Seat support layer assembly
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Solution Overview
Problem
Existing vehicle seat assemblies lack a robust and lightweight structural support system that can integrate components like air pumps and air bladders for lumbar support without the need for fasteners, while also minimizing noise, vibration, and weight.
Innovation Solution
A vehicle seat assembly featuring a rigid expanded polypropylene (EPP) support layer with cavities and channels for component integration, where components like air pumps and air bladders are mounted without fasteners, and secured by a trim material that covers the cushion layer, providing structural support and reducing noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rigid support layer with cavities is used to integrate components, then component integration and structural support are improved, but manufacturing complexity increases
Solution Approach 1:
The support layer merges structural support and component integration functions into a single element. The cavities are molded directly into the support layer structure, combining the support function with the component mounting function, thereby reducing the number of separate parts and assembly steps despite the increased structural complexity.
Solution Approach 2:
The support layer serves multiple functions simultaneously: it provides structural support, integrates components through molded-in cavities, and acts as a mounting surface. This multi-functionality reduces the need for separate fastening systems and mounting structures, offsetting the manufacturing complexity with functional consolidation.
2Ease of operation
If components are retained in cavities without fasteners, then assembly simplicity and weight reduction are improved, but component retention reliability may worsen
Solution Approach 1:
The cavities are formed with elastic material that can deform to accommodate components during assembly and then return to its original shape to retain the components. This elastic deformation mechanism provides reliable retention without requiring fasteners, maintaining both assembly simplicity and component retention reliability.
Solution Approach 2:
The support layer's elastic material serves its own retention function through its inherent elasticity. The material deforms during assembly to allow component insertion and then automatically returns to its original shape to secure the components, eliminating the need for separate fastening mechanisms while ensuring reliable retention.
3Weight of moving object
If expanded polypropylene material is used for the support layer, then weight reduction is improved, but structural strength may worsen
Solution Approach 1:
The support layer uses expanded polypropylene, which is a composite material structure consisting of polymer matrix with dispersed air pockets. This composite structure provides high strength-to-weight ratio, delivering the necessary structural support while significantly reducing the weight compared to solid materials.
Solution Approach 2:
The expanded polypropylene material has a porous cellular structure that provides both weight reduction and structural strength. The cellular structure distributes loads effectively throughout the material, maintaining structural integrity while minimizing weight, making it suitable for automotive seat applications where weight reduction is critical.
Data Source
AI summary
A seat back assembly and method of manufacture is provided. The seat back includes a foam cushion layer. A support sub-assembly is formed including a rigid support layer with a plurality of cavities and channels defined on a rear surface for receiving components and a generally smooth front surface. At least one component is retained in one of the cavities and a second component is secured on the front surface of the support layer. A trim material covers the cushion layer and secures the sub-assembly to the seat back.