Seat Back Skeletal Frame Layout for Rigidity Without Weight Gain
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Solution Overview
Problem
Existing skeletal structures for vehicle seat backrests face challenges in achieving high rigidity to prevent deformation during collisions while minimizing weight, and they often suffer from insufficient joining strength due to the use of round pipe materials and inadequate reinforcement, leading to potential breakage and abnormal noise issues.
Innovation Solution
A skeletal structure featuring a panel with a frame composed of first and second frames with open cross-sectional shapes, where non-joint portions are strategically arranged to control deformation, and reinforced with bead structures, coupled via a set bracket and joined using laser welding to enhance strength and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plate thickness is increased to achieve high rigidity, then the rigidity is improved, but the weight increases
Solution Approach 1:
The frame is divided into multiple linear tubular members arranged in a lattice pattern rather than using a single thick plate. This segmentation allows the structure to achieve required rigidity through geometric arrangement while maintaining lower weight compared to a solid plate of equivalent strength.
Solution Approach 2:
The invention uses a composite structure combining the panel with a lattice-style frame made of linear tubular members. This composite design leverages the strengths of both components - the panel provides a base surface while the lattice frame adds rigidity through its geometric configuration, achieving high strength-to-weight ratio.
2Ease of manufacture
If round pipe materials are used for the frame, then the manufacturing is simplified, but the joining strength is insufficient due to difficulty in securing contact area
Solution Approach 1:
The invention transitions from round pipe materials to linear tubular members with flat surfaces. This geometric change maintains the simplicity of using tubular materials while dramatically improving joining capability, as flat surfaces provide adequate contact area for strong connections without requiring complex filling procedures.
3Ease of manufacture
If welding is performed with insufficient contact area, then the joining process is simplified, but the joining strength becomes insufficient
Solution Approach 1:
The linear tubular members with flat surfaces eliminate the need for welding material filling that would be required with round pipes. The flat surfaces provide inherent contact area that enables direct welding without gaps, simultaneously simplifying the welding process and ensuring strong joining strength.
4Loss of energy
If the central portion of the panel deforms during collision, then the collision energy is absorbed, but the deformation amount may be maximized causing breakage
Solution Approach 1:
The lattice-style frame divides the panel into multiple smaller regions, preventing concentrated deformation in the central portion. When collision occurs, the load is distributed across multiple frame members and panel sections, allowing energy absorption through distributed deformation rather than localized maximum deformation that would cause breakage.
Solution Approach 2:
The frame provides localized reinforcement at critical positions where linear tubular members are joined to the panel. This creates zones of higher stiffness that guide deformation away from vulnerable areas, allowing controlled energy absorption in less critical regions while protecting structurally important zones from excessive deformation.
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
This configuration allows controlled deformation away from critical areas, reduces deformation and deflection, and enhances joining strength without additional welding materials, thereby improving the structural integrity and reducing noise during load changes.
Implementation Method 1
joined using laser welding to enhance strength and reduce weight
Data Source
AI summary
A skeletal structure is provided that includes a panel, and a frame joined to a front surface side of the panel. The frame includes a plurality of first frames oriented in a fixed direction and a second frame oriented in a direction orthogonal to the plurality of first frames, and each of the plurality of first frames and the second frame are formed to have an open cross-sectional shape. An end portion of each first frame of the plurality of first frames is joined to the second frame in an overlapping state.