Integrated Seat Suspension Membrane for Simpler Electrical Assembly
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Solution Overview
Problem
The assembly of vehicle seat support elements with suspension membranes and integrated electrical components is complex, requiring separate assembly of multiple components and is not suitable for all components, especially when overmolding is used.
Innovation Solution
A single-piece suspension membrane made of joined plastic layers with integrated electrical circuits and mounting elements, allowing for simplified assembly and integration of electrical components directly onto the armature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a suspension membrane is formed by assembling independent metal rods and electrical components separately, then the mechanical structure is stable, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent merges the suspension membrane structure with electrical components by integrating heating elements, sensors, and other electrical components directly into the membrane layers. This combines multiple previously separate assembly steps into a single integrated component, reducing assembly complexity while maintaining structural stability
Solution Approach 2:
The patent uses composite material structures where electrical components are embedded within or between the plastic layers of the suspension membrane. This creates a unified composite structure that provides both mechanical support and electrical functionality simultaneously, eliminating the need for separate assembly of metal rods and electrical components
2Ease of manufacture
If multiple independent components are assembled separately in the support element, then each component can be optimized independently, but the overall assembly time and manufacturing complexity increase
Solution Approach 1:
By integrating electrical components directly into the suspension membrane layers during the membrane manufacturing process, the patent enables simultaneous production of both structural and functional elements. This eliminates sequential assembly steps and improves manufacturing productivity while maintaining the ability to optimize individual components during the design phase
3Ease of operation
If the suspension membrane is assembled on the reinforcement independently of other support element components, then the membrane installation is simplified, but the overall support element assembly remains complex
Solution Approach 1:
The patent integrates the suspension membrane assembly with the armature and padding assembly into a single unified process. The membrane with integrated electrical components is installed as part of the overall support element assembly rather than as a separate step, reducing the total number of assembly operations while maintaining ease of membrane installation through its flexible nature
Data Source
AI summary
A suspension membrane of a vehicle seat support element includes a fabric made of plastic material extending between a first face and a second face and having at least a first layer made of plastic material that has an outer face forming the first face and an inner face opposite the outer face, and a second layer made of plastic material that has an outer face forming the second face and an inner face opposite the outer face, the inner faces of the first layer and of the second layer being applied against one another. The suspension membrane further includes at least one electrical circuit having at least one electrical component and a power lead to the component, extending between a part of the inner faces of the first layer and of the second layer.