Thermoplastic Backrest with Metal Brackets for Cost Reduction
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Solution Overview
Problem
Automotive seats made of carbon fiber or fiberglass composite materials offer high mechanical stiffness and aesthetics but come with high manufacturing costs, making them unaffordable for mass production.
Innovation Solution
A backrest for a motor vehicle seat constructed using thermoplastic polymeric material filled with glass fibers, featuring vertically extending metal stiffening brackets and a partially uncovered rear surface for decorative elements, reducing production costs while maintaining mechanical resistance and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber or fiberglass composite materials are used for automotive seats, then mechanical stiffness and aesthetics are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses glass fiber-filled thermoplastic polyamide material as a composite material alternative to pure carbon fiber composites. This provides adequate mechanical stiffness while reducing manufacturing cost through injection molding processes and more affordable material choices.
Solution Approach 2:
The backrest is divided into functional zones: areas requiring high stiffness are reinforced with glass fibers and metal brackets, while other areas use standard thermoplastic material. This selective reinforcement approach reduces overall material cost while maintaining necessary mechanical properties.
2Ease of manufacture
If glass fiber-filled thermoplastic polyamide material is used, then manufacturing cost is reduced, but mechanical stiffness may be compromised
Solution Approach 1:
The patent combines glass fiber-filled thermoplastic polyamide with additional reinforcement elements (unidirectional glass or carbon fiber strips, metal brackets) to achieve the required mechanical stiffness. This hybrid composite approach maintains cost-effectiveness while ensuring adequate strength.
Solution Approach 2:
Reinforcement is applied locally where mechanical stiffness is most needed - such as in the bracket regions and structural support areas - rather than uniformly throughout the entire backrest. This optimizes the balance between cost and mechanical performance.
3Shape
If the rear surface is left uncovered to show decorative elements, then aesthetics are enhanced, but protection and durability may be reduced
Solution Approach 1:
The rear surface is selectively uncovered only in specific decorative zones where aesthetics are prioritized, while other areas maintain protective coverage. This allows the thermoplastic material to provide protection where needed while showcasing decorative elements in visible areas.
Solution Approach 2:
Surface decorative elements are molded directly into the thermoplastic material, creating integrated aesthetic features that are part of the structural component itself. This eliminates the need for separate protective layers while maintaining both appearance and durability.
Data Source
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AI summary
A backrest (10) for a front seat of a motor vehicle comprises a body (11) of thermoplastic polymeric material filled with glass fibers and two metal stiffening brackets (20), transversely spaced apart from each other, integral with the backrest body. Each bracket (20) has an angular shape with a central portion (21) fixed to the central wall (12) of the backrest and a side flange (22), forming an angle with the central portion (21). Each side flange (22) has at least one engagement seat (28) for mounting the backrest in a reclining manner about a horizontal axis. The stiffening brackets (20) are not visible on the rear surface (14) of the backrest body, which has one or more surface decorative elements (30).