Rear seat occupants in newer vehicles might face a higher injury risk during traffic collisions compared to front seat occupants, whose seats have significantly improved over the last few decades. In addition, the rise in ridesharing and automation could increase exposure of rear seat occupants. Therefore, this study aims to evaluate the effects of various characteristics of rear seat design on occupant safety during frontal collisions. A simplified seat model was developed and validated against sled test data (ΔV of 32 km/h). Ten seat characteristics of the simplified seat were then investigated using two Design of Experiments techniques. Occupant injury risks were derived from crash simulations, and the correlation between the seat design and injury probabilities was evaluated. The results indicated that a more vertical seat back angle, specific D-ring location (a more rearward, inboard, a higher), and seatbelt anchorage location (wider and higher) would improve rear seat safety performance. Optimal seat models were developed based on the DOE results, and their superior performance was confirmed in finite element (FE) crash simulations. Overall, the whole-body injuries in optimized seats were significantly lower than the average injury risk in the DOE cases for both 50th percentile male Hybrid III (38.5% vs. 70.5%) and THOR (52.8% vs. 78.1%) dummies. These findings suggest substantial potential for improving rear seat designs to enhance occupant safety.
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