Suspension Mat Lumbar Plate Design to Reduce Cable Complexity
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Solution Overview
Problem
Existing suspension mats for vehicle seat backrests are complex to construct and do not provide optimal adjustment in the lumbar area for passenger comfort, often relying on Bowden cables that increase weight and assembly complexity.
Innovation Solution
A suspension mat design featuring a lumbar plate actuated by a wire cable, which distributes adjustment forces for comfortable cushioning, reduces construction complexity, and eliminates the need for Bowden cables, using a lightweight plastic material for the lumbar plate that is easily integrated with the mat element and attached via hooks, allowing for easy assembly and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If Bowden cables are used for actuating the suspension mat, then the actuator can be attached freely at the backrest frame, but the construction complexity and weight increase
Solution Approach 1:
The patent extracts and eliminates the Bowden cable from the system by directly connecting the actuator to the lumbar plate via a simple rod or link mechanism. This removes the complex cable sheath, guide conduits, and intermediate connection elements while preserving the actuator's ability to be freely positioned on the backrest frame.
Solution Approach 2:
The actuator mounting bracket is merged with the backrest frame structure, allowing the actuator to be directly mounted without requiring separate cable routing infrastructure. The lumbar plate connection points are integrated into the mat structure, eliminating the need for intermediate cable connection elements.
2Ease of operation
If Bowden cables with sheaths and guide conduits are used, then the cable can be guided from one side of the suspension mat to the opposite side, but the weight and construction complexity increase
Solution Approach 1:
The Bowden cable sheath and guide conduit are completely extracted from the system. Instead, a simple rigid rod or direct link connects the actuator to the lumbar plate, eliminating the weight of cable sheaths, lubricants, and guiding infrastructure while maintaining the ability to transmit actuation force across the mat.
3Adaptability or versatility
If manual or electric actuators with Bowden cables are used for lumbar region adjustment, then the effective length of adjustment cables can be changed, but the assembly complexity and costs increase
Solution Approach 1:
The complex Bowden cable assembly with sheaths, guides, and intermediate connections is extracted and replaced with a simple rod or link mechanism that connects the actuator directly to the lumbar plate. This maintains full adjustability of the lumbar region while dramatically simplifying assembly procedures and reducing manufacturing complexity.
Solution Approach 2:
The lumbar plate includes integrated connection points and mounting features that allow for tool-free or simplified assembly. The actuator mounting bracket is designed to be easily attached to the backrest frame, enabling quick installation and adjustment without complex assembly procedures.
4Device complexity
If a lumbar plate with wire cable is used instead of Bowden cable, then the construction complexity is reduced, but the force distribution capability must be ensured
Solution Approach 1:
The lumbar plate is segmented with multiple wire cable attachment points distributed across its surface. This segmentation allows the single wire cable to effectively distribute adjustment forces to multiple locations on the lumbar plate, ensuring uniform force distribution and preventing localized stress concentrations while maintaining simple construction.
Solution Approach 2:
The lumbar plate acts as an intermediary element between the wire cable and the suspension mat. It distributes the concentrated force from the wire cable attachment point across multiple attachment points to the mat structure, effectively transferring and distributing the adjustment force while keeping the overall construction simple.
Data Source
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AI summary
The present invention relates to a suspension mat 1 for a backrest of a vehicle seat, comprising a mat element 10, 100; a lumbar plate 30, 40, 80, 90 arranged at the lumbar area 31 of the mat element 10, 100, having a plate shape, and extending at least between both side ends 11 of the mat element 10 at the lumbar area 31, for distributing an adjustment force for the adjustment of the lumbar area 31 of the suspension mat 1; a wire cable 50 extending along and being attached to the lumbar plate 30, 40, 80, 90; and an actuator 70 for adjusting the effective length of the wire cable 50. The present invention further relates to a method for the assembly of a suspension mat 1.