09_Car Seat Design (Ver.1)

PEPM APD2505

Car Seat Design

Lecture delivered by: Prof. C. Gopinath

C.Gopinath MSRSAS

Professor Dept. of Design MSRSAS-Bangalore

M.S Ramaiah School of Advanced Studies - Bangalore

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Session Objectives

C.Gopinath MSRSAS

At the end of the module, the delegate would have understood • Seat system • Seat material • Manufacturing of seat cushion • Height adjustment of seat • Seat belt system • Smart airbag • Mounting the seat • Seat climate control system • Seat upholstery • Seat fabric M.S Ramaiah School of Advanced Studies - Bangalore

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Seat system

APD2505

C.Gopinath MSRSAS

• The standard car seat is designed to support thighs, the buttocks, lower and upper back, and head support. The front driver and passenger seats of most vehicles have three main parts: the seat back (squab), seat base (cushion), and the headrest • These components are usually constructed from foam to provide comfort to the rider. When choosing this product, foam manufacturers must consider the most suitable foam for balancing comfort, support, safety, and recycling properties • The cushioning agent is especially important when considering that moving cars can transmit vibrations near the human spine's resonant frequency of 3 Hz • The base can usually be moved forward and back on metal railings and may move up and down to adjust to different body types. This movement is accomplished either by manual latches or by electric levers • The base may also be equipped with a release lever to allow the squab to lean forward to permit access to back seats in two-door automobiles M.S Ramaiah School of Advanced Studies - Bangalore

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C.Gopinath MSRSAS

• The bottom of the squab is connected to the rear of the base and the release lever unlocks the squab from the upright position and allows for the afore-mentioned leaning • The standard base span is from the seated rear to just before the knees and the typical squab extends to the shoulders on the average height person • The head support is connected to the top of the squab by two metal circular tube shafts that are permanently attached to the head support and slide into two holes in the squab • Common available adjustments deal with concerns such as providing legroom, supplying back support, and giving head support. Available amenities include electric adjustments, choice in fabric covering, and temperature control. Important advancements in this area are of top concern to manufacturers, government officials and,Studies of course, M.S Ramaiah School of Advanced - Bangaloreconsumers. 4

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Driver seat

Seat belt Back seat

C.Gopinath MSRSAS

Center console

Front passenger seat M.S Ramaiah School of Advanced Studies - Bangalore

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Exploded view of seat

C.Gopinath MSRSAS

Back structure of seat Lumbar support pad M.S Ramaiah School of Advanced Studies - Bangalore

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This photograph shows the fairly conventional form of height adjustment mechanism. It was primarily due to fitting in sports cars that adjustments were taken out only at the front of the seat but the unconventional position of the rake adjustment was found to be more convenient in use than the conventional position.

APD2505

C.Gopinath MSRSAS

This picture shows the way in which the arrangement of cross shafts under the front of the seat means that there is no mechanism underneath the lowest part of the seat pan. In cars with very limited space, this allows the Gorman Pelvic Support Seat to keep the driver as low as possible, or to give very tall drivers extra head room. M.S Ramaiah School of Advanced Studies - Bangalore

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Head Rest

C.Gopinath MSRSAS

In most cars head restraints are kept relatively small in order not to unnecessarily obstruct the rear passenger visibility. Two seater sports cars often have a much larger head restraint area which is safer. A small head restraint has to be adjustable for the user and some are also adjustable in angle as if they might be used as a head rest. An effective comfortable head rest, as for instance on a fireside chair, has to support the base of the skull near the top of the neck. This would be extremely dangerous in a car. It is this confusion and the simple fact that what can be adjusted right will usually be adjusted wrong that led Design to avoid any adjustment in head rests. The solution chosen for rear seat visibility is to use netting with a peripheral steel frame (see section on testing for further details on this item). M.S Ramaiah School of Advanced Studies - Bangalore

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Seat Foam

C.Gopinath MSRSAS

The photograph shows the seat foam sectioned down the centre line. The angle of the seat surface is about 17° from the horizontal with an extra slightly softer area to resist forward slipping of the seat bones. The area behind the seat bones has been carefully designed to provide an upward force on the buttock behind the seat bones to provide extra pelvic support , i.e. to resist backward rolling of the pelvis.


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Manufacturing of seat cushion

APD2505

C.Gopinath MSRSAS

• Cushion design has been revolutionized by moulding techniques developed for low density flexible foams • Hot moulding has been established for over 20 years, the recent development of cold moulding has helped lower costs due to lower energy requirements and cheaper tooling • Materials used are polyethers expanded by isocyanates • Hardness of foam can be varied by adjusting the isocyanate component in different parts of the mould – giving the possibility of moulding dualhardness cushions to obtain a soft centre with stiffer side bolsters • Composite moulding of slush-moulded PVC plastisol covers, filled with cold-moulded foam, is common for industrial vehicle • For other vehicles, stretch-fabrics can be employed as the top layer of a multilayer laminate – over 23 mm thick peeled flexible foam, a PVC film and further inner layer of 1 mm thick foam • Skinform process involves such a laminate, being held under a controlled tension which is chosen according to the cushion design, drawn by vacuum into designed moulds M.Sspecially Ramaiah School of Advanced Studies - Bangalore 10

PEPM APD2505

• The cold-cure cushion-foam is then moulded in-situ • For cars, nylon faced fabrics are typical, backed by foam and a layer of knitted cotton skrim. The exposed top surface is usually proofed against stain marking • PVC coated fabrics are also available which provide excellent simulation of leather – even to the extent of fine-perforation for breathing • Foam backings and two-way stretch backing-cloths allow cooling flutes to be moulded-in and a variety of embossed surface effects are possible Foam properties

C.Gopinath MSRSAS

Density 35 to 55 kg/m3 Tensile strength 145 KPa Elongation at break 140 % Tear Strength 200 to 300 N/m M.S Ramaiah School of Advanced Studies - Bangalore

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Height adjustment Height adjustment

C.Gopinath MSRSAS

Horizontal seat adjustment

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The front section of the driver's seat can be adjusted to three height positions and the rear section to four. Lever forward = front height adjustment Lever rearward = rear height adjustment The passenger's seat is rigidly attached to the Soft floor. Tools are required to adjust the height. Firm Lumber support Both the front and the rear of the passenger's adjustment seat have two height adjustments. Seat back Horizontal seat adjustment inclination adjustment Pull control upward, then slide seat forward or rearward to desired position. The Honda City ZX has a rotary dial located on the right corner of the driver's seat along with other seat adjustment levers. This can be used to get your signature seating position customized as per your convenience M.S Ramaiah School of Advanced Studies - Bangalore 12

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Seat back inclination adjustment

C.Gopinath MSRSAS

Seat back inclination adjustment

Rotate control clockwise to tilt seat back rearward. Rotate counterclockwise to tilt seat-back forward. Note that body weight must be shifted to allow seat back to move forward or rearward.


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Seat belt

APD2505

C.Gopinath MSRSAS

• In a severe collision, the occupant can either strike the dashboard, or strike the seat belt. How much trauma the body of the occupant experiences will depend on the time period over which the force is applied and the stiffness of the body parts absorbing the force. Is it going to be applied quickly, or a longer period of time? To reduce the peak force, the occupant needs the force to be applied over a longest period of time possible. • Stretching the time epoch of the collision for the occupants and redistributing the crash forces to the stiffest parts of the human anatomy is the duty of the seat belt. Equally important, seat belts are the best way to prevent ejection from the vehicle • 1903 A patent for a sophisticated system of seat belts and upper torso restraint integrated into a seat back was obtained by a French automobile manufacturer • 1972 Seat belts became mandatory M.S Ramaiah School of Advanced Studies - Bangalore

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Seat belt system

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• The seat belt restraint system contains some or all of these components 1 shoulder guide loop, 2 webbing, 3 non-locking retractor, 3a retractors (generally), 4 automatic locking retractor, 5 emergency locking retractor,

C.Gopinath MSRSAS

6 vehicle sensitive retractors, 7 webbing sensitive retractors, 8 buckle, 9 buckle release, 10 tongue (latch plate), 11 selvage,


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C.Gopinath MSRSAS

APD2505 1. shoulder guide loop The shoulder guide loop, often spoken of as the "d" ring, is the oval guide that the webbing travels through between the retractor and the buckle. Typically attached to the 'B' pillar, or roof line, the shoulder guide loop is often made of metal with a plastic coating, or completely of a plastic. During collisions with speed changes greater than about 12 mph, the rapid pay out of webbing sliding through this ring can burn and abrade the nylon covering and leave telltale marks of usage of the belt. 2. webbing The webbing is a narrow fabric woven with continuous filling yarn and finished with selvages. During a significant collision, great enough frictional forces can be generated to melt nylon material from the d-ring onto the webbing, skin can also be abraded or melted onto the webbing. The belt is typically a polyester weave with less elastic property but higher tensile loading capabilities. The webbing should not be less than 1.8 inches except those portions that do not come into contact with the 95 percentile test M.S Ramaiah School of Advanced Studies - Bangalore 16 dummy

PEPM APD2505 3. non-locking retractor The non-locking retractor allows the webbing to be spooled out at any time without locking and stopping this from happening. This is an older form of the retractor (the original form) and the occupant was responsible for adjusting the webbing length once the belt was buckled. The retractor would spool in excess webbing for storage inside the retractor housing.

C.Gopinath MSRSAS

3a. retractors (generally) The retractor itself consists of various components. The primary parts are the frame, which houses the mechanism; the spool, which winds the webbing up; the ratchet is located on the sides of the spool and are a portion of the mechanism to stop the spool-out; the spring assembly which acts to put tension on the spool to allow it to draw up the webbing; the lock pawl (A4) is a bar that is forced into position across the teeth of the ratchets; the G-sensor is an inertial device that when free to move, releases or applies a force to a spring which moves the lock pawl or allows the lock pawl to move into position across the ratchets. For comfort, to maintain a certain length, a ratchet lever will engage with the teeth of the ratchet. M.S Ramaiah School of Advanced Studies - Bangalore

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C.Gopinath MSRSAS

Also, in webbing sensitive mechanisms, pins on the side of the ratchet stick out. Inertial bars, attached to light springs and mounted to the outer sides of the spool hub, spin freely under normal rotations. Under rapid rotation, with a sudden spool out the inertia of the bars pull them outward elongating the spring and causing the bars to quickly engage with the pins and lock the retractor. Some designs have multiple retractors, often in door mounted passive/active systems. M.S Ramaiah School of Advanced Studies - Bangalore

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C.Gopinath MSRSAS

APD2505


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4. automatic locking retractor

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The automatic locking retractor allows the webbing to be with drawn and then rewound but will not permit a second withdrawal until the belt is nearly completely rewound. This device allowed for the installation of a locking device within the mechanism located inside the retractor housing. The mechanism was typically a clutch and locking bar combination which would engage if the belt spooled up an amount when it was in use.

5. emergency locking retractor The emergency locking retractor allows the belt to spool out and rewind freely except when a vehicle acceleration demands it locks up. The mechanism may be of an inertial reel nature or vehicle sensitive type

C.Gopinath MSRSAS

6. vehicle sensitive retractors The vehicle sensitive retractors act similar to the emergency locking retractors when the vehicle tilts at greater than a 15-degree pitch (0.26 G) or decelerates at greater than or equal to 0.7 g in ANY direction. This system allows for less spool out of the webbing M.S Ramaiah School of Advanced Studies - Bangalore

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7. webbing sensitive retractors Webbing sensitive retractors automatically lock when the webbing is suddenly withdrawn, they do NOT lock when the webbing is slowly spooled out. The mechanism of lock up was a mass attached to a light spring. When the retractor began to rapidly spin with sudden pay-out, the mass would lock up the spool and prevent further withdrawal of the webbing from the spool hub

C.Gopinath MSRSAS

8. buckle The buckle is the one piece housing that surrounds the release and may extend up from the floor mounted anchorage. The system is functioning or "buckled" when the latch plate has clicked home into the receiving portion of the buckle 9. buckle release The release is the button in the portion of the buckle housing that allows the tongue to disengage from the buckle receiver. The release is designed to minimize unintended activity and should not release with a force less than or equal to 30 pounds. Releases may be on an end or located near the center of the buckle M.S Ramaiah School of Advanced Studies - Bangalore

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10. tongue (latch plate) The tongue is the metal plate that is surrounded by, but extends from the conjunction of the webbing or may slide somewhat freely on the continuous loop webbing. Typically the tongue (latch plate) has a slot in it for engaging with the receiving end of the buckle mechanism. The latch plate often has its own guide loop which may be constructed from metal or plastic 11. selvage The selvages are the woven edges of the webbing

Removal of Seat Belt Controller:

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• The structural seat with integrated retractor height adjuster allows the seatbelts to comfortably fit a large range of occupants. The seatbelts are attached to the seat instead of the body; this allows better passenger access to the rear seat • These retractors have advanced features including varying options of load limiting, pretensioning and even pre-crash pretensioning in the case of Active Control Retractor (ACR) • Figure 1 shows Active Control Retractor unit takes the slack off the seatbelt moving the passenger into a safer crash position.

Fig 1

C.Gopinath MSRSAS

• Figure 2 shows During the collision or rollover, the Active Control Retractor unit remains activated, keeping the passenger in a safe position. Fig 2


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• Since the retractor is mounted on a seatback that can recline, a typical seatback g-sensor cannot be used in the retractor. Instead, a solenoid inside the retractor is used to lock and unlock the seatbelt when electrically signaled by a remote g-sensor. The remote g-sensor is located inside the Seatbelt Control Timer Module. The Seatbelt Control Timer Module is located under the center console. The seat retractor and solenoid are located in the seatback and are serviced as an assembly • When the solenoids are powered, the seatbelt can be moved. When the solenoids are not powered, the seatbelts cannot be moved. This is necessary to ensure that occupants are always safe, even in the case of a power loss during an accident. Whether the seatbelts are in locked or unlocked position, an occupant can always release the seatbelt and it will retract

C.Gopinath MSRSAS

• The Seatbelt Control Timer Module controls the power to the seatbelt solenoids. It supplies power continuously to the seatbelts whenever the ignition key is in the RUN or ACCESSORY positions. The module has two other unique functions: that of a timer and a g-sensor M.S Ramaiah School of Advanced Studies - Bangalore

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C.Gopinath MSRSAS

• Location of SCTM. View is looking down from the driver's seat area. Gear shift is to the left, slightly out of the picture. Center console has been removed. Object just to the left of the SCTM is the passenger front seat belt receptacle • The Seatbelt Control Timer Module was designed with a timer function so that when the vehicle is not in use the battery would not be prematurely drained. The module times out after approximately 30 minutes if no inputs are sent to the module. The module will power the seatbelts for a set period of time when there is an input: - Either door ajar switch (open or closed) - Ignition switch moved from RUN or ACCESSORY to the OFF position Each time one of these inputs occurs, the timer is reset to keep the belts powered for 30 minutes M.S Ramaiah School of Advanced Studies - Bangalore

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• The g-sensor function of the Seatbelt Control Timer Module will cut power to the seatbelts whenever: - The vehicle accelerates or decelerates at a rate greater than or equal to 0.7g in any direction - The vehicle is tilted to an angle greater than or equal to 45 degrees - Input of ignition switch in the RUN or ACCESSORY positions will cause the module to power the seatbelts for as long as the condition exists APD2505

C.Gopinath MSRSAS

• The SCTM holds the occupant in place during airbag deployment, which one doesn't have to worry about with a Corvair installation, but it also helps keep the occupant from making contact with the interior of the car by holding them more firmly in place than the inertia wheel can do on its own. M.S Ramaiah School of Advanced Studies - Bangalore

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• Once you have verified the integrity of the seats, be sure to have the salvage yard also remove the Seatbelt Control Timer Module. This small black box (see Figure) is mounted between the seats, under the center console. The box has several small wiring harnesses coming out of it. You need all of the wires going to both seats, with the connectors. The connectors are unique to this application and you must have them in order to attach the wires to the seats and to the SCTM. You also need as much of the wire bundle going to the dash as possible. You don’t need the connectors on the dash end; just have the salvage yard cut the wires as far up under the dash as they can reach

C.Gopinath MSRSAS

• To lessen the risk of whiplash injuries in the event of rear-end collisions, the car is equipped with front seat passive safety head restraints which move forward automatically to cradle the head and neck.


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Seat belt at front seat

Seat belt at rear seat

C.Gopinath MSRSAS

Attached Child seat


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Smart airbag

APD2505

C.Gopinath MSRSAS

All cars feature dual-stage front airbags as well as front side-impact and side curtain airbags, controlled by a "smart" airbag system that detects passenger weight, seatbelt use and driver's seat position, then deploys the front airbags accordingly while ensuring the side-impact and side curtain airbags only deploy when needed. The dual-stage means they can be deployed in one of two ways: a low to medium speed collision will cause a single-stage deployment, while a severe impact will trigger a full deployment. The front side-impact airbags are built right into the front seats to ensure they are in proper position at all times. The side curtain airbags deploy from above the side windows to almost completely cover the front and rear side windows and the centre pillar, helping to protect against injury and intrusions into the cabin a side impact M.S in Ramaiah School of Advanced Studies - Bangalore 29

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Mounting the seat

APD2505

Driver Seat

Outboard track Inboard Track

C.Gopinath MSRSAS

Car outer wall

Left hand side Driving Car (view from the rear) M.S Ramaiah School of Advanced Studies - Bangalore

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C.Gopinath MSRSAS

APD2505 • When the seat belts are integrated into the seats, the mass of occupant’s body always pulls against the seat mounts and the floor pan during a stop. This is a much different situation than typical seats with outboard seat belts, where the belts are mounted separately, and away from, the seat mounts. It should be obvious that an extremely sturdy mounting is critical to successful installation of the seats • Tracks of the seat are welded and bolted to the floor. Fabricated new tracks, featuring - Vertical risers, to provide clearance for the power seat equipment under the driver’s seat - Spacers, to maintain the correct height/angle, with a square or triangular cross-section for strength • Note that the outboard track on each seat is longer than the inboard track. The extra length provides more floor surface area to support the seat. M.S Ramaiah School of Advanced Studies - Bangalore 31

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Outboard track Square Spacer

C.Gopinath MSRSAS

Triangular Spacer

Inboard track M.S Ramaiah School of Advanced Studies - Bangalore

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Mounting and wiring the seat electronics

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C.Gopinath MSRSAS

• Unlike the seats, mounting and wiring the electronics can be done easily and safely. First there is a need to mount the SCTM. It should be located between the two front seats because it would be easy to hide the module inside the center console . If there is no center console, one can probably mount the module under one of the seats, although some wires might need to be lengthened. • Important: Because the SCTM has a g-sensor in it, the module should be mounted as close to horizontal as possible • The SCTM should be oriented pointing rearward with the wiring harness connector, to minimize sharp turns in the wiring harness • The module has mounting ears so it is easy to use self-tapping sheet metal screws to hold it in place • The harness has six groups of wires in it. One group of wires goes to the power amplifier for the stereo. It has a ten-pin connector on one end and will basically fall out of the harness as one removes the outer covering. This group of wires can be discarded. M.S Ramaiah School of Advanced Studies - Bangalore

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SCTM Central Console

C.Gopinath MSRSAS

Controls at seat


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C.Gopinath MSRSAS

• Two groups of wires go to the driver’s seat (two wires for the powerAPD2505 seat mechanism, four wires for the seat belt solenoid & seat belt switch sense), one group goes to the passenger’s seat (two wires for the seat belt solenoid), one group goes to the dash (three power wires, two door ajar switch wires, and one seat belt switch sense wire), and one group goes to a common ground point. The group of wires going to the dash is not wrapped and neither are the ground wires. • The seat belt system is used to lock and unlock the seat belts. It consists of a seatbelt control timer module, door ajar switches, ignition switch, and solenoids located in the seats. When the operator opens the door, the door ajar switch completes a path to ground on circuit for the driver’s door, and for the passenger’s door. The seatbelt control timer module then supplies voltage to the solenoids located in the seats, unlocking the seat belts


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Example: Step by step process of mounting the controls to the seat

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Seat climate control system

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Another comfort advancement deals with a personal seat climate control system. A climate controlled seat module or CCS. A CCS can dispense noticeable cool or warm air to the dorsal sides of passengers in less than 30 seconds after activation. The CCS consists of 3 main parts: - A Thermoelectric heat pump consisting of two 1.57 inch-square Peltier Junction modules - A 30-cfm-capacity fan- A relatively simple electronic monitoring and controlling system The heating and cooling of the seats occurs through both convection and conduction. Air passes through unique channels formed in the foam seat back. These channels allow the heated or cooled air to spread throughout the seat. Additionally, a thin 20 pore-perinch layer of reticulated foam is sandwiched between the cushion and the seat fabric to allow the occupant to feel the air. This product is foreseen in the installation into electric cars. Since these vehicles can ill afford to divert 4,000 to 6,000 Watts to a climate-control system, the 110 Watts of input electricity needed to run each system is optimal M.S Ramaiah School of Advanced Studies - Bangalore

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Loss of the Lumbar Curve in the Driving Seat


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Automatic seat profile adjustment

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A marvel in seat design is BCAM International's innovation recently installed into Cadillac automobiles: the world's first "intelligent" passenger car seat. This breakthrough in ergonomic design technology does not just deal with the traditional adjustments of the lumbar support area. A computer installed in the squab controls the contour of the entire seat surface automatically. The Intelligent Seat provides custom fit to each passenger in the vehicle. When a new occupant sits in the car, the Intelligent Seat recognizes the person and adjusts the seat to best fit the individual by providing the proper lumbar, thigh, and bolster support while improving the distribution of pressure caused by the occupant's body weight on the seat. The system is dynamic and checks the comfort of the occupant every couple of minutes, and if need be, adjusts the seating surface, providing extended comfort during long drives. These automatic, adjustments enhance comfort by measurable levels and achieve a new standard in seat design. M.S Ramaiah School of Advanced Studies - Bangalore

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Seat upholstery Seat upholstery can also add years of life and increase value Vinyl Upholstery

Cloth Upholstery

C.Gopinath MSRSAS

Leather Upholstery


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Trim and upholstery work also lets individuals customize their cars, to reflect their own personal tastes. For example a customer with cloth seats may choose to upgrade to leather, or he or she can change the whole color scheme of the vehicle's interior from red to silver.

Research by the Automotive Aftermarket Industry Association in Bethesda, Md. shows that a vehicle with highly visible signs of wear - like torn upholstery, worn carpeting, cigarette burns, and damaged headliners - is worth hundreds of dollars less in resale value.

C.Gopinath MSRSAS

For example, sometimes passengers may scratch the upholstery, accelerating wear and creating a porous vinyl surface. They may pour some liquid on cloth surface or the cigarette may burn the cloth or leather surface.


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Seat upholstery manufacturing

C.Gopinath MSRSAS

Ready to break down passenger seat

Lay bottom seat cushion face down

Separates bottom and seatback cushion

Remove posterior trim panel and electrical plugs

Remove upholstery from spikes

Transfer cushion patterns to new leather


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Install wire rods

Fasten hog rings

Sew accent piping trim

Pull upholstery over and fasten to spikes

Sew the bolsters to the insert

C.Gopinath MSRSAS

Transfer insert part to sandstone gray suede


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Bottom seat finished

Finished passenger seat

C.Gopinath MSRSAS

Perforated forms of Vynide, a solid PVC-coated fabric, is attractive for headlinings. When used with knitted backcloths, allowing two-way stretch, quite sharply curved surfaces can be trimmed.


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Seat fabric


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C.Gopinath MSRSAS

• Coverings include non-woven fabrics of polyester, nylon or viscose in spun-bonded, point-bonded and needle-punched construction; polyester or nylon knitted fabrics, normally as a raised tricotte knit to give a velour effect; other options are woven fabrics, PVC washables. • Knitted fabrics can also be drawn into most shapes and are readily dyed to colour key with other parts of vehicle interior


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Passenger seat


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Summary In this session following aspects of Car seat design were explained • Seat system • Seat material • Manufacturing of seat cushion • Height adjustment of seat • Seat belt system

• Smart airbag • Mounting the seat • Seat climate control system

C.Gopinath MSRSAS

• Seat upholstery • Seat fabric M.S Ramaiah School of Advanced Studies - Bangalore

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09_Car Seat Design (Ver.1)

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