Additive Manufacturing Safety Belt Buckle Release Member
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Solution Overview
Problem
Current techniques for manufacturing safety belt buckles, such as metal casting, are not well-suited for producing small batches and are costly, making it difficult to create customized buckles efficiently.
Innovation Solution
The use of additive manufacturing (3D printing) and injection molding to form safety belt buckle structures with a base member and release member, where the release member is formed by printed device layers and coated with metal, allowing for the inclusion of 3D patterns and in-mold features, enabling efficient production of customized buckles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal casting is used to manufacture safety belt buckles, then manufacturing precision and strength are improved, but production cost increases and small batch production becomes inefficient
Solution Approach 1:
The patent changes the manufacturing method from traditional metal casting to additive manufacturing (3D printing), fundamentally altering the production parameters. This enables small batch and customized buckle production while maintaining acceptable manufacturing precision, directly resolving the contradiction between production efficiency and precision for small batches
Solution Approach 2:
The patent employs composite construction by combining printed device layers with metal coating. The base structure is created through additive manufacturing using polymer or composite materials, then enhanced with a metal coating layer to achieve the required strength and surface properties, allowing cost-effective small batch production without sacrificing performance
2Strength
If metal casting is used to manufacture safety belt buckles, then strength and durability are improved, but production cost increases
Solution Approach 1:
The patent uses composite materials where a printed base structure (polymer or composite) is combined with a metal coating layer. This composite approach achieves the required strength and durability while significantly reducing production cost compared to traditional metal casting, as the metal coating uses less material and the additive manufacturing process is more cost-effective for small batches
Solution Approach 2:
The patent adopts additive manufacturing which uses inexpensive polymer or composite materials for the base structure, replacing expensive metal casting. The printed layers provide the structural framework at lower cost, with metal coating applied only where needed for strength and appearance, making the overall manufacturing process more economical
3Adaptability or versatility
If traditional manufacturing methods are used, then customization capability is limited, but manufacturing process remains simple
Solution Approach 1:
The patent leverages additive manufacturing technology which allows easy modification of digital design files to create customized buckles. By changing the digital model parameters rather than physical tooling, the system achieves high adaptability for customization while keeping the manufacturing process relatively simple and flexible
Solution Approach 2:
The patent creates a universal manufacturing platform using additive manufacturing that can produce various buckle designs and customizations through software modification alone. The same printing equipment and basic process can generate different patterns, logos, and designs by simply loading different digital models, providing multi-functionality without increasing physical device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the cost-effective production of customized safety belt buckles with various design features, reducing production costs and enabling efficient manufacturing of small batches.
Implementation Method 1
The release member is formed by a plurality of printed device layers and a metal coating disposed over the plurality of printed device layers
Data Source
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AI summary
Passenger safety belt buckles are disclosed. In embodiments, a safety belt buckle (100) includes a base member (102) and a release member (104) coupled to the base member (102). The release member (104) is configured to release a tongue held between the release member (104) and the base member (102) when the release member (104) is pulled away from the base member (102). In an example embodiment, the release member (104) is formed by a plurality of printed device layers (116, 120) and a metal coating (122) disposed over the plurality of printed device layers (116, 120). In another example embodiment, the release member (104) is formed by a plurality of printed metal layers. In yet another example embodiment, the release member (104) includes a recess (110) with an in-mold feature disposed within the recess (110).