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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Impact of Active Climate Control Seats on Energy Use, Fuel Use, and CO2 Emissions

A project was developed through collaboration between Gentherm and NREL to determine the impact of climate control seats for light-duty vehicles in the United States. The project used a combination of experimentation and analysis, with experimental results providing critical input to the analysis process. First, outdoor stationary vehicle testing was performed at NREL's facility in Golden, CO using multiple occupants. Two pre-production Ford Focus electric vehicles were used for testing; one containing a standard inactive seat and the second vehicle containing a Gentherm climate control seat. Multiple maximum cool-down and steady-state cooling tests were performed in late summer conditions. The two vehicles were used to determine the increase in cabin temperature when using the climate control seat in comparison to the baseline vehicle cabin temperature with a standard seat at the equivalent occupant whole-body sensation. The experiments estimated that on average, the climate control seats allowed for a 2.61 degrees Celsius increase in vehicle cabin temperature at equivalent occupant body sensation compared to the baseline vehicle. The increased cabin air temperature along with their measured energy usage were then used as inputs to the national analysis process. The national analysis process was constructed from full vehicle cabin, HVAC, and propulsion models previously developed by NREL. In addition, three representative vehicle platforms, vehicle usage patterns, and vehicle registration weighted environmental data were integrated into the analysis process. Both the baseline vehicle and the vehicle with climate control seats were simulated, using the experimentally determined cabin temperature offset of 2.61degrees Celsius and added seat energy as inputs to the climate control seat vehicle model. The U.S. composite annual fuel use savings for the climate control seats over the baseline A/C system was determined to be 5.1 gallons of gasoline per year per vehicle, corresponding to 4.0 grams of CO2/mile savings. Finally, the potential impact of 100 percent adoption of climate control seats on U.S. light-duty fleet A/C fuel use was calculated to be 1.3 billion gallons of gasoline annually with a corresponding CO2 emissions reduction of 12.7 million tons. Direct comparison of the impact of the CCS to the ventilated seat off-cycle credit was not possible because the NREL analysis calculated a combined car/truck savings and the baseline A/C CO2 emissions were higher than EPA. To enable comparison, the CCS national A/C CO2 emissions were split into car/truck components and the ventilated seat credit was scaled up. The split CO2 emissions savings due to the CCS were 3.5 g/mi for a car and 4.4 g/mi for a truck. The CCS saved an additional 2.0 g/mi and 2.5 g/mi over the adjusted ventilated seat credit for a car and truck, respectively.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Configurable vehicle seat and method therefor

An adjustable vehicle seat includes a seat frame forming a seat back, the seat frame being configured to couple with an aerospace vehicle; a seat pan coupled to the seat frame, where one or more of the seat frame and the seat pan is configured to couple the seat pan to the seat frame in one of a plurality of positions relative to the seat frame so that an eye position of a seat occupant relative to instrumentation within the aerospace vehicle is decoupled from a size of the seat occupant.

McCarley, Michael C.↗
DOE OSTI2023

Configurable vehicle seat and method therefor

An adjustable vehicle seat including a seat frame forming a seat back, the seat frame being configured to couple with an aerospace vehicle, and a seat pan coupled to the seat frame, where one or more of the seat frame and the seat pan is configured to couple the seat pan to the seat frame in one of a plurality of positions relative to the seat frame so that an eye position of a seat occupant relative to instrumentation within the aerospace vehicle is decoupled from a size of the seat occupant.

McCarley, Michael C.↗
DOE OSTI2021

Configurable vehicle seat and method therefor

A conformal seat insert for an adjustable vehicle seat, the conformal seat insert comprising an insert frame, the insert frame having one or more insert reference features for locating the insert frame on a seat frame of the vehicle seat in a predetermined position relative to the seat frame, and a contoured support surface formed in the insert frame, the contoured support surface having a crew reference point corresponding to an acromial point of a shoulder of a seat occupant of the adjustable vehicle seat, the crew reference point being a datum from which an eye position of the seat occupant is established relative to instrumentation of an aerospace vehicle in which the adjustable vehicle seat is located.

McCarley, Michael C.↗
DOE OSTI2020

Review of Landscaping Equipment Vibration Risk Exposure, LLNL Site 200 (Various Locations), Whole Body Vibration Seated and Standing Mowers

WBV (Whole-Body Vibration) for operators of seated and standing lawn mowers was conducted during landscape activities from April 2019 through August 2019 at various locations around LLNL Site 200. Mowing is generally performed by each landscaper for 2-3 days every other week with a maximum duration of 3-5 hours each day. On mowing days, other tasks are performed for the remainder of the day that do not expose the worker to WBV such as irrigation, blowing, or sweeping. The mowing terrain at LLNL is variable with typical reported conditions such as gopher holes, exposed tree roots, quick turns, normal and high growth, weeds, and mushy/wet ground that can result in jolts to the mower operator. The Larson Davis HVM200 seat pad with tri-axial accelerometer was used for monitoring workers. For the seated mowers, the HVM200 seat pad with tri-axial accelerometer was placed on the seat between the user and seat pan of the mower. For standing mowers, the seat pad with tri-axial accelerometer was wrapped with Dycem (for seat pad protection) and placed directly on top of the mower deck and underneath the end-user’s right foot. Monitoring for WBV was conducted while operators used different types, makes, and models of mowers. A total of sixteen samples were collected from the operators of seated mower and 6 samples were collected from operators of standing mower. This initial data sampling was part of a discovery phase to identify if WBV exposure met the 2016 ACGIH TLVs (Threshold Limit Values). This initial data identified that workers operating the mowers do not exceed either the TLV or Action Level (AL) for Weighted Acceleration Levels (A(8)) but typically exceed the Vibration Dose Value (VDV) lower boundary for the standing mowers.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2017

Comparison of Exhibited Wear in Tefzel?, Kynar?, and UHMWPE Valve Seats Exposed to Cyclic Operations with Abrasive Slurry - 17519

Pacific Northwest National Laboratory (PNNL) conducted abrasive-wear testing of ball valves used for double valve isolation in nuclear waste process lines. The valve seat materials consisted of Kynar{sup R}, Tefzel{sup R}, and ultra-high-molecular-weight polyethylene (UHMWPE). Cycle testing was conducted for 1500 operating cycles for the Kynar{sup R} and Tefzel{sup R} valve seats and 5500 cycles for the UHMWPE valve seats. A valve operational cycle consisted of slurry flow, slurry gravity drain, flush water flow, and flush water gravity drain. Both two-way and three-way valves were evaluated, and valves were configured in simulated manifolds so the impact of serving various operational functions (e.g., slurry, flush, or drain control) could be evaluated as some valves are flushed prior to being cycled and others are not. Testing was conducted in PNNL's Multi-Phase Transport Evaluation Loop Facility using a performance-based simulant developed by PNNL specifically for this test program to emulate abrasive slurries for Hanford Tank Farms Waste Transfer System during single-shell tank retrieval and waste feed delivery to the Hanford Tank Waste Treatment and Immobilization Plant. Pre- and post-test valve tear-down evaluations were conducted to observe changes in the condition of internal components for the various seat materials. The various forms of physical wear observed for the different seat materials are presented. The wear results can be used to assess seat materials and valve configurations for application to waste transfer operations, and the observed wear mechanisms can provide insight into assessing valve service life. This information will be used to identify and select additional valve designs that should be evaluated for certification for future use. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

TU-H-CAMPUS-TeP1-02: Seated Treatment: Setup Uncertainty Comparable to Supine

Purpose: For some head and neck patients, positioning in the supine position is not well tolerated. For these patients, treatment in a seated position would be preferred. We have evaluated inter- and intra- fraction uncertainty of patient set-up in a novel treatment chair which is compatible with modern linac designs. Methods: Five head-and-neck cancer patients were positioned in the chair, fitted with immobilization devices, and imaged with orthogonal X-rays. The couch (with chair attached) was rotated to simulate delivery (without actual treatment), another set of images were acquired, providing a measure of intra-fraction displacement. The patient then got off of and back onto the chair and the process was repeated, thus providing a measure of inter-fraction set-up uncertainty. Six sub-regions in the head-and-neck were rigidly registered to evaluate local intra- and interfraction displacement. Image guidance was simulated by first registering one sub-region; the residual displacement of other sub-regions was then measured. Additionally, a patient questionnaire was administered to evaluate tolerance of the seated position. Results: The chair design is such that all advantages of couch motions may be utilized. Average inter- and intrafraction displacements of all sub-regions in the seated position were less than 2 and 3 mm, respectively. When image guidance was simulated, interfraction displacements were reduced by an average of 4 mm, providing comparable setup to the supine position. The enrolled patients, who had no indication for a seated treatment position, reported no preference for the seated or the supine position. Conclusion: The novel chair design provides acceptable inter- and intra-fraction displacement, with reproducibility similar to that observed for patients in the supine position. Such a chair will be utilized for patients who cannot tolerate the supine position and use with CBCT images for planning, in a fixed-beam linac system, and for other treatment sites is under investigation. Funding: Varian Medical Systems.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Analysis of Integrated Fuselage Composite Seat for Small Aircraft in Crashworthiness Applications

The research paper is addressed to develop and validate an aircraft seat cushion to be used for the passenger seat directly integrated in the fuselage. For very light aircraft, these systems result to be a good choice in terms of weight reduction and space optimization, but can represent a challenging problem for crashworthiness design and a key energy-absorbing function for human protection from injuries so to improve the level of the safety. The first issue was dedicated to investigate the mechanical properties of four commercial foams, diffused in different industrial applications, which present nonlinear and time-dependent viscoelastic behavior, and finally to determine whether typical seat cushion materials are rate sensitive or not. Then, numerical simulations were validated with measurements to simulate the mechanical properties of foams and to evaluate the contact pressures, stress distribution, and the dependence of stress on the strain rate in order to provide adequate levels of both comfort and energy absorption.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Spatial Environmental Assessment Tool (SEAT)

SAND2024-08551O The Spatial Environmental Assessment Tool (SEAT) evaluates potential environmental risk associated with marine energy device deployment by coupling modeled impacts with risk severity maps. As a graphical user interface-based software, it interacts with marine energy stressor and receptor data to evaluate the risk of changes to marine environment. SEAT, which relies on spatial and temporal data, is a plug-in for geospatial software QGIS. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Chartrand, Chris↗
DOE OSTI2018

Spatial Environmental Assessment Tool (SEAT): A Modeling Tool to Evaluate Potential Environmental Risks Associated with Wave Energy Converter Deployments

Wave energy converter (WEC) arrays deployed in coastal regions may create physical disturbances, potentially resulting in environmental stresses. Presently, limited information is available on the nature of these physical disturbance or the resultant effects. A quantitative Spatial Environmental Assessment Tool (SEAT) for evaluating the potential effects of wave energy converter (WEC) arrays on nearshore hydrodynamics and sediment transport is presented for the central Oregon coast (USA) through coupled numerical model simulations of an array of WECs. Derived climatological wave conditions were used as inputs to the model to allow for the calculation of risk metrics associated with various hydrodynamic and sediment transport variables such as maximum shear stress, bottom velocity, and change in bed elevation. The risk maps provided simple, quantitative, and spatially-resolved means of evaluating physical changes in the vicinity of a hypothetical WEC array in response to varying wave conditions. The near-field risk of sediment mobility was determined to be moderate in the lee of the densely spaced array, where the potential for increased sediment deposition could result in benthic habitat alteration. Modifications to the nearshore sediment deposition and erosion patterns were observed near headlands and topographic features, which could have implications for littoral sediment transport. The results illustrate the benefits of a risk evaluation tool for facilitating coastal resource management at early market marine renewable energy sites.

Jones, Craig↗
DOE OSTI2016

Haptic seat for fuel economy feedback

A process of providing driver fuel economy feedback is disclosed in which vehicle sensors provide for haptic feedback on fuel usage. Such sensors may include one or more of a speed sensors, global position satellite units, vehicle pitch/roll angle sensors, suspension displacement sensors, longitudinal accelerometer sensors, throttle position in sensors, steering angle sensors, break pressure sensors, and lateral accelerometer sensors. Sensors used singlely or collectively can provide enhanced feedback as to various environmental conditions and operating conditions such that a more accurate assessment of fuel economy information can be provided to the driver.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗