Vehicle Seat Load Sensor Mounting Structure to Prevent Wire Disconnection
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Solution Overview
Problem
Conventional load detection devices in vehicle seats face wire disconnection issues due to deformation of recessed grooves and conducting portions under seating loads, leading to stress and friction-induced disconnections.
Innovation Solution
A load detection device mounting structure with a bent conducting portion inserted into a recessed groove, featuring sliding portions and a penetrating bore that allows the bent portion to move freely, reducing reaction forces and preventing deformation, and a design where the penetrating bore is wider than the gap between sliding portions to minimize friction and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the conducting portion is fixed to cross over the recessed groove, then the structure is stable, but the wire may disconnect due to deformation under load
Solution Approach 1:
The conducting portion is designed to be movable within the recessed groove rather than fixed, allowing it to dynamically adapt to pad member deformation. The conducting portion can slide along the groove walls and move vertically within the groove, maintaining electrical connection stability while accommodating changes in seat cushion shape under various loading conditions.
2Reliability
If the conducting portion is loosely provided around the recessed groove, then wire disconnection is prevented, but the conducting portion may be sharply bent at the groove entrance
Solution Approach 1:
The recessed groove is designed with a curved bottom portion that acts as a cushioning zone. When the conducting portion moves downward with the pad member deformation, the curved bottom provides a gradual transition zone that prevents sharp bending. This beforehand cushioning design ensures that even when the conducting portion is loosely positioned, it experiences reduced stress concentration and prevents wire disconnection while maintaining structural integrity.
3Manufacturing precision
If the bent portion is fixed in the recessed groove, then positioning is precise, but friction and reaction forces cause deformation and disconnection
Solution Approach 1:
The bent portion of the conducting portion is designed to move dynamically within the recessed groove rather than being fixed. It can slide along the groove walls and adjust its position vertically, maintaining electrical connection while accommodating pad member deformation. This dynamic design eliminates excessive friction and reaction forces that would otherwise cause deformation and disconnection, while still providing sufficient positioning precision through the groove constraints.
4Device complexity
If the penetrating bore is narrow, then the structure is compact, but friction between the bent portion and bore walls increases
Solution Approach 1:
The recessed groove is designed with non-uniform cross-sectional dimensions, being narrower at the top and wider at the bottom where the penetrating bore is located. This local quality variation allows the groove to provide sufficient constraint and positioning precision at the entrance, while the wider bottom portion reduces friction and reaction forces where the bent portion moves, preventing deformation and disconnection while maintaining overall structural compactness.
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 prevents wire disconnection and damage by reducing bending deformation and frictional stress, ensuring reliable operation under varying seating loads, while also simplifying manufacturing and reducing costs.
Implementation Method 1
the bent portion is freely movable within the recessed groove in an upper/lower direction by a sliding movement between the bent portion and the sliding portions when the pad member is compressed to deform downward
Data Source
AI summary
The load detection device mounting structure for preventing a wire disconnection is structured with a film shaped load detection device having a detecting portions brought into contact with a seating-side outer surface of the pad member, an external output portion and conducting portions conducting between two of the detecting portions and between the detecting portions and the external output portion. The film shaped load detection device is mounted to the vehicle seat bey inserting a bent portion formed by the conducting portion being bent into the recesses groove between a seating-side outer surface of the pad member having a recessed groove and a surface skin member in a manner of crossing over the recessed groove. Sliding portions are provided at inner side surfaces of the groove, which back surfaces of the bent portion is brought into slideable contact with, and a penetrating bore is formed from the recessed groove at the inserting portion of the pad member for inserting the bent portion. Accordingly, the bent portion is freely movable within the penetrating bore in an upper/lower direction by a sliding movement between the bent portion and the sliding portions when the pad member is compressed to deform by the seating load.