Laser Welded Encapsulating Ring for Vehicle Recliner Mechanism

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Solution Overview

Problem

Vehicle seat recliner mechanisms are time-consuming to manufacture and prone to impairment during the manufacturing process due to complex assembly requirements.

Innovation Solution

A recliner mechanism design featuring a housing plate, a recliner heart, and an encapsulating ring, where the encapsulating ring is attached to the housing plate using laser welding, reducing manufacturing time and impairment by minimizing heat exposure and increasing torque strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional welding methods are used to attach the encapsulating ring to the housing plate, then the attachment strength is sufficient, but heat-related distortions occur and manufacturing time increases

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces traditional arc welding or resistance welding with laser welding technology. The laser beam provides concentrated thermal energy that melts and fuses the encapsulating ring to the housing plate, achieving strong attachment while reducing overall manufacturing time through faster processing speeds and minimal setup requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the thermal parameters of the welding process by using laser welding instead of conventional methods. This involves controlling laser power, beam focus, and scanning speed to achieve optimal weld quality with reduced heat input, thereby minimizing thermal distortion while maintaining attachment strength.

Inventive Principle:

Principle #35Parameter changes

2Strength

If traditional welding methods are used to attach the encapsulating ring to the housing plate, then the attachment is achieved, but heat-related distortions occur

Engineering Contradiction:

Improveattachment strengthVSAvoidheat-related distortions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies laser welding to create a highly localized heat source that concentrates thermal energy precisely at the weld zone. This localized heating minimizes the heat-affected zone and reduces thermal distortion in surrounding areas, while still achieving sufficient attachment strength at the joint interface.

Inventive Principle:

Principle #3Local quality

3Reliability

If complex assembly procedures are used for the recliner mechanism, then all components can be properly attached, but manufacturing time increases and impairment risk increases

Engineering Contradiction:

Improveassembly reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges multiple assembly operations into a single integrated laser welding process. The encapsulating ring is attached to both the housing plate and the recliner heart in one continuous manufacturing step, eliminating the need for separate positioning, clamping, and welding operations, thereby improving both efficiency and reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs preliminary positioning features and fixtures that pre-align the encapsulating ring with the housing plate and recliner heart before laser welding begins. This preliminary action ensures accurate component alignment and reduces the risk of manufacturing impairment, while the automated laser welding process maintains high productivity.

Inventive Principle:

Principle #10Preliminary action

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 design reduces manufacturing time and prevents heat-related distortions, enhancing the durability and efficiency of the recliner mechanism by using laser welding to attach the encapsulating ring to the housing plate and recliner heart.

Implementation Method 1

the laser beam contacts a portion of the first flange and a portion of the housing plate to attach the encapsulating ring and the housing plate

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

a weld is between the body of the encapsulating ring and the first plate

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS10864830B2Recliner mechanism having welded encapsulating ring

Publication Date: 2020.12.15 JPMORGAN CHASE BANK N A AS ADMINISTATIVE AGENT

AI summary

The recliner mechanism includes a housing plate, a recliner heart and an encapsulating ring. The recliner heart is mounted to the housing plate and operable in an unlocked state permitting relative rotation between a seatback and a seat bottom and a locked state preventing relative rotation between the seatback and the seat bottom. The encapsulating ring is attached to the housing plate.