Segmented Car Seat Cushion Pad for Thin Battery-Pack Seats

Solution Overview

Problem

Conventional cushion pads for car seats become uncomfortable when reduced in thickness to accommodate battery packs in hybrid electric vehicles, as they compromise on support and comfort.

Innovation Solution

A cushion pad design featuring a divided structure with soft resin foam and an elastic three-dimensional network, including a central portion and side elastic portions with varying elastic moduli, providing firm support and comfort without hardness, even at reduced thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the cushion pad thickness is reduced to accommodate battery packs, then the space for mounting the battery pack is secured, but the support function and comfort are degraded

Engineering Contradiction:

Improvespace for battery packVSAvoidsupport function

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The cushion pad is divided into multiple regions with different foam densities: a first region with lower density foam for comfort, and a second region with higher density foam for support. This segmentation allows the thin cushion pad to provide both comfort and support functions simultaneously without compromising reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cushion pad are assigned different material properties - the first region uses soft foam for comfort while the second region uses hard foam for support. This local differentiation of material quality enables the thin cushion pad to fulfill multiple functional requirements in different areas.

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If the cushion pad thickness is reduced to accommodate battery packs, then the space for mounting the battery pack is secured, but the comfort is sacrificed

Engineering Contradiction:

Improvespace for battery packVSAvoidcomfort

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The cushion pad is divided into multiple regions with different foam densities: a first region with lower density foam for comfort, and a second region with higher density foam for support. This segmentation allows the thin cushion pad to provide both comfort and support functions simultaneously without compromising reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cushion pad are assigned different material properties - the first region uses soft foam for comfort while the second region uses hard foam for support. This local differentiation of material quality enables the thin cushion pad to fulfill multiple functional requirements in different areas.

Inventive Principle:

Principle #3Local quality

3Length of stationary object

If a thinner cushion pad is used, then the overall height of the seat assembly is reduced, but the cushioning effect is weakened

Engineering Contradiction:

Improveoverall height of seat assemblyVSAvoidcushioning effect

Core Design Contradiction:

Length of stationary objectVSStrength

Solution Approach 1:

Different portions of the cushion pad are assigned different material properties - the first region uses soft foam for comfort while the second region uses hard foam for support. This local differentiation of material quality enables the thin cushion pad to fulfill multiple functional requirements in different areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cushion pad combines two different foam materials with different densities and mechanical properties into a single composite structure. The soft foam provides cushioning while the hard foam provides support, creating a composite material system that achieves both comfort and structural integrity in a thin profile.

Inventive Principle:

Principle #40Composite materials

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 cushion pad effectively supports seated individuals with a firm yet comfortable feel by distributing weight through the elastic network, maintaining comfort and support despite the thinner profile.

Implementation Method 1

the left pad section having a left holding volume for holding a first volume of an elastic three-dimensional network; and the right pad section having a right holding volume for holding a second volume of an elastic three-dimensional network

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9266455B2Cushion pad for car seat

Publication Date: 2016.02.23 TOYOBO MC CORP

AI summary

Embodiments of present invention may include a cushion pad for supporting a seated passenger; the cushion pad being divided into a left pad section, a middle pad section and a right pad section; a soft resin foam dispersed throughout the left pad section, the middle pad section and the right pad section; the left pad section having a left holding volume for holding a first volume of an elastic three-dimensional fibrous network and the soft resin foam; the right pad section having a right holding volume for holding a second volume of an elastic three-dimensional fibrous network and the soft resin foam; and the middle pad section not having a volume of an elastic three-dimensional fibrous network contained within.