Vehicle Seat Back Frame Using Molten Polymer Injection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for forming seat back frames in vehicles using alternative materials to steel lack adequate rigidity and resistance to failure, making it difficult to pass standardized regulatory tests like those set by NHTSA, while also being heavy and difficult to recycle.

Innovation Solution

A method involving a frame formed from a first polymeric material and a reinforcing composite layer with a second polymeric material and impregnated fibers, where the composite layer is supported in a mold, and the first polymeric material is introduced in a molten state to integrate with the composite layer, providing the necessary rigidity and resistance to failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If steel is used for seat back frames, then strength and rigidity are adequate, but weight is excessive and fuel economy decreases

Engineering Contradiction:

Improveframe weightVSAvoidframe strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining a polymeric material with a reinforcing composite layer containing fibers (such as glass, carbon, or aramid) impregnated in a second polymeric material. This composite structure provides both the lightweight property and the necessary strength, resolving the contradiction between reducing frame weight and maintaining frame strength.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If alternative materials are used to reduce weight, then fuel economy improves, but rigidity and resistance to failure are inadequate

Engineering Contradiction:

Improveframe weightVSAvoidresistance to failure

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The reinforcing composite layer with high-strength fibers provides the necessary rigidity and resistance to failure, while the polymeric material matrix provides structural integrity. This composite construction achieves both weight reduction and adequate reliability to pass NHTSA regulatory tests.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcing composite layer is strategically positioned within the frame structure at locations requiring enhanced strength and rigidity. This localized reinforcement provides necessary mechanical properties only where needed, optimizing both weight and reliability.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If traditional steel manufacturing processes are used, then ease of manufacture is maintained, but environmental impact increases due to recycling difficulty

Engineering Contradiction:

Improvemanufacturing easeVSAvoidrecycling difficulty

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The polymeric material components of the frame are designed to be more easily recyclable than traditional steel. The composite structure allows for recovery and reuse of the polymeric material and fiber components, reducing environmental impact while maintaining manufacturing feasibility through injection molding processes.

Inventive Principle:

Principle #34Discarding and recovering

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 method results in a lightweight, compact frame that meets regulatory standards for rigidity and resistance to failure, is easier to recycle, and reduces packaging constraints compared to traditional steel frames.

Implementation Method 1

displacing the reinforcing composite layer away from the moveable members by introducing the first polymeric material in the molten state between the moveable members and the reinforcing composite layer

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

solidifying the first polymeric material in the mold

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS10307949B2Method of forming a frame of a seat back for a vehicle

Publication Date: 2019.06.04 BASF SE

AI summary

A method forms a frame of a seat back for a vehicle. The frame includes a first polymeric material and a reinforcing composite layer that includes a second polymeric material and a plurality of fibers impregnated in the second polymeric material. The method includes the steps of supporting the reinforcing composite layer on moveable members in a mold and extending the moveable members relative to the mold to an extended position in the mold. The method also includes the steps of introducing the first polymeric material in a molten state into the mold and into contact with the reinforcing composite layer and displacing the reinforcing composite layer away from the moveable members by introducing the first polymeric material in the molten state between the moveable members and the reinforcing composite layer while the moveable members are in the extended position. The method further includes the steps of causing the first polymeric material to solidify in the mold and retracting the moveable members from the first polymeric material.