Additively Manufactured Seat Frame With Thin-Walled Load Paths
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Solution Overview
Problem
Conventional seat structures are overly complex and heavy due to numerous components that are welded or mechanically fastened together, making them inefficient in terms of production and weight.
Innovation Solution
A seat structure comprising a single, one-piece structural frame with thin-walled complex geometry, fabricated through additive manufacturing, featuring internal channels and ribs, optimized for load distribution using topological optimization software to minimize material usage and integrate movable sections and embedded elements for enhanced strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional seat structures use multiple components that are welded or mechanically fastened together, then the structure can provide required functions, but the structure becomes heavier and more complex
Solution Approach 1:
The patent merges multiple separate components into a single integrated seat frame structure. The complex geometry structure combines functions that were previously distributed across multiple components, eliminating the need for welding or mechanical fastening while reducing overall structural complexity and weight.
Solution Approach 2:
The single complex geometry structure performs multiple functions simultaneously - providing structural support, creating fluid flow paths, accommodating electrical pathways, and integrating mounting points. This multi-functionality replaces what previously required multiple separate components.
2Adaptability or versatility
If conventional seat structures use multiple components that are welded or mechanically fastened together, then the structure can provide required functions, but the structure becomes heavier
Solution Approach 1:
The patent merges multiple separate components into a single integrated seat frame structure. The complex geometry structure combines functions that were previously distributed across multiple components, eliminating the need for welding or mechanical fastening while reducing overall structural complexity and weight.
Solution Approach 2:
The complex geometry structure uses varying wall thicknesses and material distribution optimized for specific functional requirements. Material is concentrated where needed for strength and function, and reduced where not required, minimizing overall weight while maintaining functional capability.
3Weight of stationary object
If additive manufacturing is used to create thin-walled complex geometry structures, then weight and material complexity are reduced, but manufacturing precision and structural strength must be maintained
Solution Approach 1:
The patent utilizes additive manufacturing parameters to create complex geometry structures with optimized wall thicknesses, rib configurations, and internal channels. The manufacturing process parameters are controlled to ensure structural integrity while achieving weight reduction through thin-walled design.
Solution Approach 2:
The complex geometry structure may incorporate different material properties or composite materials to enhance structural strength while maintaining weight benefits. The additive manufacturing process allows for material optimization and potential gradient structures.
Data Source
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AI summary
A seat structure including at least one frame having one or more thin walled complex geometry structures and a process for forming the at least one frame via an additive manufacturing process.