Seatback Foam Cord Structure for Rigidity Without Steel Wires

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional vehicle seating assemblies rely on rigid steel wires for support, which add weight, cost, and discomfort due to hard spots, while lacking structural rigidity and passenger comfort.

Innovation Solution

A semi-rigid foam cord is integrated into the foam cushion assembly, forming a continuous loop that circumscribes the seatback, providing structural rigidity and comfort by eliminating the need for steel wires, constructed from polymeric materials like polyurethane foam with embedded shape memory polymer fibers for enhanced support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid steel wires are used for seatback support, then structural rigidity is improved, but weight increases and passenger comfort deteriorates due to hard spots

Engineering Contradiction:

Improvestructural rigidityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the physical parameters of the support structure by transitioning from rigid steel wires to a semi-rigid foam cord with varying density. The foam cord has a density gradient (higher density at outer periphery, lower density toward center) that provides structural support while reducing weight and eliminating hard spots that cause discomfort.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining foam material with embedded shape memory polymer fibers or other reinforcement elements within the foam cord. This composite structure provides the necessary structural rigidity comparable to steel wires while maintaining the weight and comfort advantages of foam material.

Inventive Principle:

Principle #40Composite materials

2Strength

If rigid steel wires are used for seatback support, then structural rigidity is improved, but passenger comfort deteriorates due to abrupt rigidity and hard spots

Engineering Contradiction:

Improvestructural rigidityVSAvoidpassenger comfort

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the rigidity parameter from abrupt and uniform (steel wires) to gradual and variable (semi-rigid foam cord with density gradient). The foam cord's semi-rigid nature provides structural support while its flexibility and density variation eliminate hard spots, providing a softened feel that improves passenger comfort.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a flexible foam cord structure that can deform and conform to passenger contact rather than maintaining rigid fixed geometry like steel wires. This flexibility allows the support structure to adapt to passenger body contours, eliminating hard spots and improving comfort while maintaining necessary structural integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If steel wires are used for seatback support, then structural support is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural supportVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the support function with the foam cushion assembly by integrating the foam cord directly into the foam structure during manufacturing. This eliminates the need for separate steel wire installation steps and reduces assembly complexity, while the foam cord itself serves both structural support and comfort functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces expensive steel wires with a cost-effective foam cord material that can be manufactured more economically. The foam cord provides sufficient structural support for the application while being cheaper to produce and install, reducing overall manufacturing cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 foam cord enhances structural integrity and comfort by distributing weight evenly, eliminating abrupt rigidity and reducing the weight and cost associated with steel wires, while maintaining the seat's structural support without seams or welds.

Implementation Method 1

constructed from polymeric materials like polyurethane foam with embedded shape memory polymer fibers for enhanced support

Methodology Applied

Scientific EffectShape memory polymer: Shape Memory Polymer

Data Source

PatentUS9637034B2Foam cord for seating foam stability and rigidity

Publication Date: 2017.05.02 FORD GLOBAL TECH LLC

AI summary

A vehicle seating assembly includes a seatback having a frame that provides structural integrity to the seatback and operably couples the seatback to a vehicle floor. A carrier is operably coupled to the frame. A foam cushion assembly is operably coupled to the carrier. The foam cushion assembly includes an upper portion, a lower portion, a first side bolster, and a second side bolster. A continuous semi-rigid foam cord is formed in the foam cushion assembly. The foam cord extends through a forward periphery of the upper portion, the lower portion, the first side bolster, and the second side bolster. The foam cord is configured to add structural rigidity to the seatback.