Injection-Molded Plastic Seating Frame With Reinforcing Ribs
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Solution Overview
Problem
Conventional automotive seating frames for electric vehicles are heavy, prone to corrosion, and have complex assemblies with high material waste due to metal usage, which complicates manufacturing and does not meet mechanical performance requirements such as stiffness and strength.
Innovation Solution
A seating frame made from a single, injection-molded plastic part with long glass fiber reinforced thermoplastic material, featuring a network of reinforcing ribs for enhanced strength and rigidity, replacing traditional metal frames to reduce weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal tubes and sheets are used for seating frames, then strength and stiffness requirements are met, but weight increases and battery efficiency decreases
Solution Approach 1:
The patent employs long glass fiber reinforced thermoplastic material as a composite material to replace conventional metal tubes and sheets. This composite material provides sufficient strength and stiffness while significantly reducing weight, thereby meeting mechanical performance requirements without increasing seating frame weight
Solution Approach 2:
The injection-molded seating frame incorporates multiple reinforcing ribs that segment the structure into functional zones. These ribs strategically distribute mechanical loads throughout the frame, enhancing overall strength and stiffness while maintaining weight efficiency through optimized material placement
2Strength
If multiple stamped steel parts are used for seating frames, then mechanical performance is achieved, but assembly complexity increases and manufacturing becomes complicated
Solution Approach 1:
The patent merges multiple separate metal components into a single injection-molded seating frame made from long glass fiber reinforced thermoplastic. This integration eliminates the need for complex assembly operations including welding, drilling, and fastening, while maintaining structural strength through the monolithic construction and embedded reinforcing ribs
3Ease of manufacture
If conventional metal manufacturing processes are used, then seating frames are produced, but material waste increases and cost rises
Solution Approach 1:
The patent replaces conventional mechanical manufacturing processes (bending, piercing, drawing, welding) with injection molding technology. This substitution enables near-net-shape manufacturing of the seating frame, minimizing material waste by forming the final product geometry directly from the molded material without requiring subsequent machining or assembly operations
4Weight of moving object
If long glass fiber reinforced thermoplastic material is used, then weight is reduced and cost is lowered, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes injection molding parameters including temperature, pressure, and cooling rates to achieve precise dimensional control of the seating frame. The process parameters are carefully controlled to ensure proper fiber orientation, minimize warpage, and achieve the required geometric precision for the integrated structure with reinforcing ribs
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 solution results in a lightweight, cost-effective seating frame that meets high mechanical performance requirements, reducing material waste and simplifying manufacturing while improving battery efficiency in electric vehicles.
Implementation Method 1
The seating frame is a one-piece injection-molded part made of plastic material
Implementation Method 2
long glass fiber reinforced thermoplastic material
Data Source
AI summary
The invention relates to a seating frame for a vehicle seat, the frame comprising a back frame component for supporting a back rest, wherein the back frame component includes a plurality of interconnected reinforcing ribs that form a single unit, and wherein the seating frame is a one-piece injection-molded part made of plastic material. The invention also relates to a process of making such a seating frame. Furthermore, the invention relates to a vehicle seat comprising such a seating frame, and a vehicle comprising such a vehicle seat or such a seating frame.