Composite Seat Back Frame for Belt Load and Bending Accuracy
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Solution Overview
Problem
Existing seat back frames for automobiles with built-in seat belts face challenges in achieving high dimensional accuracy and load-bearing performance due to complex shapes and material limitations, often resulting in issues like wrinkles and cracks during bending.
Innovation Solution
A seat back frame design featuring a columnar member made of aluminum alloy with a closed cross-section and a plate-shaped reinforcing member made of high-tension steel, where the reinforcing member is joined to the columnar member after bending, allowing for separate formation and easy assembly, thereby ensuring high load-bearing performance and dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complicated shapes are integrally formed in the seat back frame, then high load-bearing performance is achieved, but dimensional accuracy becomes difficult to ensure
Solution Approach 1:
The seat back frame is divided into multiple components: a columnar member (front side), a plate-shaped reinforcing member (rear side), and an upper frame. These segments are formed separately using appropriate manufacturing processes and then assembled together, allowing each component to be optimized for its specific function while maintaining high dimensional accuracy.
Solution Approach 2:
The invention uses composite construction by joining the columnar member made of aluminum alloy extruded material with the plate-shaped reinforcing member made of high-tension steel. This composite approach allows each material to be selected for its optimal properties (aluminum for weight and extrusion accuracy, steel for tensile strength) while achieving high overall load-bearing performance.
2Volume of moving object
If the upper portion of the seat back frame is curved rearward to secure large space, then space utilization is improved, but wrinkles and cracks occur during bending
Solution Approach 1:
The frame is segmented such that the columnar member and plate-shaped reinforcing member are formed separately before assembly. This allows the upper frame to be curved rearward after assembly rather than during forming, avoiding wrinkles and cracks that would occur if bending were performed on the plate-shaped portion before assembly.
Solution Approach 2:
The columnar member and reinforcing member are formed and assembled first, and then the upper frame is curved rearward to secure large space. This preliminary formation of components before final assembly and curvature application prevents manufacturing defects while achieving the desired spatial configuration.
3Device complexity
If the seat back frame is made as a single integrated component, then structural simplicity is achieved, but manufacturing complexity increases
Solution Approach 1:
The seat back frame is divided into a columnar member, plate-shaped reinforcing member, and upper frame that can be manufactured separately using optimized processes (extrusion for aluminum, plate forming for steel) and then assembled. This segmentation simplifies manufacturing while maintaining structural integrity and simplicity in the final assembled configuration.
Solution Approach 2:
Different materials and forming parameters are used for different components: aluminum alloy extrusion for the columnar member, high-tension steel plate for the reinforcing member. This allows each component to be manufactured using the most appropriate process parameters, simplifying overall manufacturing while achieving the desired structural simplicity.
Data Source
AI summary
A seat back frame for automobile includes a first side frame and a second side frame that are arranged apart from each other in a vehicle width direction, an upper frame that connects an upper end portion of the first side frame and an upper end portion of the second side frame, and an upper bracket that is attached to the upper end portion of the first side frame and guides a seat belt. The first side frame includes a columnar member made of an aluminum alloy extruded material and having a closed cross-section portion in a cross-section perpendicular to a vehicle vertical direction, and a plate-shaped reinforcing member made of high-tension steel, joined to the columnar member, and extending to a vehicle rear side of the columnar member.