Seat Frame Side Member With Variable Thickness Projections
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Solution Overview
Problem
Traditional vehicle seat frame side members lack optimized structural attachment points, leading to suboptimal connections with other seat components, which compromises the structural integrity and strength of the seat frame.
Innovation Solution
The seat frame side member incorporates a frame body with strategically designed structural attachment points, featuring projections with varying cross-sectional thicknesses and anisotropic microstructures built using additive manufacturing, allowing for enhanced connection and integration of seat features like cross beams, recliners, and airbags through optimized weld joints and microstructural orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional uniform thickness design is used for seat frame side members, then manufacturing is simpler, but structural attachment points lack optimization leading to compromised structural integrity
Solution Approach 1:
The side member features variable cross-sectional thickness with different regions optimized for specific functions: thicker sections at structural attachment points for strength, and thinner sections where weight reduction is beneficial. This local differentiation resolves the contradiction by providing enhanced structural integrity exactly where needed without uniformly increasing complexity throughout the entire component.
Solution Approach 2:
The invention transitions from a two-dimensional uniform thickness design to a three-dimensional variable thickness design, adding the dimension of thickness variation to optimize structural attachment points. This dimensional change allows for enhanced strength at critical locations while maintaining overall design efficiency.
2Strength
If additive manufacturing is used to create variable thickness structures, then connection strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
The invention utilizes additive manufacturing to change the geometric parameter of thickness from uniform to variable, enabling optimized connection strength at structural attachment points. The additive manufacturing process makes this parameter change feasible without proportionally increasing manufacturing complexity, as the process inherently handles complex geometries more efficiently than traditional methods.
3Manufacturing precision
If uniform cross-sectional thickness is maintained throughout the side member, then manufacturing is easier, but weld joint quality at attachment points is suboptimal
Solution Approach 1:
The variable thickness design provides locally optimized geometry at weld joint locations, with thicker sections at attachment points improving weld joint quality and strength. This local optimization through additive manufacturing achieves superior weld quality without significantly complicating the overall manufacturing process.
Data Source
AI summary
A seat frame side member includes a frame body and a structural attachment point configured to connect a seat feature to the seat frame side member. The structural attachment point includes a projection extending from the frame body to a distal end. The projection includes a seat feature receiving portion at the distal end of the projection and a seat feature seating portion between the seat feature receiving portion and the frame body, and the seat feature receiving portion has a cross-sectional thickness that is different from a cross-sectional thickness of the seat feature seating portion. The seat frame side member can have an anisotropic microstructure with a plurality of layers built by additive manufacturing.