Vehicle Seat Support Structure to Prevent Occupant Submarining
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Solution Overview
Problem
Conventional vehicle seat support elements suffer from limited adhesion between dissimilar materials, leading to reduced strength and increased cost, which can result in the 'submarining' phenomenon during impacts, where the seat occupant slides under the lap belt due to the pelvis sinking into the support element.
Innovation Solution
A support element design featuring a flexible supporting element and a rigid reinforcing element with a high-affinity reinforcing ply, made from thermoformable materials, such as polyurethane foam, that improves adhesion and provides additional reinforcement to prevent rupture during impacts, thereby preventing submarining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dissimilar materials (polyurethane and expanded polypropylene) are used for the flexible supporting element and rigid reinforcing element, then the adhesion between these elements is limited, but the cost of the support element increases and strength is reduced
Solution Approach 1:
The patent applies homogeneity by using the same material (polyurethane foam) for both the flexible supporting element and the rigid reinforcing element. This eliminates the adhesion problems between dissimilar materials while maintaining the functional differences through material density and structural design rather than material composition.
Solution Approach 2:
The patent creates a composite structure where the rigid reinforcing element is formed by a dense polyurethane foam and the flexible supporting element is formed by a less dense polyurethane foam. This composite approach using the same base material allows for both structural rigidity and flexibility while ensuring good adhesion between the elements.
2Reliability
If a rigid reinforcing element is used to prevent submarining, then the effectiveness of the seat belt is improved, but the cost of the support element increases
Solution Approach 1:
The patent changes the density parameter of the polyurethane foam to create different functional zones. The rigid reinforcing element uses dense polyurethane foam with high load-bearing capacity, while the flexible supporting element uses less dense foam for comfort. This parameter change allows cost-effective prevention of submarining without requiring expensive dissimilar materials.
3Object-affected harmful factors
If the pelvis sinks into the support element during impact, then the phenomenon of submarining occurs, but the use of a rigid reinforcing element with dissimilar materials increases manufacturing complexity
Solution Approach 1:
By using the same polyurethane foam material for both the rigid reinforcing element and flexible supporting element, the patent simplifies manufacturing processes such as molding and assembly. The homogeneous material composition eliminates the need for complex joining techniques between dissimilar materials while still providing the necessary structural reinforcement to prevent submarining.
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 enhanced adhesion and reinforcement of the support element effectively prevent submarining by maintaining structural cohesion during impacts, ensuring the seat belt's effectiveness and reducing manufacturing costs.
Implementation Method 1
the reinforcing ply is formed by a thermoformable material
Data Source
AI summary
A support element of a vehicle seat includes a body formed by a flexible supporting element and a rigid reinforcing element, with the flexible supporting element defining a cavity extending into a part of the body, the rigid reinforcing element extending into the cavity and being formed by a material that is stiffer than the flexible supporting element and having an affinity with the flexible supporting element. The body is further formed of at least one reinforcing ply extending against at least a part of the rigid reinforcing element.