Vehicle Seat Suspension Web With Embedded Circuit Layers
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Solution Overview
Problem
Existing vehicle seat support elements with integrated suspension systems and electrical components are complex to assemble, requiring separate assembly of components and are not suitable for all seat components, especially when overmolding is used.
Innovation Solution
A suspension web formed from layers of plastic material with integrated electrical circuits, allowing for a single-piece mounting on the frame and integration of electrical components, simplifying assembly by forming a flexible printed circuit board within the plastic layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent components (metal rods, electrical circuits, padding) are assembled separately, then each component can be optimized independently, but the overall assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple independent components (suspension web, electrical circuits, heating elements, vibration motors, and padding) into a single integrated assembly unit. The electrical circuits are embedded within the suspension web structure, and all components are pre-assembled together before being mounted to the frame as one piece, thereby simplifying the overall assembly process while maintaining component optimization
Solution Approach 2:
The suspension web assembly serves multiple functions simultaneously: mechanical suspension, electrical circuit routing, heating, vibration, and padding support. By designing a universal assembly that integrates all these functions into one unit, the patent reduces the number of separate assembly operations needed while maintaining the ability to optimize each functional component
2Adaptability or versatility
If traditional separate assembly of suspension system and support element is used, then each system can be designed independently, but the total assembly time and manufacturing complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the electrical circuits, heating elements, vibration motors, and padding onto the suspension web structure before final installation. This preliminary integration allows the components to be designed and tested independently while being prepared for rapid final assembly as a complete unit, thereby reducing total assembly time without sacrificing design independence
3Device complexity
If overmolding is used to simplify assembly, then certain components can be integrated, but the process remains complex and is not suitable for all seat components
Solution Approach 1:
The patent segments the integration approach by using a structured assembly method rather than universal overmolding. The suspension web, electrical circuits, and padding are integrated as a modular assembly unit that can be mounted to different frame configurations, providing a simplified process that is adaptable to various seat component types without the limitations of overmolding
Data Source
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AI summary
The suspension web (4) of a vehicle seat support element (1) includes a web (12) of plastic material extending between a first face and a second face and comprising at least a first layer of plastic material (16), comprising an outer face forming the first face and an inner face (20) opposite the outer face, and a second layer of plastic material (18) comprising an outer face forming the second face and an inner face opposite the outer face, the inner faces (20) of the first layer (16) and of the second layer (18) being applied against each other, at least one electrical circuit (22), comprising at least one electrical component (24) and a power supply track (26) of said component (24), extending between a portion of the inner faces (20) of the first layer (16) and of the second layer (18).