Headrest Bracket Support Structure for Collision Deflection Resistance
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Solution Overview
Problem
Existing headrest and upper frame structures in vehicle seats lack sufficient strength to effectively protect occupants during collisions, leading to potential whiplash and injuries due to deflection and weakness in conventional welding and reinforcement methods.
Innovation Solution
The proposed solution enhances the strength of the headrest and upper frame by reinforcing the welded areas, using a pin to insert into the upper frame, increasing the number of welding points, and employing a caulking process to connect the side frame units, thereby improving the structural integrity and resistance to collision forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding is used to attach the bracket to the upper frame, then the structure is simple and easy to manufacture, but the strength is insufficient and the upper frame deflects during collision
Solution Approach 1:
The welding structure is segmented into multiple welding portions (first welding portion at the upper end, second welding portion at the lower end, and third welding portion at the side surface) instead of using a single welding location. This segmentation distributes the collision forces across multiple points, significantly improving the overall strength of the bracket-upper frame connection while maintaining manufacturing simplicity.
Solution Approach 2:
The welding arrangement transitions from a single-plane vertical welding to a three-dimensional distribution of welding portions across different surfaces (upper end, lower end, and side surface) of the attaching portion. This spatial distribution in multiple dimensions enhances the structural strength by creating a more robust connection that resists deflection during collision.
2Strength
If reinforcing plates are added to improve strength, then the strength of the upper frame is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The attaching portion is formed by integrating the pressing operation directly into the upper frame manufacturing process, rather than adding it as a separate reinforcing component. The pressing operation creates a localized flat region with increased thickness that serves both as an attachment surface and a strength enhancement, merging the functions of connection and reinforcement into a single integrated feature.
Solution Approach 2:
The pressing operation serves multiple functions simultaneously: it creates a flat attaching portion for bracket mounting, increases the local thickness for improved strength, and provides a rigid surface for welding. This multi-functionality eliminates the need for separate reinforcing plates while achieving the desired strength improvement.
3Reliability
If the number of welding points is increased, then the strength and reliability are improved, but the manufacturing time and cost increase
Solution Approach 1:
The pressing operation that creates the attaching portion with increased thickness is performed in advance during the upper frame manufacturing process, before the bracket assembly and welding operations. This preliminary preparation of the attaching portion ensures that the subsequent welding operations occur on a pre-strengthened surface, improving reliability without adding post-manufacturing steps.
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 enhanced structure effectively minimizes deflection and improves the overall strength of the headrest and upper frame, providing better protection against whiplash and injuries by distributing collision forces more effectively and ensuring the headrest remains in position during impacts.
Implementation Method 1
The bracket is reinforced by inserting a pin into the upper frame
Implementation Method 2
the welding points made between the free ends of the attaching wall portions and on both sides of the headrest bracket provided on the free ends are vertically welded
Implementation Method 3
employing a caulking process to connect the side frame units
Data Source
AI summary
A supporting structure of a headrest bracket is disclosed comprising attaching portions (flat areas in the frontal view) provided on an upper frame of a vehicle seat, with attaching wall portions formed on both ends of each flat attaching portion, whereby one side of the headrest bracket is put onto the attaching portion, so that welding points made between the free ends of the attaching wall and on the sides of the headrest bracket are provided, and the free ends are welded, and the welding point made between the upper and/or lower ends of the attaching portion and on the sides of the headrest bracket is horizontally welded.