U-Shaped Vehicle Seat Backrest Frame with Bonded Half-Shells
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Solution Overview
Problem
Existing backrest frames for vehicle seats, especially those with integrated belts, require high strength, minimal weight, and cost-effectiveness, but existing solutions are not optimized for the smallest number of parts and are difficult to adapt.
Innovation Solution
A U-shaped backrest frame using two half-shell metal sheets, where the second half-shell reinforces the transverse and vertical frame regions, allowing for simple adaptation to seats with integrated belts and reducing tooling costs by using a 'tailored blank' or T3 technology for hollow profiles with minimal weld seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a box-shaped backrest frame with multiple metal profiles is used, then the structural strength is sufficient, but the number of components increases and adaptability to seatbelt-integrated seats deteriorates
Solution Approach 1:
The patent merges multiple separate metal profiles into a single U-shaped backrest frame made from one piece of sheet metal. This integration maintains the structural strength of multiple profiles while reducing the component count to one, thereby resolving the contradiction between strength and device complexity
Solution Approach 2:
The U-shaped backrest frame design provides universal applicability by accommodating both regular seats and seatbelt-integrated seats through a single basic structure. The frame can be adapted to different configurations without requiring complete redesign, thus improving adaptability while maintaining structural integrity
2Strength
If the backrest frame is reinforced for seatbelt integration, then the force absorption capability improves, but the tooling costs and manufacturing complexity increase
Solution Approach 1:
The patent applies local quality by providing selective reinforcement only in the transverse frame area where seatbelt integration is required, rather than reinforcing the entire frame. This localized approach maintains force absorption capability while reducing material usage and manufacturing complexity
Solution Approach 2:
The patent utilizes parameter changes by varying the sheet metal thickness locally - thinner in areas requiring less strength and thicker in areas requiring reinforcement for seatbelt integration. This allows optimization of both strength and manufacturing cost by matching material properties to functional requirements
3Adaptability or versatility
If multiple half-shell components are used to form the backrest frame, then the manufacturing flexibility increases, but the assembly effort and number of parts increase
Solution Approach 1:
The patent combines multiple half-shell components into a single integrated U-shaped backrest frame made from one piece of sheet metal. This eliminates the need for assembling multiple separate half-shells, reducing the number of parts while maintaining the manufacturing flexibility to adapt to different seat configurations
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 provides a robust, lightweight backrest frame with a minimal number of components, capable of absorbing forces from integrated belts while reducing production costs and material usage, allowing for optimal adaptation to design specifications.
Implementation Method 1
The material-bonded connection between the half-shell sheets can be achieved by welding, brazing, or bonding.
Implementation Method 2
By using half-shell sheets, which are preferably deep-drawn, complex structures can be provided that are capable of absorbing and dissipating the forces occurring in the backrest frame.
Data Source
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AI summary
The invention relates to a seat-back frame for a vehicle seat, which seat-back frame has a frame region extending transversely and two frame regions extending vertically and is of a U-shaped form. The object to provide a seat-back frame of the generic kind which has a minimum of components and at the same time allows a seat-back frame for belt-integrated vehicle seats to be provided easily is met in that there is provided a first half-shell made of a metal, which first half-shell forms a sub-region of each of the vertically extending frame regions of the seat-back frame and forms a sub-region of the transversely extending frame region of the seat-back frame, and there is provided a second sheet-metal half-shell which is connected to the first half-shell by bonding and which reinforces at least the transversely extending frame region of the seat-back frame.