Segmented Armrest Frame Overmolding for Simpler Seat Assembly
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Solution Overview
Problem
Existing seat armrest frames for motor vehicles have complex and costly manufacturing processes due to large molds and multiple injection points for overmolding, and require specific precautions during transport and storage to avoid damage.
Innovation Solution
A simplified armrest frame design featuring a shaft with a single plastic lining overmolded around it, and a second portion with branches attached, allowing for a single injection point mold and easier assembly, reducing manufacturing costs and improving transport and storage handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the armrest frame is formed by overmolding metal rods with plastic connection elements at four corners, then the frame structure is complete and functional, but the mold dimensions become significant and manufacturing cost increases
Solution Approach 1:
The invention divides the armrest frame into two separate portions: a first portion with the shaft and plastic lining, and a second portion with branches. This segmentation allows each portion to be manufactured independently using smaller, less expensive molds, eliminating the need for a large complex mold that would be required to overmold all metal rods simultaneously.
Solution Approach 2:
The plastic lining is formed by overmolding the shaft first, before the branches are attached. This preliminary action creates a prepared base with integrated plastic material that simplifies subsequent assembly operations and reduces the complexity of the final molding operation.
2Productivity
If connection elements are arranged at four corners of the frame with simultaneous overmolding, then the frame is fully assembled, but at least four injection points are required making the process complex
Solution Approach 1:
The manufacturing process is segmented into two stages: first overmolding the shaft with plastic material, then separately attaching the branches. This segmentation reduces the number of injection points from four to one, significantly simplifying the molding process while maintaining complete frame assembly.
Solution Approach 2:
The plastic lining is formed in advance by overmolding the shaft before the branches are attached. This preliminary overmolding action creates a prepared structure that simplifies subsequent assembly, eliminating the need for multiple simultaneous injection operations.
3Productivity
If the full armrest frame is obtained after overmolding, then the complete structure is available, but specific precautions are needed during transport and storage to avoid damage
Solution Approach 1:
The armrest frame is delivered as two separate portions rather than a fully assembled unit. This segmentation reduces the overall size and complexity of the transported components, minimizing the risk of damage during transport and storage while maintaining the ability to assemble the complete functional structure at the destination.
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
The design simplifies manufacturing, reduces material costs, and minimizes the need for special precautions during transport and storage, while maintaining structural integrity and functionality.
Implementation Method 1
forming the first portion by overmolding of the single lining around the shaft by introducing the plastic material into the mold through the injection point
Data Source
AI summary
An armrest frame including a first portion including a shaft and a single plastic material lining overmolded around the shaft and a second portion including at least one branch attached to the lining. A seat including a backrest and an armrest including such a frame, pivotally connected to the backrest.