Vehicle Seat Frame Mechanical Fastening and Swaged Joints

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Solution Overview

Problem

Existing vehicle seat frame manufacturing methods rely heavily on welding, which is costly and time-consuming, and do not efficiently allow for both fixed and pivot connections between components without compromising structural integrity.

Innovation Solution

The use of structural adhesive, fasteners, and swaged joints to connect frame components, eliminating the need for welding and enabling both fixed and pivot connections without welding, thereby reducing manufacturing time and cost while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to connect frame components, then structural integrity is achieved, but manufacturing cost and time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with mechanical fastening systems including swaged joints, rivets, and interlocking features. This substitution eliminates the need for welding equipment and operators while maintaining structural integrity through mechanically secured connections between frame components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The seat frame is divided into multiple separate components that can be independently manufactured and then assembled through mechanical fastening. This segmentation allows for parallel manufacturing of components and simplifies assembly operations, reducing overall manufacturing time while maintaining structural strength through dedicated fastening mechanisms.

Inventive Principle:

Principle #1Segmentation

2Strength

If welding is used to connect frame components, then structural integrity is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces complex welding processes with simpler mechanical fastening operations. Swaged joints, rivets, and interlocking features can be installed with basic tooling and require less specialized equipment and operator training compared to welding, thereby reducing manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs disposable or replaceable fastening components such as rivets and mechanical fasteners that can be easily replaced if needed, eliminating the permanent and difficult-to-reverse nature of welding. This approach simplifies manufacturing and maintenance while ensuring structural integrity through proven mechanical connection methods.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If welding is used to connect frame components, then fixed connections are achieved, but adaptability for pivot connections is reduced

Engineering Contradiction:

Improvefixed connection stabilityVSAvoidpivot connection capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs different fastening mechanisms for different functional requirements: rigid mechanical fasteners for fixed connections requiring stability, and swaged joints with pivot capabilities for connections requiring rotational movement. This dynamic selection of connection types allows the same manufacturing approach to accommodate both stable fixed connections and adaptable pivot connections without compromising either function.

Inventive Principle:

Principle #15Dynamics

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 approach reduces manufacturing time and cost by eliminating the need for welding equipment and operators, while providing reliable and rigid joints that allow for adjustable seating configurations without compromising structural support.

Implementation Method 1

one of the frame components is connected to another of the frame components only by at least one of structural adhesive, a fastener, and a fixed swaged joint

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

one of the frame components is connected to another of the frame components only by at least one of structural adhesive, a fastener, and a fixed swaged joint

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Implementation Method 3

by means of swaging two portions of the tube to form radially outwardly extending beads, thereby trapping the bracket therebetween

Methodology Applied

Scientific EffectSwaging: Deformation

Data Source

PatentUS9126518B2Vehicle seat frame and method of making

Publication Date: 2015.09.08 LEAR CORP

AI summary

A vehicle seat frame (10) includes a plurality of frame components (16, 40, 42, 50, 60, 62, 64). At least one of the frame components (16, 40, 42, 50, 60, 62, 64) is fixedly connected to another of the frame components (16, 40, 42, 50, 60, 62, 64), defining a fixed joint (84, 86, 88, 90). In each fixed joint (84, 86, 88, 90), one of the frame components (16, 40, 42, 50, 60, 62, 64) is connected to another of the frame components (16, 40, 42, 50, 60, 62, 64) only by at least one of structural adhesive, a fastener (72, 74), and a fixed swaged joint (76).