Upholstery Occupancy Sensor Mat Anchor Tab Integration
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Solution Overview
Problem
Film-type occupancy sensor mats in upholstery items face issues such as chemical aggression from oil films, loss of flexibility over time, deformation, and interference with trim cover attachment, leading to deterioration and damage, especially when crossing crimp channels.
Innovation Solution
The upholstery item features a padding with openings for anchor tabs from the sensor mat, secured by retention elements, reducing the need for long connection tails to cross crimp channels and enhancing stability through lateral protrusions and insulating plastic blocks, allowing for secure attachment and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fixation methods (double-sided tape or Velcro) are used to attach the sensor mat to the padding, then the sensor mat can be easily installed, but the fixation may disengage due to oil film on the padding, causing the sensor mat to move
Solution Approach 1:
The sensor mat is divided into multiple segments or zones with different attachment mechanisms. Some areas use adhesive fixation while others use mechanical anchoring through the padding, allowing each region to be optimized for its specific function and resistance to disengagement
Solution Approach 2:
Holes or cavities are pre-formed in the padding before the sensor mat is installed. This preliminary action ensures that the mechanical anchoring points are ready to receive the sensor mat tabs, preventing any movement or misalignment during installation and ensuring reliable long-term fixation
2Reliability
If barbed members or tabs are forced into cavities in the foam to secure the sensor mat, then the sensor mat is firmly attached, but the tabs are strongly deformed or compressed and may break under repeated loading
Solution Approach 1:
The geometric parameters of the tabs and cavities are optimized to reduce stress concentration. The tabs are designed with gradual transitions and appropriate thickness variations that allow them to flex within safe limits under repeated loading, preventing fatigue failure while maintaining strong attachment
Solution Approach 2:
The cavity design incorporates cushioning features such as rounded corners, tapered walls, and appropriate depth that absorb and distribute the mechanical stress from tab insertion and subsequent loading. This preliminary cushioning design prevents excessive deformation and protects the tabs from breaking under repeated use
3Adaptability or versatility
If the sensor mat is designed with long connection tails to connect to electronic control units, then the sensor mat can be positioned flexibly, but the tails may cross crimp channels and suffer from repeated buckling and deterioration
Solution Approach 1:
The connection tails are extracted from the main sensor mat body and routed through dedicated pathways or channels in the padding that avoid crimp channels. This separation allows the sensor mat to be positioned flexibly while protecting the connection tails from buckling and deterioration by keeping them in stable, protected routes
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
This solution effectively reduces the risk of sensor mat deterioration, maintains flexibility, and simplifies integration with trim covers, enabling cost-effective and durable occupancy sensing without compromising the appearance or functionality of the upholstery item.
Implementation Method 1
the anchor tab is inserted into the opening and secured against slipping out of the opening in direction of the front side by a retention element of the padding
Implementation Method 2
An occupancy sensor mat with sensor elements responsive to pressure is disclosed
Data Source
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AI summary
An upholstery item (12) with an occupiable surface for supporting an occupant comprises a padding having a front side turned towards the occupiable surface, a back side turned away from the occupiable surface and an opening extending therein from the front side to the back side. A film-type occupancy sensor mat (24) arranged on the front side of the padding is equipped with an anchor tab (34,42) comprising a proximal portion integrally formed with the sensor mat (24) and a distal portion. The anchor tab (34,42) is inserted into the opening and secured against slipping out of the opening in direction of the front side by a retention element of the padding, provided at the opening. The anchor tab (34,42) is configured as an electric-connection portion of the sensor mat (24) adapted for connecting the sensor mat (24) to an electronic control unit.