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).

To name a few alterations, side-impact needs to be taken into account as well as the ability to place children up to an age of fifteen months in a rearward facing position for a better protection of the head and neck during an impact.


OUR SOLUTION

Computer Aided Engineering-driven design enabled us to use less prototypes in the development process. This reduced costs and fastened time-to-market. Next to that, the CAE-driven approach allowed us to create a first-time-right design, implementing light-weight thermoplastic materials.
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 molded 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 PP plastics. This material is highly suitable for large structured parts that are being strengthened with ribs. PP LGF or PA GF are used for compact structural parts. Both of these materials are reinforced with glass fibre to improve strength and stiffness.

INJECTION MOULDING

Injection moulding simulations determine the optimum gate location for stiffness and strength of the glass fibre reinforced composite parts. On the heavy loaded components, the results of the injection moulding simulations are directly mapped for use in the mechanical simulations. Therefore, the influence of the fibre orientation on the stiffness and strength of the product are taken into account in the mechanical simulation.


LATEST SAFETY REGULATIONS

It’s key to know and understand what implications regional legislations and consumer test methods have on design and engineering 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.

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