Composite Seat Backrest Border With U-Shaped Reinforcing Ribs
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Solution Overview
Problem
Composite structures for automobile seat backrests face challenges in resisting crash tests, particularly when impacted from the rear, as they lack sufficient reinforcement to withstand forces along the anticipated direction of impact.
Innovation Solution
The composite structure incorporates a U-shaped border with reinforcing ribs parallel and perpendicular to the axis, and preimpregnated continuous fiber-reinforced thermoplastic organs on the surface, providing enhanced tensile resistance and structural integrity by distributing forces across the anticipated impact direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the composite structure uses a standard border design without additional reinforcement, then the manufacturing complexity is low, but the strength and resistance to crash impacts are insufficient
Solution Approach 1:
The border is segmented into distinct functional zones: linking zones at the ends for connection purposes and a reinforcing zone in the middle with enhanced structural features. This segmentation allows targeted reinforcement where needed while maintaining simplicity in other areas, resolving the contradiction between strength and complexity.
Solution Approach 2:
The border profile transitions from a simple planar shape to a three-dimensional U-shaped cross-section with ribs extending in multiple directions. This dimensional enhancement provides structural reinforcement against crash impacts from multiple angles without requiring a completely complex redesign of the entire border system.
2Reliability
If the border is reinforced with multiple ribs and organos, then the structural integrity improves, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple reinforcement elements (ribs oriented in different directions and organos) are merged into a single integrated border component manufactured in one molding process. This combining approach maintains high structural integrity while avoiding the complexity of assembling multiple separate reinforcement parts, thus improving reliability without excessively complicating manufacturing.
3Force
If the border has a U-shaped profile with reinforcing zone, then the tensile resistance increases, but the amount of material and device complexity increase
Solution Approach 1:
The U-shaped profile and reinforcing features are concentrated specifically in the reinforcing zone of the border rather than being uniformly distributed throughout. This localized application of enhanced geometry provides maximum tensile resistance where structurally necessary while minimizing overall material consumption, resolving the contradiction between force resistance and material quantity.
Data Source
AI summary
A composite structure comprising a substantially planar portion and a border arranged on the border of the substantially planar portion. A first linking zone is arranged at one end of the border along a first axis and a second linking zone is arranged at another end of the border along the first axis. The border further comprises a reinforcing zone connecting the first and second linking zones, in that the border has a profile transverse to the first axis that is substantially U-shaped opening on a side opposite the substantially planar portion and in that the border is reinforced by at least one rib substantially parallel to a second axis perpendicular to the first axis and included in the plane of the portion.