Prefabricated Mounting Bracket With Floating Reinforcement Fit
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Solution Overview
Problem
Existing seat mounting brackets made of extruded aluminum face challenges in applying high-strength hardware due to complex internal rib structures, requiring additional machining that compromises rigidity and increases costs, and assembly is complicated by the need for separate reinforcement components and precise jig equipment.
Innovation Solution
A prefabricated mounting assembly with a floating reinforcement component that is easily assembled into an extruded aluminum bracket, featuring inwardly protruding ribs and stopper notches, allowing for interference fit without welding or riveting, and enabling easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength hardware is applied to extruded aluminum bracket with complex internal rib structure, then mounting strength is improved, but assembly difficulty increases and machining costs increase
Solution Approach 1:
The bracket is divided into multiple segments: the extruded aluminum body with internal ribs, and separate reinforcement plates that can be independently assembled. This segmentation allows the complex rib structure to remain intact while enabling separate assembly of reinforcement components through pass-through holes, resolving the contradiction between maintaining structural integrity and enabling ease of assembly.
Solution Approach 2:
The reinforcement plates are nested within the extruded bracket structure, with pass-through holes positioned to allow assembly devices to access the interior space. The reinforcement components are inserted and secured within the existing rib structure, enabling high-strength hardware application without compromising the external rib geometry or requiring complex disassembly procedures.
2Ease of manufacture
If passing hole is added to apply hardware to extruded material, then hardware application is enabled, but rigidity decreases and machining costs increase
Solution Approach 1:
Pass-through holes are strategically positioned in specific locations where they minimize impact on overall bracket rigidity. The holes are placed in regions that do not compromise the structural integrity of the internal rib system, allowing hardware application while maintaining the bracket's load-bearing capacity. The local modification is confined to specific areas rather than affecting the entire structure.
3Strength
If internal ribs are tightened to increase stiffness, then bracket strength is improved, but hardware application difficulty increases
Solution Approach 1:
The solution transitions from trying to access the interior space through the closed end (one-dimensional approach) to accessing it through the lateral surfaces (two-dimensional approach). Pass-through holes are created in the side walls of the extruded bracket, providing a new dimensional pathway for assembly devices to reach the interior reinforcement components without compromising the integrity of the internal rib structure.
Data Source
AI summary
An embodiment prefabricated mounting assembly includes a mounting bracket, the mounting bracket including a top surface having a first fastening hole, a pair of side parts extending downward from opposite ends of the top surface, and a plurality of ribs disposed between the side parts, and a reinforcement component disposed between the top surface of the mounting bracket and a rib of the plurality of ribs and including a first fastener engaged in a second fastening hole disposed in a main body of the reinforcement component.