Vehicle Seat Wire Frame Segmentation and Welding
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Solution Overview
Problem
Current methods for producing vehicle seats with rigid foam and wire frames result in complex, costly, and time-consuming manufacturing processes, with potential for component distortion and increased assembly complexity due to the need for additional fastening elements and tolerance compensation, especially when dealing with different elasticities of materials.
Innovation Solution
A method involving separate wire segments inserted into channel contours of a rigid foam body, which are then welded together to form a stable wire frame, utilizing intersecting channel contours and undercuts for precise positioning and fixation, allowing for a stronger bond between the foam and wire frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire clips are embedded in rigid foam body with permanent bonding, then strong bond between foam and frame is achieved, but manufacturing process becomes time-consuming and costly
Solution Approach 1:
The wire frame is divided into multiple separate wire clips that are individually inserted into channel contours of the rigid foam body. This segmentation allows for simpler, faster insertion processes compared to embedding a complete frame assembly, while maintaining structural integrity through the distributed arrangement of multiple clips.
Solution Approach 2:
The wire clips are pre-formed with specific geometries including projections and undercut sections that match the channel contours. This preliminary preparation enables direct insertion and automatic positioning within the foam body channels, eliminating the need for complex assembly operations during the main manufacturing process.
2Ease of operation
If complete frame assembly is inserted into foam mold, then frame positioning is simplified, but component warping occurs during cooling
Solution Approach 1:
The frame is segmented into multiple independent wire clips that are inserted separately into the foam body. This segmentation reduces the thermal mass and cooling time required, minimizing warping risks while allowing each clip to be independently positioned in its channel contour without affecting the entire frame assembly.
3Reliability
If material-bonded fixation with hot melt adhesive is used, then frame is fixed in rigid foam body, but manufacturing costs increase and warpage occurs
Solution Approach 1:
The chemical bonding method (hot melt adhesive) is replaced with a mechanical interlocking system. Wire clips with specific geometries are inserted into matching channel contours in the rigid foam body, creating secure fixation through physical interlocking rather than chemical adhesion. This eliminates adhesive-related costs and warping issues while maintaining reliable frame fixation.
4Reliability
If projections and undercuts are designed in receiving channels, then force-locking and form-locking are achieved, but additional fastening elements are required
Solution Approach 1:
The wire clips integrate multiple functions into single components: they provide structural support, mechanical interlocking through projections and undercuts, and positioning features all in one element. This merging eliminates the need for separate fastening elements and reduces assembly complexity while maintaining reliable fixation.
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 a more stable and secure fixation of the wire frame within the rigid foam body, reducing assembly complexity, distortion, and production costs, while providing improved tolerance compensation and modularity for different vehicle models.
Implementation Method 1
the wires are joined together by welding, in particular by spot welding
Data Source
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AI summary
The invention relates to a method for manufacturing a vehicle seat comprising a rigid foam body with channel contours open towards at least one side surface, in which a separate wire frame is inserted and fixed in position by means of several projections and/or undercuts formed in the area of the channel contours, either by force-locking and/or form-locking. The object of the invention is to provide such a method with which – relative to the wire cross-section – greater overlaps than previously achievable can be reached by the projections or undercuts formed on the rigid foam body.This task is solved by first inserting a first wire into a first channel contour of the rigid foam body, then inserting a second wire into a second channel contour that intersects the first channel contour at an angle, such that the first wire and the second wire are in direct contact with each other in the area where the first and second channel contours intersect, subsequently inserting further wires into further intersecting channel contours of the rigid foam body in such a way that each wire is in direct contact with at least one other wire in at least one area of two intersecting channel contours, and finally joining these two wires together by welding at at least some of the interfaces resulting from each pair of overlapping wires.