Segmented Vehicle Seatback Frame with Variable Rigidity
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Solution Overview
Problem
Conventional seatback frames for vehicles face challenges in achieving the required rigidity while increasing weight and production costs due to the need for thicker pipes and extensive welding, leading to overdesign and inefficiencies.
Innovation Solution
A segmented seatback frame design with distinct parts having varying strengths and thicknesses, utilizing hinge coupling units for rotational mounting and welding of protrusions, eliminating the need for separate brackets, and optimizing material distribution based on load-bearing requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thicknesses of pipes are increased to satisfy strength regulations, then the rigidity of the back frame is improved, but the weight of the back frame increases
Solution Approach 1:
The back frame is divided into multiple segments (first back frame, second back frame, third back frame) with different thickness specifications. The first back frame has a first thickness, the second back frame has a second thickness greater than the first, and the third back frame has a third thickness greater than the second. This segmentation allows each component to have the minimum necessary thickness for its specific load requirements, rather than uniformly increasing thickness throughout the entire structure.
Solution Approach 2:
Different portions of the back frame are assigned different thickness qualities based on their functional requirements. The second back frame (mounting portion) has increased thickness to provide strong mounting capability for safety belts and auxiliary devices, while the first and third back frames maintain thinner profiles. This local quality differentiation ensures high strength where needed without unnecessarily increasing weight in less critical areas.
2Strength
If several kinds of brackets are welded to connect pipes, then the rigidity of the back frame is improved, but the production cost increases
Solution Approach 1:
The mounting portion (second back frame) integrates multiple functions into a single component. It simultaneously serves as the structural connection element between the first and third back frames and as the mounting base for safety belts and auxiliary devices. This merging eliminates the need for separate brackets and reduces the number of welding operations required, thereby lowering production costs while maintaining structural rigidity.
Solution Approach 2:
The second back frame is designed as a multi-functional component that performs both structural support (connecting first and third back frames) and mounting functions (providing attachment points for safety belts and auxiliary devices). This universality reduces the total number of parts needed in the assembly, simplifying manufacturing and reducing costs.
3Strength
If the thicknesses of pipes are increased to raise rigidity, then the strength regulations are satisfied, but the overall design becomes overdesigned and inefficient
Solution Approach 1:
The back frame is segmented into three distinct portions (first, second, and third back frames) with progressively increasing thicknesses. This segmentation prevents overdesign by allowing each segment to have the minimum necessary thickness for its specific structural role, rather than uniformly thickening the entire frame.
Solution Approach 2:
The design applies local quality differentiation where the second back frame (mounting portion) has increased thickness specifically at the location requiring high strength for auxiliary device mounting, while other portions maintain optimized, thinner profiles. This prevents unnecessary material usage and design complexity in areas that do not require high strength.
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 design achieves cost reduction and weight reduction by optimizing material usage, ensuring high strength only where necessary, and enhancing rigidity through localized reinforcement, thereby preventing overdesign and improving durability.
Implementation Method 1
the lower part and the hinge coupling unit may be coupled by welding the protrusions and the through holes
Data Source
AI summary
A seatback frame for vehicles is disclosed. The seatback frame for vehicles has a simple structure without bracket structures used to install a conventional seatback frame and thus achieves cost reduction and weight reduction. In particular, the seatback frame is segmented into several parts having different rigidities so that only a part, on which load is concentrated, is set to have high strength and thus avoids overdesign for excessively high strength of an unnecessary part.