Rear Seat Backrest Frame With Integrated Cushion Channels
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Solution Overview
Problem
Existing modular rear seat backrest frames are costly to produce due to complex shaped corner regions and limited variant options, requiring additional mounting elements and specialized tools for attaching cushions and covers, especially for asymmetrical partitions and different vehicle types.
Innovation Solution
A modular rear seat backrest frame system using standard hat-shaped sections welded to a main plate with integrated cushion channels, allowing for flexible adaptation to varying widths and easy manufacturing without additional tools, where hat-shaped sections can be cut or adjusted to fit, and cushion channels are formed uniformly for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex shaped corner regions are used in modular backrest frames, then structural strength is improved, but production cost increases
Solution Approach 1:
The backrest frame is divided into standardized hat-shaped sections that can be independently produced and assembled. These sections are segmented at regular intervals with standardized connection points, allowing modular assembly while maintaining structural integrity through standardized welding positions.
Solution Approach 2:
The hat-shaped sections are designed as universal modular components that can serve multiple functions: providing structural strength, enabling modular assembly, and accommodating various cushion widths. The standardized connection geometry allows the same component type to be used across different backrest configurations.
2Reliability
If additional mounting elements are added for cushion attachment, then attachment security is improved, but device complexity increases
Solution Approach 1:
The cushion attachment function is merged into the structural hat-shaped sections themselves. The cushion channels are integrated directly into the hat-section geometry, eliminating the need for separate mounting elements. The structural components serve dual purposes: providing framework strength and enabling cushion attachment.
Solution Approach 2:
The hat-shaped sections are designed to automatically provide cushion attachment capabilities through their inherent geometry. The cushion channels are formed as part of the section structure, allowing cushions to be attached directly to the frame without requiring additional specialized mounting hardware or tools.
3Manufacturing precision
If specialized tools are used for cushion attachment, then attachment precision is improved, but manufacturing cost increases
Solution Approach 1:
The cushion attachment features are pre-formed during the production of the hat-shaped sections themselves. The cushion channels are created as integral parts of the sections during their initial manufacturing process, so no additional specialized tools are needed during final assembly. The precision is built into the component during its primary fabrication.
4Productivity
If modular components are used for backrest frames, then production flexibility is improved, but the range of variants is limited
Solution Approach 1:
The backrest frame is segmented into standardized hat-shaped sections that can be produced in standard lengths and then cut to specific sizes as needed. This segmentation allows the same basic component to be adapted to different width requirements by simple cutting and welding, greatly expanding the range of possible variants from a single standardized component design.
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
Enables cost-effective, flexible, and easy production of backrest frames with a broad range of variants, ensuring secure attachment of cushions and covers across different seat configurations without the need for complex tools or additional modules.
Implementation Method 1
the hat-shaped sections are welded to the front surface of the main plate
Data Source
AI summary
Rear backrest frame for a rear backrest component of a vehicle seat, with at least one main plate, one left and one right lateral hat-shaped section extending vertically, one upper and one lower hat-shaped section extending in a transverse direction, and the hat-shaped sections are welded to the front surface of the main plate. The rear backrest frame has cushion channels on its lateral edges and its upper and lower edges, for attachment of a cushion and/or cover. In order to enable a secure mounting of the backrest cushion and/or cover and a cost-effective, flexible production with a wide range of possible variants, it is provided that the hat-shaped sections are rectilinear in configuration, the lateral hat-shaped sections are welded to the hat-shaped sections that extend in a transverse direction, and the lateral cushion channels are formed on the lateral hat-shaped sections. Further, a corresponding production process is provided.