Headrest Module With Integrated Stop for Slim Seat Adjustment
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Solution Overview
Problem
Existing headrest modules for vehicles have complex structures and require many parts, making them difficult to manufacture and limiting their slimness, which obstructs maximizing interior space, especially in self-driving vehicles.
Innovation Solution
A headrest module design that reduces the number of parts and simplifies the manufacturing process by incorporating a mounting base, a rack bracket with a rack gear, a moving gear with a pinion gear, and a stopping unit, allowing for translational and rotational motion while maintaining a slim profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a slide module is used for linear movement of the headrest, then the headrest can be adjusted in position, but the structure becomes complex and the manufacturing process becomes difficult
Solution Approach 1:
The patent combines the rack bracket and moving gear into an integrated assembly where the rack gear part and pinion gear part work together as a unified mechanism. This merging eliminates the need for separate slide module components while maintaining the linear adjustment function through the engagement between the rack and pinion gears.
Solution Approach 2:
The rack bracket serves multiple functions: it provides the rack gear part for linear motion conversion, acts as a structural support mounting the moving gear, and includes guidance members for motion control. This multi-functionality reduces the overall number of components needed in the system.
2Ease of operation
If a slide module is used for linear movement of the headrest, then the headrest can be adjusted in position, but the headrest cannot be slimmed
Solution Approach 1:
The moving gear is rotatably inserted into the first guide groove of the base plate, creating a nested arrangement where the rotating component fits within the structural framework. This nesting allows the mechanism to maintain a compact profile while enabling full adjustment functionality.
Solution Approach 2:
The invention transitions from a linear slide mechanism to a rotational mechanism (pinion gear) that achieves linear motion through gear engagement. This dimensional change from direct linear sliding to rotational-to-linear conversion allows for a slimmer design by eliminating the need for extensive linear guide structures.
3Ease of manufacture
If the number of parts is reduced, then the manufacturing process is simplified, but the functionality to stop rotational motion must be maintained
Solution Approach 1:
The stopping unit is integrated with the rack bracket structure, where the first engaging part is formed as part of the rack bracket assembly. This merging ensures that the stopping function is built into the existing structural component rather than requiring a separate mechanism, maintaining reliability while simplifying manufacturing.
Solution Approach 2:
The engagement between the first engaging part of the rack bracket and the second engaging part of the moving gear creates a self-locking mechanism. When the moving gear rotates, the engaging parts naturally engage to stop further rotation, eliminating the need for external stopping mechanisms and ensuring reliable position holding.
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 proposed headrest module achieves a slimmer design while reducing the number of parts and simplifying the manufacturing process, thereby maximizing interior space without compromising functionality.
Implementation Method 1
a moving gear (130) having a pinion gear part (131) engaged with the rack gear part (121)
Implementation Method 2
The drive unit may include a checking spring configured to elastically bias the central shaft toward the stopping unit
Data Source
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AI summary
The present invention provides a headrest module including a mounting base; a rack bracket having a rack gear part and mounted on the mounting base to enable translational motion along an extended direction of the rack gear part; a moving gear having a pinion gear part engaged with the rack gear part and being installed to enable rotational motion and translational motion with respect to the mounting base; and a stopping unit formed to stop the rotational motion of the moving gear as the pinion gear part, which makes the rotational motion due to the translational motion of the rack gear part, makes the translational motion in one direction.