Laser-Welded Seat Frame Assembly With Single-Clamp Positioning
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Solution Overview
Problem
Existing methods for joining seat frame parts in motor vehicles, such as protective gas welding, are time-consuming and costly due to the need for repeated clamping and position adjustments, and are relatively slow.
Innovation Solution
The use of laser-welding to join seat frame parts with specifically designed joining surfaces and positional fixing means, allowing for a single clamping action and minimizing manufacturing tolerances, enabling efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If protective gas welding is used to join seat frame parts, then the parts can be joined together, but the process requires repeated clamping and position adjustments which increases time consumption and cost
Solution Approach 1:
The patent applies preliminary action by designing joining surfaces with integrated positioning means (such as recesses, protrusions, or geometric features) that pre-establish the correct relative positions of parts before welding begins. This allows all parts to be clamped in their final positions once before laser welding, eliminating the need for repeated clamping and position adjustments during the welding process, thereby significantly reducing time loss and increasing productivity
2Productivity
If protective gas welding is used to join seat frame parts, then the parts can be joined together, but the process is relatively slow
Solution Approach 1:
The patent replaces the complex mechanical clamping and positioning system required for protective gas welding with a laser welding process. Laser welding eliminates the need for extensive mechanical clamping apparatus and complex positioning mechanisms, as the laser beam can precisely weld parts in their natural positioned state. This substitution of mechanical systems with optical/thermal energy delivery simplifies the overall device complexity while dramatically increasing welding speed and productivity
3Manufacturing precision
If joining surfaces are designed with tight tolerances to minimize gaps, then welding quality improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the surface geometry parameters of the joining surfaces. Specifically, the joining surfaces are designed with specific geometric features (such as angled surfaces, recesses, or interlocking profiles) that inherently maintain consistent spacing and alignment between parts. This geometric parameter design allows for adequate manufacturing tolerances while ensuring optimal welding conditions, thereby improving ease of manufacture without sacrificing welding quality or joint strength
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
Laser-welding allows for the production of seat frames with stable, low-tolerance joints that can withstand high strength requirements, including accidents, and simplifies the manufacturing process by eliminating the need for multiple clamping actions and position adjustments.
Implementation Method 1
During laser-welding, a laser beam is focused onto the tools to be welded and heats the welding point up to the welding temperature
Implementation Method 2
at which the material of at least one of the two parts to be welded becomes fluid
Implementation Method 3
Preferably the laser oscillates during the welding, so that a straight welded seam is not produced but a welded seam which oscillates about a straight line
Data Source
AI summary
A seat structure includes a frame having a plurality of parts having respective joining surfaces. Two respective joining surfaces, which belong to two respective different parts, are joined to one another by laser-welding. A method of forming a seat frame having a plurality of parts includes the steps of positioning the parts in a fixture, fixing the position of the parts relative to one another and laser-welding the parts to form the seat frame.