecting occupants while maintaining the external appearance of the seat unchanged.
Solution Approach 2:
The resilient insert is positioned specifically at the B-surface area where impact protection is needed, rather than adding cushioning throughout the entire seat. This localized approach provides safety where required while preserving the overall seat appearance and structure.
2Strength
If a rigid structural frame is used for the seat back, then structural integrity is improved, but occupant protection during impact is worsened
Solution Approach 1:
The resilient insert acts as an intermediary element positioned between the rigid seat frame and the occupant support surface. During impact, this intermediary absorbs and dissipates energy, protecting occupants from the rigid frame while the frame itself maintains its structural integrity.
Solution Approach 2:
The seat back portion combines the rigid structural frame with the resilient insert made of expanded polypropylene. This composite structure leverages the strength of the rigid frame for structural integrity while utilizing the energy-absorbing properties of the resilient material for occupant protection.
3Ease of operation
If traditional cushioning materials are used throughout the seat back, then occupant comfort is improved, but energy absorption during impact is worsened
Solution Approach 1:
The resilient insert with superior energy absorption properties is localized at the B-surface area where impact occurs, while the rest of the occupant support maintains the original foam cushioning for comfort. This differentiated approach optimizes both comfort and safety performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively absorbs energy during impacts, protecting occupants from the seat frame while maintaining the seat's appearance and structural integrity.
Implementation Method 1
the insert is made from a softer material than the foam that the occupant support is made from such that when the occupant support is compressed between the back panel and the frame, the insert is compressed more than the foam
Data Source
AI summary
A back portion of a seat includes a frame and an occupant support that is supported on the frame. The occupant support defines an A-surface and a B-surface located on an opposed side of the frame from the A-surface. An insert is located in the occupant support between the frame and the B-surface. The insert includes a frame cradle, and the frame has an upper end that is located in the frame cradle.