Variable-Sized Vehicle Seat Pad with Nested Extension to Prevent Gaps

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing occupant support systems in vehicles lack the ability to adjust dimensions comfortably and aesthetically without creating gaps or accumulating dirt, compromising both user experience and maintenance.

Innovation Solution

An occupant-support base with a pad-extension system that includes a movable pad support, a pan mount, and a pad-support mover, such as an inflatable bladder or electric motor, allowing the pad to change size between retracted and expanded configurations without gaps, and a cushion-cover extender using slip belts to maintain aesthetics and prevent dirt accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the pad is made extendable to adjust size for comfort, then adaptability is improved, but gaps may form during movement compromising aesthetics and causing dirt accumulation

Engineering Contradiction:

Improvepad size adjustmentVSAvoidgap formation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The movable pad support is received within the seat pan structure, and the cushion cover extends over both the seat pan and movable pad support to create a continuous surface. The nested arrangement ensures that when the pad extends or retracts, the cushion cover maintains an uninterrupted appearance without gaps, while the movable support operates smoothly within the seat pan boundaries.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The cushion cover functions as a flexible film that drapes over the seat pan and movable pad support. This flexible covering conceals the mechanical movement components and maintains a continuous aesthetic surface throughout the pad's range of motion, preventing visible gaps and protecting underlying mechanisms from dirt accumulation.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If the pad is made extendable to vary size, then comfort is improved, but device complexity increases due to additional moving components

Engineering Contradiction:

Improvepad dimension adjustmentVSAvoidpad-extension system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

An inflatable bladder positioned between the movable pad support and pan mount provides the driving force for extension and retraction. This pneumatic actuator simplifies the mechanism by replacing complex mechanical linkages with a single inflatable element that can be controlled through air pressure, reducing the number of moving parts while maintaining adjustability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent replaces traditional mechanical actuation systems (motors, linkages, gears) with an inflatable bladder system. This substitution reduces mechanical complexity by eliminating multiple moving components, bearings, and control mechanisms, while achieving the same pad adjustment function through pneumatic pressure control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If the cushion cover size is varied during pad extension, then aesthetics are maintained without gaps, but device complexity increases

Engineering Contradiction:

Improveaesthetic continuityVSAvoidcushion-cover extender

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cushion cover is designed as an extensible flexible film that can stretch and drape over the movable pad support. This flexible covering automatically adjusts its effective size as the pad extends or retracts, maintaining a continuous aesthetic surface without requiring active control mechanisms, thereby achieving aesthetic continuity with minimal added complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The cushion cover is designed with dynamic extensibility, allowing it to stretch and conform as the movable pad support changes position. This dynamic adaptation enables the cover to maintain a gapless appearance throughout the full range of motion, automatically adjusting its configuration as the pad extends or retracts without requiring additional actuation mechanisms.

Inventive Principle:

Principle #15Dynamics

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 system provides adjustable comfort and aesthetics by varying the pad's size and shape without gaps, ensuring cleanliness and user satisfaction, while maintaining an uninterrupted surface.

Implementation Method 1

The pad-support mover is an inflatable bladder arranged between the movable pad support and the pan mount. The inflatable bladder pushes the movable leg support away from the pan mount when inflated

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Implementation Method 2

Return springs are provided in the illustrative embodiment to pull the movable pad support back toward the pan mount when the inflatable bladder is deflated

Methodology Applied

Scientific EffectSpring force: Spring

Data Source

PatentUS9809132B2Variable-sized occupant support

Publication Date: 2017.11.07 FAURECIA AUTOMOTIVE SEATING LLC

AI summary

A pad is adapted to set on a seat pan included in a vehicle seat. The pad includes a cushion on the seat pan and a cushion cover on the cushion.