Composite Vehicle Seat Shell for Hinge Load Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle seats with hinge mechanisms lack sufficient mechanical strength, particularly in areas subjected to high stress during accidents, due to potential rearrangement of fibers during the molding process of composite materials.
Innovation Solution
The use of two composite parts with L-shaped cross-sections, integrally attached to each other and overmolded with plastic material, along with a metal plate that covers the core and side flanges, providing enhanced mechanical strength through riveting and fusion, ensuring optimal fiber orientation and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single composite insert is molded during the hold molding process, then the manufacturing process is simpler, but the fibers may rearrange during molding reducing mechanical strength
Solution Approach 1:
The composite insert is divided into two separate L-shaped composite parts instead of one single insert. Each part is molded independently and then assembled together to form the complete U-shaped insert. This segmentation prevents fiber rearrangement during molding since each smaller part can be molded with optimized fiber orientation, while still achieving the full structural function when assembled.
Solution Approach 2:
The two composite parts are molded separately in advance with optimized fiber orientation for their specific regions. By preparing these parts beforehand with correct fiber alignment, the final assembled structure achieves superior mechanical strength without the fiber rearrangement problems that would occur if a single large insert were molded in one operation.
2Strength
If two composite parts are used and assembled, then fiber orientation and stress distribution are optimized, but the device complexity increases
Solution Approach 1:
The two separately molded L-shaped composite parts are assembled together and then overmolded with a single plastic material that integrally attaches both parts to each other and to the shell. This merging process creates a unified structural component that combines the advantages of segmented molding (optimized fiber orientation) with the simplicity of an integrated final product.
Solution Approach 2:
The invention uses composite materials (fiberglass-reinforced plastic) for the inserts and combines them with a different plastic material for the shell and overmolding. This multi-material approach allows each material to be optimized for its specific function: the composite provides high mechanical strength and stiffness where needed, while the plastic provides molding flexibility and integral attachment.
3Stability of the object's composition
If the plastic shell overmolds the composite insert, then integral attachment is achieved, but the composite material quality may deteriorate due to fiber rearrangement
Solution Approach 1:
By segmenting the composite insert into two smaller L-shaped parts, each part can be molded with controlled fiber orientation that is maintained during the subsequent overmolding process. The smaller size and simpler geometry of each segment prevent the fiber rearrangement that would occur in a single large insert during the hold molding process.
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 configuration enhances the mechanical strength of the seat by preventing fiber rearrangement and distributing stress effectively, particularly in areas subjected to high mechanical loads, thereby improving safety in accidents.
Implementation Method 1
the two composite parts are integrally attached to each other by the shell of plastic material, which is overmolded onto said two composite parts
Implementation Method 2
the two composite parts are integrally attached to each other by fusion along a joining line between the core portions of the two composite parts
Implementation Method 3
each composite part is manufactured by shaping a blank comprising superimposed composite sheets, by pressing the blank in a hot mold
Data Source
AI summary
The invention relates to a vehicle seat comprising a seat portion and a backrest connected to the seat portion by a hinge mechanism. A seat element selected from among the backrest and the seat portion comprises a shell, which is made of a plastic material and the side edges of which are overmolded onto composite reinforcement inserts. Each of the inserts comprises a core perpendicular to the medium plane of the seat element, and two side flanges parallel to the medium plane of the seat element. The insert is formed by assembling two composite parts having an L-shaped cross-section and forming a portion of the core and one of the side flanges of the insert.