Seatback Frame Structure With Integrated Pole Guide and Curved Cross Member
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Solution Overview
Problem
Conventional seatback frame structures for vehicles face issues with low frame compatibility, increased manufacturing costs and weight due to additional components, and safety concerns in head-on collisions, as well as reduced design freedom and productivity due to complex component variations and insufficient space for mounting components.
Innovation Solution
A seatback frame structure with a pair of side brackets and an upper cross member featuring inclined and curved surfaces, height adjusting gaps, and integrated pole guides without a separate pole guide tube, allowing for adjustable height and rounded edges, reducing the need for additional side brackets and enhancing compatibility across vehicle types while ensuring passenger safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple upper cross member shape is used, then manufacturing is easier, but frame compatibility between different vehicle types is reduced
Solution Approach 1:
The upper cross member incorporates an adjustable mechanism that allows its effective length and configuration to be dynamically changed. This enables the same basic structure to adapt to different seatback heights and vehicle types, resolving the contradiction between manufacturing simplicity and frame compatibility.
Solution Approach 2:
The design allows modification of key parameters such as the length and angle of the upper cross member through adjustment mechanisms. By changing these parameters, the same upper cross member can accommodate different vehicle seat configurations, maintaining compatibility across various vehicle types without requiring custom manufacturing for each application.
2Reliability
If additional components like pole guide tubes are used, then pole guide securing is achieved, but manufacturing costs and weight increase
Solution Approach 1:
The pole guide tube function is merged directly into the upper cross member structure itself, eliminating the need for separate pole guide tube components. This integration maintains the pole guide securing function while reducing the total number of parts, decreasing weight, and lowering manufacturing costs.
Solution Approach 2:
The upper cross member is designed to perform multiple functions simultaneously: it provides structural support, serves as the pole guide mounting structure, and enables height adjustment. This multi-functionality eliminates the need for dedicated pole guide tubes, reducing component count and overall weight while maintaining reliability.
3Reliability
If more components are used for pole guide securing, then assembly is achieved, but product variation and welding variation increase causing gaps and defects
Solution Approach 1:
By integrating the pole guide securing function directly into the upper cross member, the design eliminates multiple separate components and their associated assembly steps. This reduction in component count directly decreases the sources of product variation and welding variation, improving coupling precision and eliminating gaps and defects.
4Strength
If the upper cross member edge is bent downwards for structural reasons, then structural integrity is maintained, but passenger safety in head-on collisions is compromised
Solution Approach 1:
The dangerous sharp edge of the upper cross member is replaced with a rounded or curved surface. This curvature eliminates the hazard of head injury during collisions while maintaining the structural integrity of the cross member through proper radii design that distributes stress appropriately.
5Strength
If the rear edge of the upper cross member is positioned for structural reasons, then structural support is provided, but mounting space for power motors and working space are insufficient
Solution Approach 1:
The design repositions or reconfigures the upper cross member in a way that creates additional space in the rear region. By optimizing the spatial arrangement and utilizing available volume more effectively, the design provides sufficient mounting space for power motors and adequate working space while maintaining structural support functions.
Data Source
AI summary
A seatback frame structure is provided for the manufacture of a seat of a vehicle. The seatback frame structure includes a pair of side brackets and an upper cross member. The side brackets are coupled at lower ends thereof to left and right sides of a seat frame. The upper cross member is transversely mounted between the upper ends of the side brackets, and a headrest is placed on the upper portion of the upper cross member. Each of opposite ends of the upper cross member comprises a downwardly inclined surface, and is coupled to the upper end of a corresponding side bracket.