Headrest Tube Chamfer Forming With Segmented Teeth

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for forming endforms on headrest stays require significant force, often exceeding 30,000 lbs., which can cause the tube to swell and become unusable, and also require multiple passes increasing cycle time.

Innovation Solution

A method of manufacturing a headrest stay that involves removing material from a tubular body to form teeth, which are then pressed inward to form a chamfered endform, reducing the force required to less than 2,000 lbs. and minimizing cycle time to a single pass.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional endforming method is used to form chamfered endform on headrest stay, then the endform is successfully formed to enable insertion into seat sleeve, but the force required is considerable (30,000 lbs) causing tube swelling and outer diameter change making the tube unusable

Engineering Contradiction:

Improveendform formationVSAvoidtube swelling

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The end of the tubular body is segmented into multiple teeth by removing material. These teeth are then pressed inward individually or in groups to form the chamfered endform. This segmentation allows the forming force to be distributed across multiple smaller elements rather than applying force to the entire end surface at once, significantly reducing the peak force required and preventing tube swelling.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If traditional endforming method is used, then the endform is formed, but multiple passes are necessary completing the endform which significantly increases cycle time

Engineering Contradiction:

Improveendform formationVSAvoidcycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Material is removed in advance to pre-form the teeth structure on the tubular body before the pressing operation. This preliminary action prepares the workpiece so that the final chamfered endform can be achieved in a single pressing pass rather than requiring multiple incremental passes, thereby significantly reducing cycle time while maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If material is removed to form teeth and pressed inward, then the force required is reduced to less than 2,000 lbs and cycle time is minimized to single pass, but material is removed from the tubular body

Engineering Contradiction:

Improvecycle timeVSAvoidmaterial removal

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

Material is extracted from the end of the tubular body to create the teeth structure. This extraction is intentional and necessary to enable the low-force forming process. The removed material allows the remaining structure to be reconfigured into the desired chamfered endform shape through pressing, achieving both productivity improvement and acceptable material utilization.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12240363B2Headrest tube and method of forming same

Publication Date: 2025.03.04 INNOTEC CORP

AI summary

The present disclosure provides a method of manufacturing a headrest stay formed end. The method includes cutting teeth on the insertion end of a headrest stay and pressing the teeth inwardly to form a chamfered endform on the insertion end. A headrest stay having a chamfered endform comprising a plurality of curved teeth is also provided.