Vehicle Seat Laser Welding Radial Gap Control
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Solution Overview
Problem
Existing vehicle seat arrangements face challenges in laser welding with filler material, particularly in maintaining a consistent radial gap for low distortion connections between inner and outer elements, which affects the stability and accuracy of fittings in two-door motor vehicles.
Innovation Solution
The introduction of a radial gap with defined minimum width between the outer and inner elements, utilizing bearing points to maintain the gap width during laser welding, allowing for a secure and distortion-free connection by filling the gap with filler material that solidifies into a weld seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the edge of the opening is pressed tightly against the inner element for secure connection, then the connection strength is improved, but the gap width becomes inconsistent leading to high distortion during welding
Solution Approach 1:
The contact interface between the outer element and inner element is segmented into discrete bearing points rather than continuous contact. This segmentation allows the gap width to be consistently maintained at non-bearing point areas while still achieving secure connection through the bearing points, resolving the contradiction between connection strength and gap width consistency.
Solution Approach 2:
Different regions of the opening edge have different functions: bearing points provide localized contact for positioning and connection strength, while the intervening gap regions maintain consistent spacing for controlled filler material insertion and low distortion welding. This local differentiation resolves the contradiction by optimizing each region for its specific purpose.
2Ease of manufacture
If the radial gap width is increased to allow filler material insertion, then the ease of manufacture is improved, but the connection distortion increases
Solution Approach 1:
The bearing points are designed with specific dimensional tolerances that allow for controlled variation in gap width. This dynamic approach enables the gap to be sufficiently wide for filler material insertion while maintaining enough constraint to minimize welding distortion, balancing ease of manufacture with manufacturing precision.
3Manufacturing precision
If the bearing points are made larger to improve positioning accuracy, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The positioning function is extracted from the general opening structure and concentrated into specific bearing points. This extraction allows for simplified overall design while achieving high positioning accuracy through the specialized bearing point features, resolving the contradiction between manufacturing precision and device complexity.
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 solution ensures a secure, crack-free connection with minimal distortion between the outer and inner elements, enabling precise positioning and stable operation of vehicle seat components, such as between the seat part and backrest, while allowing for easy entry functions and complex adjustments.
Implementation Method 1
For laser welding with filler material, a gap could be present for inserting the weld filler material
Implementation Method 2
a weld seam connects the outer element to the inner element. The edge of the opening of the outer element is spaced apart from the inner element over the largest part of its periphery, forming a radial gap with a defined minimum width. The weld seam is introduced into the gap, in particular by using a filler material
Data Source
AI summary
An arrangement for a vehicle seat includes an inner element (11c, 11d), an outer element (9, 16a), which has an opening (16b) having an edge (9c, 16c) and receives the inner element (11c, 11d), and a weld seam (20) which connects the outer element (9, 16a) to the inner element (11c, 11d). The edge (16c) of the opening of the outer element (9, 16a) is interspaced from the inner element (11c, 11d) over the largest part of its circumference and defines a radial gap (G) having a defined maximum width, the weld seam (20) being introduced into the gap (G).