Vehicle Seat Trim and Foam Assembly with Composite Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle seating assemblies face challenges in achieving a lightweight, rigid, and comfortable design while minimizing manufacturing complexity and costs, particularly in providing effective support and comfort to passengers with minimal parts.
Innovation Solution
A modular vehicle seating assembly design featuring a composite support member encompassed by a cushion assembly with snap-fit features and retaining rings, which is securely engaged with an inner close-out panel and seat frame, along with an upper trim piece extending over the seat frame, back panel, and inner close-out panel, reducing the need for additional fasteners and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional vehicle seating assembly uses multiple separate components (support members, cushion assemblies, fasteners), then the structural strength and support capability are improved, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent combines the support member and cushion assembly into a single integrated composite support member. The foam cushion is molded directly onto the support structure, eliminating the need for separate fasteners and reducing assembly complexity while maintaining structural strength through the unified design.
Solution Approach 2:
The composite support member serves multiple functions simultaneously: it provides structural support, cushioning comfort, and acts as an integrated attachment mechanism. The snap-fit features are built into the composite structure itself, eliminating the need for separate fastening components.
2Reliability
If additional fasteners and separate components are used to secure the cushion assembly, then the reliability of attachment is improved, but the manufacturing complexity and part quantity increase
Solution Approach 1:
The attachment mechanism is merged into the composite support member itself. The snap-fit features are molded as integral parts of the foam-cushion composite structure, providing reliable attachment without requiring separate fasteners or complex assembly procedures.
3Strength
If a robust seating assembly is designed with multiple components for support and comfort, then the passenger support capability is improved, but the weight and manufacturing costs increase
Solution Approach 1:
By merging the support structure and cushioning into a single composite component, the patent eliminates the weight of separate fasteners, adhesives, and additional structural elements. The integrated design provides robust passenger support through the foam-cushion composite itself without the added weight of multiple components.
Data Source
AI summary
A vehicle seating assembly includes a seat frame disposed between an integrally formed back panel and an inner close-out panel. A cushion assembly is operably coupled to the inner close-out panel. A composite support member is substantially encompassed by the cushion assembly. The composite support member includes attachment members projecting rearwardly from inside the cushion assembly that engage with the inner close-out panel. The attachment members include snap-fit features disposed at a lower portion of the composite support member. Retaining rings are disposed at an upper portion of the composite support member. An upper trim piece extends over a top portion of the seat frame, the back panel, and the inner close-out panel.