Seat Tube Structure With Localized Strength-to-Mass Optimization
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Solution Overview
Problem
Conventional seat structures face challenges in achieving optimal strength, durability, and cost efficiency due to over-designing or adding redundant components to accommodate varying stress levels, which increases mass and manufacturing costs, and limits design efficiency and manufacturability.
Innovation Solution
A seat structure composed of multiple tube members with varying dimensional and material properties, configured to meet specific stress requirements in different regions, joined using a panel member and laser welding to form a substantially closed structure, reducing redundant components and manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monolithic tube with constant cross section is used to accommodate maximum stresses, then strength requirements are met, but mass and cost increase due to over-designing
Solution Approach 1:
The patent applies local quality by varying the cross-sectional dimensions of tube members along their length and using different materials for different tube members. High-strength tubes with larger cross-sections are placed in high-stress regions, while lower-strength tubes with smaller cross-sections are used in low-stress regions, eliminating the need to over-design the entire structure and reducing overall mass.
Solution Approach 2:
The patent segments the monolithic tube into multiple discrete tube members with different dimensional and material properties. This segmentation allows each tube member to be optimized for its specific stress requirements, rather than designing a single tube to handle all stress conditions, thereby reducing unnecessary material usage.
2Strength
If additional support members are added to reinforce high stress regions, then strength requirements are met, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of adding redundant support members throughout the structure, the patent uses local quality by optimizing the cross-sectional dimensions and materials of individual tube members based on their specific stress requirements. This approach provides necessary strength without increasing the number of parts or structural complexity.
3Ease of manufacture
If conventional tube bending and joining processes are used, then manufacturability is achieved, but design efficiency is limited due to bend radius constraints
Solution Approach 1:
The patent segments the structure into multiple tube members that can be manufactured using standard bend radii and then joined together. This segmentation allows greater design flexibility, as the overall complex geometry can be achieved through assembly of simpler, manufacturable components rather than requiring a single complex tube with impractical bend radii.
4Ease of manufacture
If the number of parts is reduced to lower cost, then cost per structure decreases, but mass and strength are compromised due to structural over-design
Solution Approach 1:
The patent uses local quality to optimize each tube member's cross-section and material for its specific stress requirements, eliminating the need for structural over-design. This allows the structure to use the minimum necessary material while maintaining strength, thereby reducing mass and cost without compromising performance.
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 optimizes mass and strength by eliminating redundant components, reducing handling and processing costs, and improving geometry for enhanced strength-to-mass efficiency, while minimizing the need for additional mounting brackets.
Implementation Method 1
joined using a panel member and laser welding to form a substantially closed structure
Data Source
AI summary
A seat structure may be installed in a seat assembly. The seat structure may comprise plurality of tube members forming a substantially closed structure. Some of the tube members have a substantially uniform cross-sectional area along a substantial portion of its respective longitudinal length. At least a first set of the tube members has at least one of a different dimensional property and a different material property from a second set of the tube members such that mechanical properties of each tube member is configured for stress requirements for a respective region that the respective tube member occupies. The plurality of tube members are joined such that the plurality of tube members are in fixed positions relative to each other.