Natural Fiber Polypropylene Seat Structure for Lightweight Assembly
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Solution Overview
Problem
Manufacturing vehicle seat components is energy intensive and time consuming due to the need for multiple steps and the use of heavier-than-necessary traditional materials that are labor intensive to work with.
Innovation Solution
A seat component assembly utilizing a structural body made of natural fiber polypropylene material, combined with additional components such as a foam layer and cover material, and ribbed structures to provide a lightweight, rigid, and cost-effective seat back or seat cushion, using compression molding and cover carving technology to reduce weight and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional materials and multiple manufacturing steps are used, then structural support and durability are achieved, but weight increases and manufacturing becomes energy intensive and time consuming
Solution Approach 1:
The patent combines multiple manufacturing steps into a single compression molding process. The structural body, foam layer, and cover material are molded simultaneously in one operation, eliminating the need for separate assembly steps. This merging of processes reduces manufacturing time and energy consumption while producing a lightweight seat component with integrated structural support.
Solution Approach 2:
The patent uses composite materials consisting of a structural body made from lightweight material, a foam layer for cushioning, and a cover material with perimeter portions. This composite structure achieves the required structural support and durability while significantly reducing weight compared to traditional solid materials.
2Strength
If traditional materials are used for structural support, then strength and rigidity are achieved, but weight increases and labor intensity increases
Solution Approach 1:
The patent applies local quality by providing structural support only where needed through the structural body's optimized geometry and the ribbed structure on the second surface. Rather than using heavy solid materials throughout, the design concentrates structural elements in specific locations to achieve required strength and rigidity while minimizing overall weight.
Solution Approach 2:
The patent employs thin film structures including the cover material that wraps around the perimeter portions and the foam layer bonded to the structural body. These thin structures provide necessary structural support and cushioning functions while contributing minimal weight to the overall assembly.
3Manufacturing precision
If multiple manufacturing steps are used, then assembly precision is achieved, but manufacturing time increases and complexity increases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single compression molding operation. The structural body, foam layer, and cover material are formed and assembled simultaneously in one process step, eliminating the need for multiple separate operations and reducing manufacturing time while maintaining assembly precision through integrated molding.
Solution Approach 2:
The patent incorporates preliminary action by pre-forming the structural body with integrated attachment features and perimeter structures during the initial compression molding process. This preliminary preparation of structural elements with built-in attachment capabilities eliminates the need for subsequent assembly operations, reducing manufacturing time while ensuring precise alignment.
Data Source
AI summary
A seat component assembly includes a structural body comprised of a natural fiber polypropylene material and an additional seat component attached to the structural body to provide a seat back or a seat cushion. A method of forming a seat component assembly includes forming a structural body comprised of a natural fiber polypropylene material and attaching an additional seat component to the structural body to provide a seat back or a seat cushion.