Integrated Seat Rail Body Structure for Fewer Parts and Higher Rigidity
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Solution Overview
Problem
Conventional body member assemblies for vehicles have excessive parts, leading to complex assembly processes, increased weight, and reduced structural rigidity, with potential for joint and buzz, squeak, rattle issues, and limited impact resistance.
Innovation Solution
An integrated seat rail and body member assembly is developed, featuring continuous body longitudinal members and cross members bonded by MIG welding, reducing parts and weight, and enhancing structural rigidity through a continuous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional body member assembly uses multiple separate parts (body longitudinal members and seat rails), then it allows flexible assembly, but it increases the number of parts, assembly complexity, and weight
Solution Approach 1:
The patent combines the body longitudinal member and seat rail into a single integrated body member that performs both functions. The integrated body member includes a longitudinal extending portion serving as the body structural member and a transverse extending portion serving as the seat rail, eliminating the need for separate components and reducing assembly complexity
2Ease of manufacture
If conventional body member assembly uses multiple separate parts bonded together, then it allows modular manufacturing, but it creates joint and buzz, squeak, rattle problems and requires excessive quality control
Solution Approach 1:
By integrating the body longitudinal member and seat rail into one continuous piece, the patent eliminates all bonding joints between these components. The integrated structure removes sources of joint and buzz, squeak, rattle problems while maintaining manufacturing feasibility through single-piece fabrication or forging processes
3Ease of manufacture
If conventional body longitudinal members have disconnected structure, then it allows easier manufacturing, but it limits coupling with seat rail and reduces structural rigidity
Solution Approach 1:
The integrated body member creates a continuous, unbroken structural path from the body floor through the longitudinal extending portion to the transverse seat rail portion. This continuous structure significantly enhances structural rigidity and coupling strength compared to disconnected members, while still allowing manufacturing through integrated forming processes
4Ease of manufacture
If seat rail is disposed separately on body longitudinal members, then it allows independent manufacturing, but it causes redundancy and increases weight
Solution Approach 1:
The patent merges the seat rail function into the body longitudinal member by extending it transversely, eliminating the need for separate seat rail components. This integration removes redundant materials and reduces overall assembly weight while maintaining all necessary structural and seating functions
Solution Approach 2:
The integrated body member serves multiple functions simultaneously: it provides the body's structural longitudinal support, acts as the seat rail for mounting seats, and maintains coupling with the floor panel. This multi-functionality eliminates the need for separate dedicated components for each function
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 integrated assembly reduces assembly processes, improves structural rigidity, minimizes joint issues, and expands seat sliding range, enabling a lounge concept interior design.
Implementation Method 1
The body longitudinal member and the side reinforcing member may be bonded by metal inert gas (MIG) welding. In addition, the body longitudinal members and the seat cross members may be bonded by MIG welding, spot welding, self-piercing rivet (SPR), or any combination thereof.
Data Source
AI summary
A body member assembly has an integrated seat rail and is coupled to a floor panel for a vehicle. The body member assembly includes a plurality of body longitudinal member coupled to the floor panel and disposed in a transverse direction of a vehicle body. The body member assembly also includes a plurality of seat cross members coupled to the floor panel and with end portions coupled to side end portions of neighboring body longitudinal members, respectively. Thus, it is possible to integrate overlapping functions, secure body rigidity, and reduce the number of parts and/or manufacturing or assembly processes by constituting the integrated body member and at the same time, integrating a seat rail with a vehicle body.