Integral Headrest Frame with U-Shaped Rod Assembly
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Solution Overview
Problem
Conventional two-way headrests face issues with reduced strength and increased labor costs due to complex assembly processes and material inefficiencies, particularly with U-shaped single rod and split frame structures.
Innovation Solution
An integral single-frame two-way headrest design featuring a hollow integral frame with a U-shaped single rod, rod guide sleeve, and unlocking mechanism that simplifies assembly, enhances strength, and reduces material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a combined headrest frame with U-shaped single rod is used, then the assembly process is simplified, but the strength of the headrest frame is reduced
Solution Approach 1:
The patent merges the U-shaped rod and the headrest frame into an integrated structure where the U-shaped rod is inserted into a hollow cavity within the frame, creating a unified load-bearing system that maintains strength while simplifying assembly to a single insertion operation
Solution Approach 2:
The U-shaped rod is nested within the hollow cavity of the headrest frame, with the rod positioned inside the frame's internal space. This nesting arrangement allows both components to work together structurally while maintaining a compact design and simplified assembly process
2Strength
If two separate rods are used and connected by welding, then the structural integrity is improved, but the assembly process becomes complex and labor-intensive
Solution Approach 1:
The patent combines two separate rod structures into a single U-shaped rod that spans the entire headrest width, eliminating the need for welding operations while maintaining structural integrity through the U-shape's inherent load distribution
Solution Approach 2:
The U-shaped rod is designed with positioning grooves at specific locations that allow it to be segmented into manageable installation sections while remaining a single continuous piece, facilitating easier handling and positioning during assembly without requiring welding
3Productivity
If conventional assembly methods are used, then production can proceed, but labor costs and production time increase
Solution Approach 1:
The U-shaped rod is pre-formed with positioning grooves and the hollow frame is pre-designed with matching cavities, allowing the components to be prepared in advance and assembled through a simple insertion operation without requiring complex alignment or additional fastening steps during assembly
Solution Approach 2:
The positioning grooves on the U-shaped rod and corresponding cavities in the frame create a self-aligning assembly system where the components guide themselves into the correct position during insertion, eliminating the need for additional alignment operations or skilled labor
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 design improves assembly efficiency, strengthens the headrest, and decreases production costs by using a compact, integrated structure with a U-shaped rod and optimized components like rod guide sleeves and metal elastic sheets.
Implementation Method 1
a metal elastic sheet that passes through the leakage groove is installed between two mounting grooves
Data Source
AI summary
Provided is an integral single-frame two-way headrest with a U-shaped single rod, comprising a U-shaped rod, an integral frame and a cover, the integral frame being externally covered with the cove, and the integral frame is hollow inside. An opening is arranged at a lower end of the integral frame, and an upper portion of the U-shaped rod is inserted into the inner frame from the opening, a plurality of positioning grooves is arranged on the right side of two downwardly extending ends of the U-shaped rod. A rod guide sleeve sleeved on both ends of the U-shaped rod is mounted at both ends of the opening, and the outer side of the integral frame is mounted with an unlocking steel wire corresponding to the positioning groove at both ends of the U-shaped rod, an unlocking lever connected with the unlocking steel wire and laterally movable is mounted in a hollow portion of the integral frame. The present invention has the characteristics of simple structure, convenient assembly and greatly reduced production cost.