Fabric-Reinforced Thermoplastic Motor Vehicle Seat Support Structures
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Solution Overview
Problem
The challenge lies in manufacturing motor vehicle support structures that require high strength and durability while minimizing material, time, and manufacturing effort, as traditional metallic materials are being replaced by plastics, but current plastic materials often fail to meet strength requirements and have long curing cycles, making them unsuitable for high-volume production.
Innovation Solution
A method combining the forming process of a base element made of fabric-reinforced thermoplastic material with an additional process such as injection molding for reinforcement, allowing for the integration of stiffening elements and functional parts, which addresses the strength and durability needs while reducing manufacturing effort and cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If plastic materials are used to replace metallic materials for weight minimization and cost reduction, then manufacturing costs and cycle times are reduced, but strength and durability requirements are not met
Solution Approach 1:
The patent uses fabric-reinforced thermoplastic materials that combine plastic matrix with fabric reinforcement (such as glass fiber mats) to create a composite material that achieves both weight reduction and high strength requirements, resolving the contradiction between using lightweight plastics and meeting strength requirements
Solution Approach 2:
The patent applies selective reinforcement by inserting stiffening elements and injecting material accumulations only in specific regions where strength is required, rather than uniformly reinforcing the entire component, thus achieving strength requirements while minimizing material usage and maintaining weight benefits
2Strength
If thermosetting plastics are used to satisfy strength requirements, then strength and durability are achieved, but cycle times become too long for high-volume manufacturing
Solution Approach 1:
The patent changes the material state parameter from thermosetting to thermoplastic, which allows for faster processing cycles while maintaining strength through fabric reinforcement and selective stiffening elements, thus resolving the contradiction between strength requirements and manufacturing cycle time
Solution Approach 2:
The patent performs preliminary reinforcement by pre-placing stiffening elements and fabric reinforcements in the mold before final molding, allowing the thermoplastic material to be quickly formed around these pre-positioned strength-enhancing components, achieving both strength and short cycle times
3Productivity
If fabric-reinforced thermoplastic materials are used for manufacturing support structures, then weight and cycle time are reduced, but manufacturing effort increases due to multiple consecutive processes
Solution Approach 1:
The patent merges multiple manufacturing operations into a single integrated molding process, where fabric reinforcement, stiffening element insertion, material accumulation injection, and final forming are all performed in one continuous operation within the same mold, thus reducing manufacturing effort despite the complexity of the multi-step process
4Strength
If selective reinforcement with material accumulations and stiffening elements is applied, then strength requirements are met in specific regions, but device complexity increases
Solution Approach 1:
The patent applies reinforcement measures only in specific local regions where strength is required, using material accumulations and stiffening elements selectively positioned in high-stress areas, thus achieving strength requirements without unnecessarily complicating the overall structure
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 enables the creation of support structures with enhanced strength and durability using fabric-reinforced thermoplastic materials, optimizing material usage and manufacturing efficiency by selectively reinforcing regions with different types and forms of fabric and injection-molded elements, suitable for complex motor vehicle parts like seat pans.
Implementation Method 1
a base element (BE) is thermoplastically formed in a mold
Implementation Method 2
injection-molded to the support structure base (TB)
Data Source
AI summary
According to a method for producing support structures in motor vehicles, especially parts of a motor vehicle seat, at least one base element (BE) consisting of a thermoplastic material with a fabric back stay, especially a glass fiber reinforced thermoplastic (GMT) is inserted into tool (8) to form a support structure base (TB), is thermoplastically deformed and is subjected, at the same time or subsequently, to at least one additional process for reinforcing the support structure base (TB), integrally forming at least one additional structure (ZS), and integration of functional parts or integration of interfaces for additional components into the support structure (TB).