Welded Metal Pillar Anchor Structure for Lightweight Durability
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Solution Overview
Problem
Existing pillar anchors for automobiles are manufactured in complex structures and high weights, making them difficult and costly to produce, and they do not meet the lightweight requirements of electric vehicles, particularly due to environmental concerns related to injection molding.
Innovation Solution
A pillar anchor design featuring a pair of metal anchor plates integrated by welding, with reinforcement flanges along the outer perimeter of belt movement guide recess portions, formed through drawing and welding processes, to provide strength and durability while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing pillar anchors are manufactured using complex structures and injection molding methods to achieve high durability, then durability is improved, but manufacturing complexity and cost increase, and weight increases
Solution Approach 1:
The pillar anchor is divided into two separate metal anchor plates instead of using a complex injection molded structure. Each anchor plate is independently formed and then joined together, simplifying the manufacturing process while maintaining durability through the use of robust metal construction and reinforcement flanges.
Solution Approach 2:
The invention changes the material parameter from composite (metal + synthetic resin) to pure metal construction. This parameter change eliminates the need for injection molding processes, reduces manufacturing complexity, and achieves both durability and weight reduction simultaneously.
2Reliability
If existing pillar anchors are manufactured by processing thick iron plates and insert-injecting synthetic resin to achieve high durability, then durability is improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The synthetic resin injection process is completely removed from the manufacturing procedure. Only metal anchor plates are used, which are formed through drawing processes and joined by welding, eliminating the complex insert-injection step while maintaining structural integrity and durability.
Solution Approach 2:
The formation of the anchor plates and the creation of reinforcement flanges are merged into a single drawing process step. This integration simplifies manufacturing by combining multiple operations into one process, reducing both complexity and cost while ensuring durability through proper structural design.
3Reliability
If existing pillar anchors are designed with complex structures for high durability, then durability is improved, but weight increases, which does not match lightweight requirements of electric vehicles
Solution Approach 1:
The invention uses metal-to-metal composite construction with two anchor plates joined together, replacing the traditional metal-resin composite. This approach achieves the necessary durability through the strength of metal bonds and reinforcement flanges while significantly reducing weight compared to thick iron plate constructions, meeting the lightweight requirements of electric vehicles.
4Reliability
If existing pillar anchors are manufactured using traditional methods to ensure high durability, then durability is improved, but manufacturing cost increases
Solution Approach 1:
The invention employs standard metal drawing and welding processes that are already well-established in automotive manufacturing, replacing expensive and specialized injection molding operations. This substitution reduces manufacturing cost while maintaining durability through the use of conventional, cost-effective metal forming and joining techniques.
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
The pillar anchor is easily manufactured in a simple structure, exhibits high durability, and supports seat belts effectively during collisions, ensuring occupant safety without the weight and cost issues of traditional methods.
Implementation Method 1
a pair of first and second anchor plates (110, 120) which are drawn to form a pillar anchor
Implementation Method 2
integrated by welding
Data Source
AI summary
Disclosed are a pillar anchor for an automobile and a method of manufacturing the same. According to an embodiment of the disclosure, the pillar anchor for an automobile includes a pair of first and second anchor plates including metal, integrated in one body, and guiding a movement of a seat belt of a vehicle, wherein each of the first and second anchor plates includes a belt movement guide recess portion protruding toward one side of the first and second anchor plates through drawing processing, and guiding the movement of the seat belt, and a reinforcement flange formed at edge portions of the first and second anchor plates to reinforce the first and second anchor plates.