Toyota Boshoku exhibits thin and light car seat without back padding
At the 40th Tokyo Motor Show in 2007, Toyota Boshoku exhibited a concept model of a lightweight and thin car seat made of elastic polyester fabric with high cushioning properties (picture). The fabric used is “banex” developed by Japan’s Kawashima Textile Selkon. Use it on the seat, backrest and headrest, eliminating the need for padding on the back.
The frame of the backrest and headrest is made of magnesium alloy. The frame of the backrest is shaped like a violin for comfort. Due to the removal of the padding, the thickness of the backrest is about 80mm thinner than that of a normal car seat. The weight of the saddle has not been announced, but the goal of this concept is to reduce the weight to 60 to 70% of previous saddles. Although there are still problems that must be overcome in terms of strength and safety, the company strives to realize the practical use of this kind of saddle around 2012.
The reason why riding comfort is better when using a violin shape is because the elasticity of the fabric can change with the position in the height direction. Increasing the elasticity of the fabric near the waist can provide stronger support for the waist. The company supplies the “Lexus LS460” special magnesium alloy frame seat to Toyota Motor, and this time it was developed using this technology. In terms of creativity, the exterior design with exposed frame is boldly adopted. There are places to accommodate airbags on the left and right sides of the violin-shaped frame. These parts mentioned above are all made of resin.
The magnesium alloy frame is made by thixotropic molding (Thixo-molding) technology. In order to improve its production efficiency, the company has been committed to improving production technology. When using thixotropic molding technology, it is difficult to increase production efficiency because increasing the speed makes the nozzle more likely to clog. Furthermore, automobile seat frames are not allowed to bend during a collision, so they must be manufactured to prevent air bubbles from entering. About a year ago, the company improved the production efficiency of this magnesium alloy saddle frame by improving the feeding method and nozzle shape in the manufacturing process up to the nozzle, and optimizing the setting conditions of temperature and pressure. 50% to 60%. Currently, two thixotropic molding machines are used to produce 6,000 to 8,000 saddle frames per month.
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