case | child car seat

“We care about the smallest passengers”

THE CHALLENGE

Developing a child restraint system (CRS) that meets the challenging ECE-R129 European safety standard (i-Size, evolution of the ECE-R44 standard).

The ECE-R129 features more load cases than the ECE-R44. This brings more complexity to the design; for instance the need of additional side-impact performance.


OUR SOLUTION

Computer Aided Engineering (CAE)-driven design enabled us to do a multitude of iterations in a very early development stage. This enables us to reduce the development time significantly and improve the overall design in terms of costs and performance.

We validate full product designs, to enable mass production. We do this by our CAE-driven design approach, in combination with our experience in material technology, design and processing. This enables a first-time-right design.

WHAT WE DID

CONCEPTUAL DESIGN

We have analysed the performance of the existing Car Seat Family for compliance with the new standards using crash simulations including dummy and seatbelt. We specifically paid attention to rearward facing positioning during rear impact and the available design space in the car. The new concept has been drawn up based on this analysis.

PRODUCTION PROCESS

This specific child seat is convertible (i.e., front/rear facing and upright and reclined) using an adjustment mechanism. Therefore, the design has to endure for multiple load cases. This calls for an innovative production process, so it was chosen to use multiple plastic parts injection moulded around metal components. This resulted in a robust mechanism without an additional fixing process.

MATERIAL SELECTION

On each part, the most suitable material is selected. These are chosen based on stiffness, density and toughness. In esthetical parts, which also need to fulfil a structural function, we used polypropylen (PP). This material is highly suitable for large structured parts that are being strengthened with ribs. Long-glassfibre reinforced polypropylen (PP-LGF) and reinforced polyamide (PA-GF) are used for compact structural parts.

INJECTION MOULDING

Injection moulding simulations determine the optimum gate locations to determine the most optimal fibre orientation. This is all done to optimise stiffness and strength and to manage the location of weld lines.

The outcome of the injection moulding simulations is directly used for our strength analysis. By coupling both analyses and using our insights in material and processing knowledge. This enables us to deliver the most optimal design in terms of strength and cycle time.




LATEST SAFETY REGULATIONS

It’s key to know and understand what implications regional legislations and consumer test methods have on design and engineering. This is especially important for a high safety and quality product, like a child car seat. Therefore, we continuously invest in being up to date in the newest safety requirements.

Want to know more about our Safety Solutions?
Read more...

INQUIRIES?

Interested to learn more about our way of working?

CONTACT PAUL HABETS

Are you thinking of developing a new child car seat? Or do you wish to have your current design validated? Please give us a call. We look forward to talk with you.

Click here to get in touch.

LET'S GET IN TOUCH!

simulate to innovate
follow us on