Discontinuous Recliner Single Actuating Element Component Reduction
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Solution Overview
Problem
Existing discontinuous recliners for vehicle seats have a high number of components, leading to manufacturing malfunctions, complex assembly, and increased weight, which are detrimental to vehicle manufacturers' goals of reducing weight and simplifying the reclining mechanism.
Innovation Solution
A discontinuous recliner design featuring a single actuating element that drives locking pawls from their locking to unlocking position and vice versa, reducing the overall number of components by integrating the actuating element with the return spring, thereby simplifying the mechanism and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high number of separate components are used in the discontinuous recliner, then the locking and unlocking function can be achieved, but the manufacturing complexity increases and the risk of malfunction due to tolerances and clearances increases
Solution Approach 1:
The patent merges the first cam, second cam, and return spring into a single integrated actuating element. This actuating element comprises a first portion forming the first cam, a second portion forming the second cam, and a third portion forming the return spring. By combining these previously separate components into one monolithic piece, the patent eliminates the need for multiple separate parts, reducing assembly complexity and eliminating tolerance accumulation between components while maintaining the locking and unlocking functionality.
2Ease of manufacture
If multiple separate components are used in the discontinuous recliner, then the locking mechanism can function, but the assembly process becomes expensive and time consuming
Solution Approach 1:
The patent combines multiple discrete components (first cam, second cam, return spring) into a single integrated actuating element that can be manufactured as one piece. This integration dramatically simplifies the assembly process, as the actuating element can be installed as a single unit rather than requiring the assembly of multiple separate components. The monolithic structure eliminates the need for fastening operations between these elements, reducing both assembly time and cost.
3Weight of moving object
If a high number of components are used in the discontinuous recliner, then the locking and unlocking function is achieved, but the overall weight of the recliner increases
Solution Approach 1:
The patent integrates the first cam, second cam, and return spring into a single actuating element, eliminating the weight of multiple separate components and their associated fasteners and mounting structures. By manufacturing these elements as one monolithic piece, the patent reduces the total material required and eliminates redundant structural elements, thereby reducing the overall weight of the discontinuous recliner mechanism.
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 minimizes the risk of malfunction due to manufacturing tolerances, reduces assembly time, and decreases the recliner's weight, while maintaining reliable operation and user-adjustable inclination of the seat backrest.
Implementation Method 1
a return spring (19) which is configured to bias the actuating element (9) to a configuration in which the locking pawls (7) are in their locking position
Data Source
AI summary
A discontinuous recliner for a vehicle seat is provided. The discontinuous recliner comprises one or more locking pawls and a single actuating element which is configured to drive the locking pawl(s) both from the locking position to the unlocking position and from the unlocking position to the locking position. Thanks to the provision of the single actuating element, the overall number of components of the discontinuous recliner is significantly reduced. This allows to obtain a discontinuous recliner which is lighter, easier to be assembled and more reliable.