Laser-Brazed Dual-Tube Headrest Bracket for Lighter Rust Resistance
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Solution Overview
Problem
Existing headrest supports in vehicles are heavy due to thick materials and require complex and costly plating processes for anti-rusting, which increases production complexity and costs.
Innovation Solution
A dual-layer headrest support system comprising an inner iron tube and an outer stainless steel tube, secured by laser brazing, where the outer tube provides anti-rusting properties and encloses the inner tube to reduce weight and processing complexity, while only the outer tube requires anti-rusting treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral piece of metal tube with large thickness is used to ensure support strength, then the support strength is improved, but the weight of the support increases
Solution Approach 1:
The patent applies nesting by placing the inner tube inside the outer tube, creating a dual-layer structure where the inner tube provides structural support and the outer tube provides protective functions. This nested configuration allows both tubes to have thinner walls than a single integral tube would require, significantly reducing the overall weight while maintaining necessary strength through the combined structure.
Solution Approach 2:
The patent applies local quality by assigning different functions and material properties to different parts of the support structure. The inner tube is made of iron with galvanized coating for structural support, while the outer tube is made of stainless steel for corrosion protection and aesthetic appearance. This localized differentiation allows each component to be optimized for its specific function, reducing overall material usage and weight.
2Strength
If an integral piece of metal tube is used to ensure support strength, then the support strength is improved, but the processing costs and complexity increase due to plating process
Solution Approach 1:
The patent applies segmentation by dividing the support into two separate tube components (inner tube and outer tube) that are assembled together. This segmentation allows each tube to be manufactured and treated independently according to its specific requirements, eliminating the need for complex plating processes on a single integral tube and simplifying the overall manufacturing process.
Solution Approach 2:
The patent applies local quality by assigning different material properties and treatments to different parts. The inner tube receives galvanized coating for basic corrosion protection, while the outer tube is made of stainless steel for superior corrosion resistance and aesthetic appearance. This localized differentiation eliminates the need for extensive plating on the entire structure, reducing processing complexity and cost.
3Reliability
If the outer tube completely encloses the inner tube, then rusting prevention is improved, but the complexity of assembly increases
Solution Approach 1:
The patent applies nesting by placing the inner tube inside the outer tube, creating a protected configuration where the outer tube acts as a barrier against moisture and corrosion. This nested structure naturally provides rusting prevention while the simple insert-and-weld assembly process keeps the manufacturing complexity low.
Solution Approach 2:
The patent replaces traditional mechanical fastening methods with laser welding to join the inner and outer tubes. This substitution provides a more reliable, permanent connection that ensures the outer tube remains tightly enclosed around the inner tube for optimal corrosion protection, while the automated laser welding process actually reduces assembly complexity compared to multiple mechanical fasteners.
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 dual-layer structure achieves necessary strength with reduced weight and material usage, prevents rusting, and simplifies the production process, saving costs and materials.
Implementation Method 1
The outer tube is secured to the inner tube by laser brazing
Implementation Method 2
the inner tube has undergone galvanization
Data Source
AI summary
A headrest support and a seat headrest in which the headrest support has a U shape and is configured for supporting a headrest. The headrest support includes an inner tube and an outer tube. The outer tube covers at least two end portions of the inner tube. The outer tube is secured to the inner tube by laser brazing.