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An Integrated Restraint Seat (IRS) improves occupant protection, comfort, ease of rear seat ingress and egress, and eliminates special restraint packaging issues normally associated with convertible top vehicles. Two years ago, seven companies formed a Consortium which is now known as the Lear Seat Consortium. The goal of the Consortium is to provide cost and mass effective Integral Restraint Seats. A composite seat frame consisting of high modulus metal stabilized by low modulus plastic results in a low mass, cost effective seat. A unique insert extrusion blow molding process is utilized to form the composite structure. This paper describes the design, materials, process, load criteria, structural analysis and testing of the composite IRS.

This paper examines the design challenge represented by the development of the various lightweight automotive wheel programs such as HSLA, aluminum, and plastic. A survey of the various design analysis tools available are made and the phenomenon of correlation between theoretical finite element computer analysis and experimental analysis is investigated. The design issues of optimum weight versus fatigue life, failure detection, material properties, manufacturing stresses, work hardening, temperature sensitivity, creep, and lugnut torque retention are discussed and the new experimental tools required to monitor these issues are described. This paper describes the required link between theoretical and experimental analysis, and specifically describes the creation of the sophisticated testing systems required to accomplish these analyses.