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Automotive Seat Design


and Collision Performance
D. M. Severy, D. M. Blaisdell, and J. F. Kerkhoff
Severy, Inc.

ALTHOUGH SAFETY IS A BASIC CONSIDERATION research up to that time. Although some research
in all aspects of automotive engineering, it is a has been conducted since that time, the development
fact of life that safety advances are not uniformly of a safety seat still has not been accomplished. In
accomplished. Some essential aspects of motorist the same study special devices, including the air
protection have in the past, and probably will in the bag, were rated as only of moderate relative im-
future, continue to be greatly outstripped by advances portance.
made in other areas. In some instances, the design After 10 years of government regulated safety
challenge simply exceeds current technology; on standards and nearly that many years of intensive
other occasions an adequate safety standard and con- air bag development sponsored by both government
certed industry interest can correct obvious safety and industry, the consensus of many automotive
deficiencies. For example, although improved safety researchers in Europe (2), (3) and elsewhere
tires resulted only after new materials evolved, a is to change the emphasis back to development of
greatly improved motorist restraining system active restraint systems and to increase effective-
resulted from industry initiated research that cul- ness by means of mandatory use laws. Air bags,
minated in a standard requiring installation of com- if used, would serve a supplementary function in
bination cross chest lap belts for all outboard front conjunction with active systems. Progress in
seat locations. safer seat design has been impeded throughout a
During the past 20 years, new materials and decade of automotive safety standard making, and
techniques have improved the comfort and wear many lives have been lost that could have been fully
resistance of automotive seats while simultaneously protected with a fraction of the inventive genius and
reducing their weight and cost; however, significant funding lost to air bag development. A basic common
safety related improvement in seat design during sense approach to motorist protection from collision
this period has not been accomplished. A summary trauma calls for special attention to design of the
of findings from prior research (l)* published in critically important structure nearest the motorist,
1966 classified a structurally redesigned Integral his seat.
Seat with built-in S-point belt restraint as critically A vital consideration of seat design is its cap-
important for reduction of motorist injuries; this acity to protect motorists, to the extent practical,
summary also pointed out the lack of safety-seat from all types of collision injury exposures. This
paper provides basic design data for crashworthy
*Number in parentheses designate References
automotive seat systems with integral active re-
at end of paper.

Eighty-five laboratory full-scale force-deflec- tive significance to the requirements of automotive


tion tests were conducted on passenger vehicle seat collision performance.
seats, foreign and domestic, for purposes of evaluat- The foregoing research provided foundation for
ing specific resistance to a collision environment modification of a production automobile seat into an
and mechanisms of collision induced seat distortion. integral safety seat, based on a design concept that
These tests evaluated seats that span the past thirty minimizes bending moments during collision. The
years; additionally, seat design studies were con- modified seat was subjected to the same laboratory
ducted evaluating basic features of automotive seat- test procedure applied to the 85 non-modified pro-
ing during the past eighty years. duction seats and results of its performance is
Data from full-scale collision experiments and given.
from a large number of actual accidents facilitated Design concepts are presented that would serve
the establishment of seat design criteria for greatly to mitigate undesirable seat distortions during col-
improved collision performance. Evolution of seat lision and thus improve seat restraint capabilities
and head support standards in the United States and without compromising the important factors of com-
Europe are presented with evaluation of their rela- fort and cost.

2551
2552 D. M. SEVERY

straints, as determined from the authors’ collision a seat also should have adequate structure for
research and laboratory studies as well as experi- housing safety and convenience accessories. Trade-
ence gained from investigation of relevant accidents. offs are imposed by this complex mix of require-
ments; however, in seat design we should no longer
BACKGROUND overlook the requirement for a reasonably safe,
collision resistive structure with built-in active
The first automotive seat, like the first restraint system.
automobile was an adaptation from the horse-drawn SEATING CATEGORIES - Automotive seats
carriage. Springs to absorb road shocks were for passenger vehicles have a number of basic
primitive, effective padding was non-existent and configurations and sizes depending on intended use
seat adjustability had not yet been considered. C o m - and location. Position adjustment depends on
mencing around 1900, motorist safety while travel- factors such as location (front or rear): availability
ling over rough roads was improved by development of comfort features, including center armrests,
of deeply contoured seats that reduced the likeli- depends on vehicle price, type, purpose and country
hood of motorist ejection as the car body pitched of origin.
and rolled. Generally, however, little considera- BENCH SEAT - SOLID BACK - Standard and
tion was given for the safety of the occupants, compact 4-doer sedans are frequently equipped with
Fig. 1. solid-back berth seats, front and rear. The front
Front seat fore-and-aft adjustment was not seat has a single adjustment mechanism and the
available until about 1929 when adjustable front entire seat is usually adjusted according to the
seats for the driver became a feature of higher
priced automobiles. Occupant comfort was given
increased attention as engineering problems con-
cerning motor vehicle performance and reliability
became more effectively managed. Improvements
in seat design continued and by the mid 1930’s,
seats, tracks and runners closely resembled those
of the mid 1960’s. During the period between the
thirties and the sixties, the only significant in-
novation in seat design was the introduction of power
seats and adjustable reclining backrests during
the early 1950’s, Table 1. Seatback height reached
reasonable levels in the late 1960’s but by the mid-
seventies the height of backrests on many models
had declined to levels less effective than thirty
BJtLAWt v”
years ago. Seatback strength has not increased
significantly over the past thirty years and remains Fig. 1 - D r i v e r ’ s s e a t , h o r s e l e s s c a r r i a g e
inadequate to resist even moderate collision forces.
The remarkable safety improvement facilitated by -
the backrest head support standard FMVSS 202 has
TABLE 1
been compromised through failure to upgrade cri-
teria to maintain performance commensurate with SEAT DESIGN EVOLUTION
intent. Seventy percent of adjustable head restraints
are used in the downmost position (4). Little ef- INTRODUCED ITEM EXAMPLE
fective protection is afforded the motorist unless 1890 - 1900 Automotive Bench Seats Philion*
the head restraint is positioned behind or slightly 1900 - 1910 Deep Bucket Seats Thomas*
1910 - 1915 Fold-forward Backrests [Model-T Ford*
above the head and remains in such support posi- 1910 - 1915 Console Between Seats Wescott*
tion during collision. 1910 - 1915 Pedestal Seat Argo Electric*
1915 - 1920 Swivel Seat Cole*
SEAT FUNCTION AND CONFIGURATIONS 1920 - 1925 Fold-down Armrest Dusenberg*
1925 - 1930 Fore-and-aft Adjustment Viking*
1950 - 1952 Power Seats Packard
It is not a simple engineering task to design a 1960 - 1963 Optional Head Restraints All U.S.
good automotive seat; it must provide comfort, 1968 Integrated Head Restraint Volkswagen
style and safety, and yet be sufficiently light weight 1969 Standard Head Restraints All U.S.
to facilitate vehicle fuel economy and to minimize
collision inertial stresses. Seat designs and mater- _ _ _ _ _ - - .----- -
ials must be affordable and durable to give accept- *Based on authors’ study of vehicles made available through coopera-
able service over the life of the car. In addition to tion of Harrah’s Automotive Museum, Reno, Nevada.
provisions for comfort and position adjustments,
AUTOMOTIVE SEAT DESIGN AND COLLISION PERFORMANCE 2553

needs of the driver. A bench seat, if adequately their elevation, direct restraint system attachment
designed for three occupants, must be capable of requires special design considerations.
sustaining a rearward static moment, calculated FIXED, BUS-TYPE BENCH SEATS - Although
about the H-point of the seat, equal to three times similar to the rear seats of passenger sedans these
that of a single seat. seats are elevated and generally provide open
BENCH SEAT - SPLIT BACK - Fold-forward space beneath; structural limitations and remoteness
backrests provide access to the rear seat of 2-doer of seat from floor increase the difficulty of direct
vehicles. Since only the upper portion of the seat restraint attachment. Seats used in buses that
is divided, the fore-and-aft adjustment can accom- transport children require special considerations,
modate only one person. Backrest angle, however, (91, (10).
can be made adjustable according to the individual
needs of driver and passenger. SEAT SYSTEM COMPONENTS
BUCKET SEATS - Contoured seats for indi-
vidual occupancy are called bucket seats, although A brief description of seat components will
this term originally applied to more deeply con- allow a better understanding of basic seat require-
toured racing-type seats. The containment feature ments and the special seat structure necessary for
of deeply contoured bucket seats has been identified adequate passenger protection from collision trauma,
by the authors and others (5), (6), (7) as a consi- Fig. 2.
deration in design of a safer seat, owing to improved STRUCTURAL FRAME MEMBERS - The seat
lateral retention; however, the extent of contouring framework is usually constructed of steel that has
must be based on consideration of comfort and been formed into tubular configurations or of stamped
practicality as well as safety. or rolled sheet metal. Historically, the function
Adustable backrest angle is commonly available of this structural backbone has been limited to pro-
and provides improved comfort and reduced muscle viding shape for the cushioning members and support
fatigue. Direct attachment to the seat of both lap for its own weight and that of its occupant. Rede-
and shoulder belts is a safety and convenience goal sign and strengthening of the seat framework in
that has been identified previously, (l), (5)) (6), conjunction with its anchorages can provide the
(7), (8) and is further evaluated in this study. force resistance necessary for occupant restraint
FOLDING SEATS - These seats require special during moderate and severe front, side and rear-
design considerations to allow them to be folded end collisions.
flat when hauling cargo. These requirements include NON-STRUCTURAL SEAT MATERIAL - Cushions,
special sizing, latching devices and flat, durable springs and upholstery provide the necessary means
cargo surfaces. Seatback height and strength as of load distribution between occupant and seat frame;
well as provision for isolating cargo are collision they also provide contour and geometry necessary
safety factors to be considered. for occupant comfort. A redesigned integral seat
would include energy absorbing (E-A) padding at
PEDESTAL BUCKET SEATS - These seats are the sides, top and back to provide additional force
common to buses, vans, motor homes and trucks. moderation and load distribution during collision.
In addition to the normal fore-and-aft position ad- This concept is typified by the Crandell-Liberty
justments, variable backrest angle and swivelling Mutual Survival Car II (11).
mechanisms are sometimes provided. Because of

D RESTRAINT
/INTEGRAL OR ADJU.STAlsLE/

UPHOLSTERY
STRUCTURAL FRAMEWORK

LUMBAR CONTOUR ADJUSTMENT


ACKREST ANGLE ADJUSThfENT
SEAT/BACKREST JUNCTION
w c PIVOT ARM
Fig. 2 - Seat nomenclature
PIVOT FOR REAR SEAT ACCESS
LFORE AND AFT AND V.ERT/CAL ADJUSTMENT
2554 D. M. SEVERY

SEAT ADJUSTMENT MECHANISMS - These and attachments require a design of adequate strength
mechanisms should be strengthened to withstand to accommodate seat and occupant inertial forces
collision forces as well as the rigors of everyday identified specificaIly in other sections of the paper.
usage. Considerations of driver anthropometric Besides the usual floor, sill and tunnel anchorages,
differences necessitate a multiplicity of seat other potential anchorage locations for strengthened
adjustments to assure that a given seat provides seat systems include side and roof attachment.
the multiple functions of driver positioning for
correct reach and view, as well as for adequate SEAT DESIGN CONCEPTS
comfort. Desired seat position may be accomplished
by means of longitudinal, vertical and tilt adjust- Restraint compliance, is the change in re-
ments . Other adjustments include backrest angle, straint geometry induced by motorist’s inertial
head restraint position and lumbar support stiffness. forces during collision. For example, a lap belt
Head restraint height adjustment is a common may initially course from its floor anchorage to-
feature of current production seats. Unfortunately, ward the lap of the wearer at 45 degrees but as a
many recent seat designs provide no head support frontal impact develops, this angle is reduced owing
protection from even minor rear-end collisions to a combination of factors that result in the
when the head restraint is in its most commonly used, occupant’s buttocks being compressed downward and
retracted position. Proposed legislation (12) would forward on his seat as the belt restraining forces
modify head restraint requirements to ensure pro- increase, (13). Similar ily , variations in support
per utilization by preventing mis-adjustment or force, restraint angle and resulting backrest
complete removal. Backrests with integral head pressure modulations occur for the seated occupant
restraints eliminate adjustability deficiencies, but as the seat backrest undergoes restraint compliance
should be designed to protect 95th percentile adult during a rear-end collision. This is illustrated for
male occupants. Adjustable headrests should extend restrained and also for inadequately restrained
to 80 cm (32-in) and not allow adjustment below occupants, by the geometric areas within the curves
70 cm (28 in); the headrest in its adjusted elevated depicting displacements of occupants relative to
position must not collapse from head impact. their vehicle, Fig. 3. Also shown is the added
SEAT ANCHORAGES - Most vehicle designs physiological trauma associated with unstructured,
depend on seat attachments at the floor or at the inefficient restraint compliance. Variations in occu-
sill and tunnel to transmit forces between the pant collision-induced accelerations (slopes, Fig. 3)
vehicle and the seat. This anchorage is generally depend on the effectiveness of occupant restraints
interposed between the seat adjustment mechanism which determines in large measure the trauma
and the vehicle floor pan or lower structure. during ride-up/ride-down accelerations; the mech-
Under static conditions, the seat anchorage anism of transmission of accelerative forces re-
transmits compression, tension and shearforces present the other operative factor for such trauma-
from the seat to the floor or side structure. In tic exposures. The problem faced by a seat designer
the event of collision or handling accelerations, the is to determine the force resistive levels, and there-
resulting forces are transmitted in reverse direction fore the degree of collision severity, a specific seat
from floor to seat. The seat anchorage structures design should be able to accommodate before back-

TIME, MILLISECONDS

Fig. 3 - Relative abruptness of occupant “Ride-down/Ride-up ,I’


according to efficiency of restraint
AUTOMOTIVE SEAT DESIGN AND COLLISION PERFORMANCE 2555

rest restraint compliance reaches values where burdens remain yet unsolved. With this in mind,
occupant forced displacements expose him to serious the authors redesigned a Volvo production bucket
or critical injuries. seat into an integrated safety seat. This approach
When not faced with the realities of cost and should facilitate recognition by automobile manu-
operational practicality, as well as the need to pro- facturers and the Federal Government’s safety
vide design features that favor public acceptance, standards making authority, that the goal for greatly
a simplistic approach is to set safety design criteria improved motorist safety is reasonably attainable
at some arbitrarily high level, one considered suf- through development of an integrated front seat.
ficient to encompass virtually all probable collision The Volvo seat was stripped of its upholstery
exposures. Such arbitrary criteria is insensitive and subjected to an evaluation of modifications con-
to orders of priority and cost for safety design im- sidered essential to developing performance speci-
provement and disregards the interactive response fications for an integrated safety seat, Fig. 6.
it may impose on other related, or concurrently Next, this production seat frame was modified to
important, passenger and operational safety features. provide the added structural support required for
The front seat backrest and the steering column the special protective hardware, Fig. 6b.
have in common the engineering design problems Seat Modifications - Changes were made in the
that result from dealing with cantilevered structures production seat by additions of components to aug-
acted upon by occupant collision forces. Additional- ment existing safety and comfort features and to
ly, backrest angles of 15 to 25 degrees increase introduce new protective functions as follows:
design difficulties by incorporating angles that allow
less efficient crash force moderation. (a) High section-modulus tubular steel back-
rest, from seat attachment through head support.
LABORATORY SEAT TESTS (b) Double seat tracks, for more positive
anchorages.
Passenger vehicle seats of differing make (c) Lap and cross-chest safety belt inertial
vehicles are as varied structurally as the motor reels mounted to seat frame for ease of fastening
vehicles within which they are mounted. Aside from and for optimum occupant restraint for all adjust-
their apparent commonalities consisting of seat, ment positions.
backrest, head support, covering, padding, springs, (d) Energy absorbing back panel, to moderate
and frame, the multiplicity of design and size and pocket occupant inertial loads during medium
variations account for their significantly differing and high-speed rear-end collisions and to provide
weights (under 9 kg to over 45 kg or about 20 to knee pocketing for kinematic control of rear seat
over 100 lbs.) height of backrests (from 51 cm to occupants thrown forward during frontal collisions.
about 76 cm or from 20 to about 30 in) and maximum (e) A pair of seat-mounted inertial reels for
bending moment before excessive backrest deflect- belt fabric which connects the base of the seat at
ion (from 45 m-kg to about 95 m-kg or about 4000 its rear to the roof; the belt fabric is passed through
in-lbs to 17,000 in-lbs), Fig. 4. As remarkable the backrest to the roof anchorage. This arrange-
as these variations would appear, they represent ment allows the seat to be adjusted fore-and-aft
little difference in motorist protective capacity and folded for entry accommodation; however during
owing to the fact that none of them are capable of a front or rear-end collision, the dual “safety
effectively resisting motorist inertial forces for belts” are capable of immediate seat inertial snub-
any substantial impact exposure. bing.
Based on laboratory tests of seats from cars (f) Deeply contoured bucket seat geometry to
large and small, foreign and domestic, and from assure occupant positive lateral support and to
vehicles 30 years old to near new, backrest strengths improve comfort.
were found to be remarkably alike, Fig, 4. Force- (g) Retention of the most advanced comfort
deflection performance curves of representative pro- and safety features of backrest angle adjustment,
duction seats as well as recommended performance lumbar spine firmness adjustment and louvered see-
for passenger vehicle seats capable of protecting through head restraint.
their occupants during severe collisions are shown, Most prior integrated seat concepts have
Fig. 5. utilized the backrest cantilever principle which
INTEGRATED SEAT - The concept of an in- necessitates strengthening floor and seat anchorages
tegrated seat for motorists has been considered along with seat and backrest framing in an effort
and evaluated theoretically; experimental seats to combat the extreme bending moments, especially
have been constructed and tested experimentally, attending front and rear -end collisions, (7)) (8))
(I), (2), (5), (6), (7), (II), (14). In general, the (14). The advantage of this approach is that seat
approach has been to design an entirely new seat, fore-and-aft positioning and backrest folding for
inducing the argument that practical aspects of access to the rear seat can be accommodated with-
manufacturing, occupant comfort and similar design out roof or side attachment; disadvantage is that
2556 D. M. SEVERY

1940 1950 1960 1970 1960


YEAR

z 1200- (RECOMMENOEO S T R E N G T H ) \\a\\\\


c.3 _1104.000,
$2 IOOO-
LT 1 ~87,000,
k-i
U-J = ,,&?~

Fig. 4 - Automotive seat strength and backrest height

(PREVAILING STRENGTH) variations over the past thirty years


~.~\\\\...~\\~

1940 1950 1960 I970 1960


YEAR

* STATIC REARWARD FORCE


APPLIED 35 CM ABOVE
SEAT/BACKREST JUNCTION

Fig. 5 - Backrest force-deflection data for 85 production B A C K R E S T D E F L E C T I O N , CM (IN)


automobiles, foreign and domestic, large and small sized
vehicles

it is a very inefficient method of resisting large tests along the lines previously described as shown
forces owing to the massive increases in structure by Fig. 8. The improvement in force-displacement
required to offset extremes in bending moments. over non-modified production seats is shown by the
The authors found that many production seats could dotted curve of Fig. 5. Considering the nature of
resist between 900 and 1800 kg force (about 2000 to changes necessitated by using an existing seat, it
4000 lbs) horizontally rearward or forward at the is apparent that a somewhat lighter seat could be
seat rail. If these floor anchorages were only made even stronger if it were an original design
slightly improved, and connected by belt webbing rather than a retrofit. The composite design
to the roof, the cantilever design could be replaced factors for a remarkably stronger, attractively
by the basically greater efficiency of the tension contoured seat are shown by Fig. 7. Extensive
semi-hoop design spanning floor to ceiling. The crash testing of such new concepts are recommended
Experimental Safety Vehicle by Opel also uses a for sound development before they are used in pro-
form of roof anchorage for its front seat backrests, duction vehicles.
(2). Encouragement was given to the practicality
of this concept by a preliminary test of roof strength SEAT COLLISION PERFORMANCE
of a mid-sixties 2-doer hardtop sedan. This un-
modified roof structure withstood over 1800 kg Relative to vehicle safety, performance connotes
(4000 lbs) horizontally rearward at a localized back- a level of attainment, a plateau from which concepts
rest to roof attachment location, without significant for improvement may be assessed, both as to prac-
downward crush. ticality and possible adverse influence on other safety
The integrated seat was subjected to laboratory requirements. Like the occupant that uses it, a
AUTOMOTIVE SEAT DESIGN AND COLLISION PERFORMANCE 2557
2558 D. M. SEVERY

ROOF ATTACHMENT: ;;;

ROOF ANCHORED BELTS TRAVERSE


DOWNWARD THROUGH SEAT
INTEGRATED SEE- THRU HEAD RESTRAINT
PADDED LATERAL SUPPORT
BlJlL T- /N 3 PO/NT BELT /
BACKREST PANEL DEFORMABLE MA
ROOF ATTACHMENT INERTIAL
EXTENDED LATERAL STRUC
ROCKER S/L L

Fig. 7 - The Integral Safety Seat conceptualized and tested


by the authors

Fig. 8 - Integrated seat during testing; 2268 kg (5000 lb)


force applied rearward

seat has rather specific collision force tolerances: The basic collision performance criteria that
exceeding its design criteria allows crash forces applies to a seat is its resistance to backrest yield
to yield or fracture whatever component of the seat and its ability to transmit forces through the seat
is most susceptible. This collision response is to its anchorages. Although seat design has in no
common to all seats, as determined from destruc- way kept pace with advances made in other safety
tive tests to over 85 different automobile seats related areas, there are some notable exceptions;
mounted on their floor pans. Although individual certain Mercedes and Porsche automobiles, for
designs determine which components may fail first, example, attach lap belts to the seat, rather than
their level of susceptibility is remarkably similar. using the less satisfactory arrangement of floor
Perhaps the foundation for this similarity in seat anchorages. Volvo and Saab have provided see-
strength levels is generic to the basic design require- through head restraints that improve visibility. The
ments that were dictated long before collision forces track record of most vehicles, however is not
were identified as factors for consideration. For impressive. In general, backrest strength and
example, an adult male can apply 90 to 135 kg (200 height has not improved, possibly because the need
to 300 lbs) force to the backrest during emergency for stronger, full-support backrests is not fully
braking. If passengers also brace for a possible understood by regulatory agencies and those making
collision, the backrest of a bench seat can be called design decisions.
upon to resist as much as 275 kg (600 lbs) force, SEAT COLLISION PERFORMANCE - FRONTAL
It is understandable, therefore, that seats in the COLLISIONS - It is becoming increasingly apparent
forties and fifties had backrest yield resistance of that passive restraint systems alone cannot protect
about 275 kg (600 lbs) even though they were not motorists from the varied exposures encountered
designed in a period when collision safety was a during motor vehicle accidents (2), (3). Systems
prominant consideration: incomprehensible is the that protect during a barrier-type crash may be
fact that seats in the seventies show no significant completely ineffective if the same frontal collision
improvement. is accompanied by one or more minor impacts or
AUTOMOTIVE SEAT DE,‘,IGN AND COLLISION PERFORMANCE 2559

an upset. The cross-chest lap belt restraint system, the lap safety belt. This arrangement maintains
on the other hand, provides effective motorist pro- the lap belt across the pelvic girdle during collision
tection during most collisions or combinations of and, for non-integral seats, reduces mal-alignment
collisions, including upset. If an integral three- of the cross chest strap as the torso flails forward
point restraint system is available, in conjunction against it.
with the strengthened seat to which it should be SEAT COLLISION PERFORMANCE - REAR-
attached, it can provide levels of protection unat- END COLLISIONS - The most frequently occurring
tainable with any other single system, however type of motor vehicle collision is the rear-end im-
costly or complex. In addition to minimizing or pact. For example, forty-nine percent of the 14.6
eliminating impact forces to the vehicle interior, million accidents involving motor vehicles in the
the combined restraint system appreciably reduces United States during 1968 were same direction or
the forces that would be applied for a lap belt only rear-end type accidents; representing nine percent
protective system, (15). of the total number of fatal collisions, (17).
One advantage claimed by air bag proponents is Seat backrest performance during rear-end
the additional ride-down distance provided as the collisions parallels a condition of walking on thin
motorist crushes forward relative to the vehicle ice; minor torso inertial forces receive adequate
interior. Direct attachment of belt restraints to support but as impact severity increases, the
the seat minimizes uncontrolled belt slack and at resistive support approaches negligible values. The
the same time allows the designer to incorporate mechanism by which this passive restraint is lost
belt pre-stressing and other ride-down improve- is generally unimportant insofar as its effect on
ments for the belt and seat anchorages. The belt motorist kinematics is concerned. Torso inertial
system can thereby provide maximum protection for movement does not respond differently with differing
front-end collisions and also provide more adequate mechanism of loss of back support; it simply re-
protection during the wide range of other collision sponds inertially to fall-off of resistive force. Thus,
exposures, including moderate to severe rear-end whether backrest resistance is subsequently lost
collisions by keeping the occupant in the seat. Even because of excessive backrest yield or by combina-
a floor mounted lap belt can provide considerable tions of baclcrest yield and anchorage separations,
protection under these conditions, (16). the motorist inertial forces will act in the same
Rear seat occupants that fail to fasten their manner.
belt would obtain some degree of passive restraint Backrests are slightly reclined for comfort
from a strengthened front seat backrest. The knee and to assist with torso support. However, as the
pocketing concept evaluated and described previously seat is forced to recline additionally during rear-
(6), will add considerably to rear seat occupants’ end collision, the torso is predisposed to ramping
collision protection by controlling posture during up the plane of the backrest, Fig. 9. On reaching
their “second collision. ” The spacing between rear backrest angles exceeding 45 degrees, the ramp
occupants and front backrest provides a time delay component falls off according to the function “sin CY
before the rear occupants strike the front backrest; cos CX, I’ where alpha (a) is the backrest angle rear-
therefore, front seat occupant ride-down would not ward from the vertical axis. Simultaneously, the
be compromised significantly from subsequent backrest support force, FSB, which accelerates
impact to the backrest by the rear seat occupant. the motorist as the backrest bears against him
Rear seat occupant protection for all but rear-end during a rear-end collision, falls off as a function
collision exposures can best be accomplished by of backrest yield-angle, likewise depicted by Fig. 9.
means of active restraint systems. Obviously, a zero or near zero angle provides the
OCCUPANT RESTRAINT WITH A RECLINED most effective torso support by the backrest during
SEAT - The cross-chest lap belt is less effective rear-ending and torso support tends to fall off
in front-end impacts where the passenger has thereafter, as a cosine function of increases in the
reclined his seat; the torso slides forward, shifting baclu-est angle.
the lap belt upward across the viscera. When belt These factors are particularly relevant for
snubbing eventually occurs, forces are transmitted production seats involved in light to moderate
to portions of the body unable to sustain them with- rear-end collisions where bachest strengths
out exposure to serious injury. Also, the neck or generally are adequate for those respective exposures.
head may strike the cross-chest belt in an ineffec- However, for most moderate to severe rear end
tive, if not dangerous manner. One solution is to collisions, all production seat backrests deflect to
provide an additional pair of straps attached at the angles providing no effective motorist support.
front of the seat and passed upwards through posi- This situation is illustrated by considering the re-
tioning guides. Before reclining the backrest, the lationship of backrest support provided the torso as
hanging ends of the straps are pulled up between a function of rear-end collision speed, Fig. 10.
the legs and fastened to attachment loops sewn to Sixty-five percent of the body weight may be used
D. M. SEVERY

I,
c
/
I_---,
IO 20 30 40 50
SEAT BACKiEST 4NGLE
60 ‘70
,o< , DCWCES
RO
Fig. 9 - Degradation of backrest support as function
of collision induced deflection

as a minimal approximation of the torso and requirements for individual components. For ex-
adjacent flailing body components that operate any ample, the extremely difficult design task of
instant to inertially act on the backrest and may be providing 75,000 inch-lbs yield resistance at the
characterized as the occupant inertial force, F . bachest pivot for a 50% adult male in a 30G seat
The seat backrest yield point, or point of maxizim system can be easily managed by utilization of a
battiest resistive force, F , is reached when the roof ant hor . If one-third of the 6540 pound hori-
occupant inertial force plus 7 he seat backrest zontal force is applied at the top of t,he seat and
inertia force exceeds FR as shown by F acts 32 inches above the backrest pivot, we now have
8’t;eFsI =
Based on collision experiments (1 the following moment at the pivot arm:
FR’
torso inertial force increases with collision speed, MI = 75,000 - (32) (2180) = 5300 in-lbs, a
in the manner shown by Fig. 10. Regardless of reduction to 7% of the original required bending
speed of impact, the backrest can provide only a moment. Most production seats can provide this
given maximum resistance to yield; however, as level of bending resistance without need for modi-
rear-ending speeds increase, the collision severity fication. With a roof attachment, the maximum
is reached where the baclu-est can at best support bending moment will be at a higher elevation on the
solely its own weight, but none of the occupant, seat and in a location of the backrest free of com-
Fig. 10. Thus the effective backrest strength is plications of pivots and adjustment mechanisms.
dependent on a combination of backrest resistance Correspondingly, the reduction in reaction strength
to yield and backrest weight, referred to as back- required at R , RH and RF, if a roof anchorage is
rest weight, referred to as backrest inertial yield added, prove*%es a requirement of only 2%, 65%,
resistive force. The lighter the weight of a seat, and 2% respectively of the values necessary without
relative to a given resistance to deflection, the a roof attachment.
better able the seat to resist torso displacement SEAT COLLISION PERFORMANCE - SIDE IMPACTS -
during rear-end collision. Direct side impacts into the passenger compartment
Given a sufficiently severe collision, any seat represent the gravest danger to motorists at a given
will fail; the type of failure however, depends on speed of impact for any type of collision, (18).
design. Rear-end collisions induce five basic Usually less than a foot of intervening structure,
types of failure; a particular collision exposure for much of which is non-structured space, separates
a particular seat design may result in one or a the motorist on the impacted side from the front
combination of these five types of failure: end of the impacting vehicle. During collision,
(a) Excessive backrest yield the near-side occupant suffers a considerably more
(b) Track-runner vertical separation severe acceleration than does the vehicle in which
(c) Track-runner longitudinal separation he is riding. This impact exposure can be lessened
(d) Compressive crush at seat base somewhat by increasing the amount of side structure
(e) Floor yield at seat attachment stiffness and thereby minimizing passenger compart-
All automotive seats have collision induced ment intrusion. However, the point of diminishing
failure modes that are caused by moments and return is soon reached as intervening structure is
forces exceeding one or more of the seat compo- added, since crush distance is still limited, and
nent yield points. Critical reaction requirements delayed occupant response serves to magnify the
can be calculated for various occupant sizes and resulting exposure, A considerably simpler
acceleration exposures using free body analyses of solution is to attach the motorist firmly to a deeply
the seat system, Fig. 11. contoured seat by means of an integral 3-point belt
For rear-end collision exposures, the addition and to provide intermediate structural members
of a roof anchorage for the backrest serves to between striking car and seat to cause the seat,
distribute forces and considerably lessens design
AUTOMOTIVE SEAT DE:XGN AND COLLISION PERFORMANCE 2561

IL 400-

BACKREST PEAK
RESISTAANCE TO YIELD

0 20 100
(124) u44093 ($33) 14% 162 I)
REAR-END COLLISION CLOSURE VELOCITY, KWHR (MPH)

Fig. 10 - The relationship of backrest torso support, a s


a function of rear-end collision speed

3
-1 8,000-
$ (69,000)
-

iz
2

0 IO 20 30 40
COLLISION ACCELERATION, G’s

Fig. 11 - Collision induced seat stresses, rear-end


collision exposure

with occupant attached thereto, to be accelerated up, ” is similar to the “ride-down” concept of
more promptly but less abruptly. protection from frontal collisions, identified by
Analysis of the velocity-time profile of a prior publication, (19). The more prompt
typical side impact collision, Fig. 12, provides acceleration also reduces the impact abruptness or
further understanding of the nature of accelerative “Stapp’‘-factor. Since the combined weight of the
exposure and resulting injury mechanism as it seat and the occupant is often less than 90 kg
exists for the unrestrained struck motorist. This (200 lbs), it is not necessary to provide significantly
graph also shows the remarkable reduction in heavier structure than already present to accomplish
occupant acceleration that can be accomplished if the objective of prompt seat acceleration during a
the seat is structured and interlocked with side collision. It is only necessary to position the
panels so that it is accelerated more promptly structure at the proper elevation and location to
following initial contact by the striking vehicle. allow more direct collision force application to
This improved side impact acceleration, or “ride- the seat structure to occur before substantial in-
2562 D. M. SEVERY

50 K#/l

kl;
G ‘MAXIMUM ACCELERATIONS (APPROX.)
8 0 STRIKING VEHICLE C.G. ,..... .._......... ._... 20 G
\
t IO 0 STRU C K VE HICLE C.G ._...... 20 G

-(33) OUTER SURFACE _......_... + @ G

/‘m f : : ;,;z;;;;;pzg(,G
? INNER D O O R S U R F A C E 1706

;,.,li ,, 3tfl’
@ 4, u
ENERGY A B S O R P T I O N 6 0 G

FULLY RESTRAINED
I-X-CliPANT IN INTFGRAI
““““. _.. , . . . ,.. . L.,I.__

S E A T . . . __. __... ._. ._. __ .__. 30 G

F i g . 1 2 - I n t e g r a l s e a t , side-impact e x p o s u r e a n a l y s i s
ward crush has taken place. Additional motorist STANDARDS AND RECOMMENDED PRACTICES
force moderation is provided by the pocketing
effect of the integrated seat. This seat side-struc- In November 1963, a Society of Automotive
ture tends to shield the motorist from direct Engineers Committee report on passenger seats
impact by his vehicle side structure as well as to and adjusters was approved. This action, for the
minimize “slack” between the motorist and his first time, extended the concept of recommended
restraint system. This shielding also reduces practices and performance standards to include
motorist exposure to punctures and shear forces. automotive seats. Two tests were specified by
ROLLOVER PROTECTION - Injuries and recommended practice 5879, the first of which
fatalities during rollover accidents occur most established minimum strength requirements for
frequently as a result of ejection (20), (21); a horizontal inertial seat loadings for front and rear
basic requirement for occupant restraint systems impacts. This 20G specification corresponds to
is to retain the occupant within the vehicle during approximately a 900 kg (about 2000 lbs) seat an-
upset. Even if adequate retention is achieved, chorage loading for a typically large domestic
protection is compromised if there is inadequate bench seat and serves to evaluate the retention
supportive roof structure. capability of the adjuster mechanism and seat
Roof structures are sometimes flattened during anchorages. The second test prescribed by SAF
upset sufficient to dangerously reduce the motorist 5879 concerned backrest strength and specified
sur viva1 space. This crush can be reduced consider- a minimum moment of 4250 in-lbs. Although the
ably by constructing the seat backrests with suf- scope of the recommended practice included an
ficient strength to act as central pillars for the intent to submit it to a “continuing review” no
roof. A strengthened seat with integrated head substantial changes were made until July 1968.
restraint of a height necessary for adequate head In 1965 the Federal Register published General
support for taller persons 80 cm or more (32 in) Services Administration (GSA) Federal Standard
is recommended if central roof collapse resistance 515-6 governing “Anchorage of Seats. ” This initial
is to be increased by backrest structural support. seat standard became effective in 1966 for 1967 mo-
Seat backrest structure of sufficient strength and del automobiles. GSA adopted basically the original
height to answer the requirements imposed by SAE recommendations with no major changes.
other collision exposures will also prevent complete Although this transfer of 5879 from an SAE Recom-
collapse of roof structure in nearly all collision mended Practice to a GSA standard was applicable
exposures. only to government purchased vehicles, it was
understood to be the forerunner for a standard
directly affecting every passenger car sold in the
United States.
AUTOMOTIVE SEAT DE.;IGN AND COLLISION PERFORMANCE 2563

In 1966, by act of Congress, the Department of tion (NHTSA). However, with respect to automo-
Transportation (DOT) was added to the Federal bile seat collision safety, little progress has been
Government. The 1965 GSA 515-6 Standard, which made. A near obsession with air bag development
was actually the SAE Recommended Practice of 1963, regrettably has diverted a tremendous amount of
was adopted by DOT in January 1968 as Federal research time and resources from the readily
Motor Vehicle Safety Standard (FMVSS) 207. The achieveable goal of making the automobile seat
FMVSS 207 established backrest strength for crashworthy. As a result, many automobiles
standard passenger vehicles at 3300 in-lb, differing being manufactured a decade after the onset of
insignificantly from the GSA/SAE 4250 in-lb value, Federal Government standard making still have
owing to a change in reference systems. FMVSS seats no stronger than they were during the pre-
207 references the Hip Pivot or H-point (as described regulatory period. Any real improvements made
by SAE J826b) whereas the SAE 58’79 and GSA 515-6 in seat design have been on the initiative of the
used a reference pivot point that was about 20 cm manufacturers because the seatback standards
lower (8 in) at the interface between the seat frame relating to strength have remained virtually un-
and adjuster. Although 3300 in-lbs may appear to changed. The presence of an inadequate, seldom
be an impressive value, production seats from the upgraded standard limits initiative of automotive
nineteen forties and fifties tested by the authors were manufacturers because of the implication that
found to substantially exceed this standard. FMVSS satisfactory conditions prevail.
207 included the requirement that the fold-forward
backrest locks withstand a 20G minimum inertial SUMMARY OF FINDINGS
load which represented a modest improvement. In
1972, FMVSS 207 was amended to include multipur- 1. Improved automotive seat systems should pro-
pose passenger vehicles, trucks, and buses. Addi- vide adequate structure and built-in active restraints
tionally, the standard was expanded to include re- to insure a reasonable degree of protection from
quirements relating to rear seats. collision forces. Seats need adequate contour to
Head restraints, whether separable, or integral provide effective support and sufficient adjustments
with the front seat backrest were regulated by to meet the varied and changing requirements of
FMVSS 202 in 1969. This standard requires the their occupants. Redesign and strengthening of the
head restraint to be capable of resisting a 200 pound seat framework and anchorages is required for
force applied horizontally to it and actually consists direct attachment of lap and shoulder belts and to
of a more severe loading to the backrest pivot than provide the force resistance necessary for occupant
does FMVSS 207, to reduce the chances of head restraint during moderate and severe front, side
support failure before backrest failure. and rear-end collisions.
In Europe, seat strength standards applicable 2. All automotive seats develop collision-induced
to non-exported vehicles were enacted by the Council yield or separation modes caused by forces and
of European Communities in 1974; these are moments from motorist and seat inertia when such
basically the same as FMVSS 207, except for an stresses exceed one or more of the seat component
increase in the minimum moment resistance of yield points. Although the specific component of a
the backrest from 3300 in-lb to about 4700 in-lb seat that fails first may differ, the degree of sus-
(54 m kgf), both with respect to the same H-point ceptibility of all seats is remarkably similar. Lab-
reference. oratory tests establish that production seats from
Prior to the advent of the automotive standards cars large and small, foreign and domestic, and
making authority by the Federal Government, the from vehicles 30 years old to near new, have back-
automotive industry was largely self-governed, rest strengths remarkably alike. All are incapable
relative to implementation of safety concepts. of effectively resisting motorist inertial forces for
Slow, methodical but nevertheless significant any but light impact exposures without inducing
progress was made during this self-governed period, excessive yield and/or component separation.
as pointed out in a prior publication, (19). The 3. Variations in support force and restraint angle
emphasis was on operational and performance occur for the seated occupant as the seat backrest
safety; accordingly, collision safety advances were undergoes restraint compliance during a rear-end
limited. collision. The mechanism by which this passive
Following the mid-sixties, the responsibility restraint is lost is generally unimportant insofar
for progress in collision safety was taken over by as its effect on motorist kinematics is concerned.
the Federal Government and assessment of the Torso inertial movement does not respond dif-
progress made in this more recent period depends ferently with differing mechanism of loss of back
on the specific safety category being considered. support; it simply responds inertially to the degrada-
In general, commendable improvement in collision tion in resistive force.
safety has occurred during this period of regulation 4. Intended headrest height requirements are
by the National Highway Traffic Safety Administra- not met for many seats when the headrest is in its
2564 D. M. SEVERY

most commonly used, retracted position. Backrests 9. The integral safety seat protective capability
with integral head restraint should protect 95th per- against frontal impacts is well established, and
centile adult occupants; it is preferred that head- roof crush during rollover can be considerably
rests be contiguous with the backrest and of fixed reduced by taller and strengthened front seat back-
elevation; if adjustable, headrest adjustment should rests serving as central pillars for augmentation of
provide extension to 80 cm (32 in) and not allow roof support: with an integral seat-restraint system,
adjustment below 70 cm (28 in). regardless of the direction of impact, levels of
5. Passive restraint systems that effectively con- motorist protection can be achieved that are un-
trol motorist collision dynamics during a barrier attainable with any other single system, however
crash may be ineffective if the same frontal collision costly or complex.
is complicated by multiple impacts or upset. The 10. Commendable improvement in collision safety
cross-chest lap belt restraint system, on the other has occurred during a decade of regulation by the
hand, provides effective motorist protection during National Highway Traffic Safety Administration.
most collisions or combinations of collisions, However, with respect to automobile seat collision
including upset. safety, effective progress has been negligible. A
6. Collision-induced occupant accelerations near obsession with air bag development regrettably
vary according to the effectiveness of occupant has diverted a tremendous amount of research time
restraints. These variations in “ride-up” and and resources from the readily achievable goal of
“ride-down” velocity changes determine in large making the automobile seat crashworthy. Although
measure the extent of trauma during collision; the the 3300 in-lbs backrest resistance feature of the
mechanism of transmission of accelerative forces FMVSS 207 sounds impressive, production seats
represent the other operative factor for such from the nineteen forties and fifties tested by the
traumatic exposures. authors were found to substantially exceed this 207
7. The authors designed, constructed and labora- principal criteria.
tory tested a high performance integral safety seat 11. Judged on any rational basis, whether as to
that was made by structurally modifying an existing initial cost, maintenance costs, functional reliability,
production seat design without compromising its exposure to dangerous malfunction or lack of
advanced design comfort features. The roof-to- effectiveness for many types of collision exposures,
floor anchored webbing for backrest crash force the air bag comes up as a king-size loser when com-
attenuation remarkably simplifies seat structural pared with the collision protection of the integrated
requirements because bending moments are de- seat which includes integral cross-chest lap belt
creased more than ten-fold. By use of inertial restraint. While the United States endlessly ponders
reels this front seat conversion is accomplished the air bag issue, the rest of the automotive world
without inhibiting rear seat access for two-door has reached the conclusion that cross-chest lap
vehicles or backrest reclining or seat fore-and- belts in combination with mandatory use laws
aft positioning. Direct attachment of cross chest, represents the simplest, least costly and most
lap belt restraints to the seat minimizes uncontrol- effective motorist protection measure.
led belt slack and allows incorporation of belt pre-
stressing and other restraint compliance improve- REFERENCES
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AUTOMOTIVE SEAT DE! IGN AND COLLISION PERFORMANCE 2565

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