Isofix Tube and Wire Rivet Assembly Without Welding
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Solution Overview
Problem
The production of motor vehicles, particularly child seat restraint systems, is hindered by complex and costly vertical manufacturing processes, where multiple parts and assemblies increase handling complexity and costs, and existing solutions like Isofix bars require separate manufacturing and handling of tubular bars with attached latch wires, leading to inefficiencies.
Innovation Solution
A vertically integrated method combining tube and rivet assembly, where a die-formed or roll-formed sheet tube is sealed with rivets formed from latch wires, eliminating the need for separate manufacturing and handling of tubular bars, and allowing for adjustable latch ring configurations to secure the tube, reducing manufacturing and material handling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate manufacturing and handling of tubular bars is used for Isofix bars, then manufacturing flexibility is maintained, but manufacturing complexity and handling costs increase
Solution Approach 1:
The patent combines the manufacturing of the tubular bar and the attachment of latch wires into a single integrated process. The latch wires are attached to the tube during the tube formation process itself, eliminating the need for separate manufacturing and assembly steps. This merging of operations reduces manufacturing complexity while maintaining flexibility.
Solution Approach 2:
The tube structure serves multiple functions: it provides the structural framework for the Isofix bar and simultaneously serves as the substrate for attaching latch wires. The integrated design allows the same component to fulfill both structural and fastening functions, reducing the number of separate manufacturing operations required.
2Manufacturing precision
If multiple separate assembly steps are used for attaching latch wires to tubes, then assembly precision can be controlled, but production time and handling complexity increase
Solution Approach 1:
The latch wires are attached to the tube during the tube formation process itself, before the tube is completed and removed for separate assembly operations. This preliminary attachment action eliminates subsequent assembly steps, reducing production time while maintaining precision through the integrated forming process.
Solution Approach 2:
The tube formation and latch wire attachment operations are merged into a single simultaneous process. The latch wires are formed and attached to the tube as the tube is being formed, eliminating the need for separate assembly operations and reducing overall production time.
3Strength
If traditional welding is used to secure tube seams, then structural integrity is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces welding with a mechanical fastening system using latch wires that are formed into collars. These collars mechanically secure the tube seams through friction and geometric interlocking, eliminating the need for thermal welding processes while maintaining structural integrity.
Solution Approach 2:
The latch wire collars are formed directly from the latch wire material itself, which serves dual purposes: providing the latching function and simultaneously providing the fastening mechanism for securing tube seams. This self-service approach eliminates the need for separate fastening components and reduces manufacturing complexity.
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 approach reduces manufacturing and material handling costs, simplifies the production of Isofix child seat restraint anchorages, and eliminates the need for welding, while ensuring structural integrity and compliance with safety standards.
Implementation Method 1
A die formed or roll formed sheet curved to form a tube includes a longitudinal slit that is sealed, at least in part, by rivets. In a preferred embodiment, the rivets are formed by latch wires of the type used for child seat restraints, whose legs may be formed to make collars, and protruding ends that may be enlarged
Data Source
AI summary
A method performed and apparatus formed to fabricate an Isofix latch wire arrangement bends an elongated strip about an open profile to form an elongated tubular member, radially penetrating the member with wires across the open profile, and forming enlarged portions on the legs. The enlargements engage opposite sides of the tube to complete abutment of the strip edges to close the profile and join the wires as rivets to the tubular member formed.