Laser-Welded Vehicle Seatback With Integrated Latch
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Solution Overview
Problem
Vehicle seatbacks have high part counts and mass due to complex welding requirements, and existing latch systems are inefficiently located and lack intuitive warning mechanisms for occupancy safety.
Innovation Solution
A vehicle seatback design featuring laser-welded stamped steel panels with exposed stitching patterns for simplified assembly and a center-mounted latch system with a remote handle and integrated flag for ergonomic and intuitive operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used for seatback assembly, then structural integrity can be achieved, but multiple separate welding operations are required increasing manufacturing complexity and time
Solution Approach 1:
The patent combines multiple welding operations into a single laser welding process by positioning all welding locations accessible from one side of the seatback. This merging approach maintains structural integrity through comprehensive welding while reducing manufacturing complexity by eliminating the need for multiple separate operations and tool repositioning.
Solution Approach 2:
The invention transitions from multi-directional welding access to single-direction welding access by redesigning the seatback structure. All welding locations are positioned on one face of the seatback, allowing the laser welding tool to access all joints from a single dimension without requiring repositioning or complex fixture arrangements.
2Reliability
If traditional seatback design is used, then cargo support function is provided, but high mass and high part count result
Solution Approach 1:
The seatback is divided into two primary panels (front panel and rear panel) that are joined through laser welding. This segmentation allows for optimized material usage and reduced part count while maintaining the cargo support function. The panels are designed to work together structurally, providing necessary support with minimal mass.
Solution Approach 2:
The patent changes the material parameters by using laser-weldable stamped steel panels instead of traditional tubular steel components. This parameter change enables reduced material thickness and weight while maintaining structural integrity through the precision and strength of laser welding joints.
3Ease of operation
If latch is positioned in outboard location near actuating handle, then ease of operation is improved, but structural load management becomes less optimal
Solution Approach 1:
The patent introduces a centrally positioned latch mechanism that acts as an intermediary between the actuating handle and the seatback structure. The latch is positioned at the center of the rear panel where it can optimally manage structural loads, while the actuating handle remains accessible to the user. This intermediary positioning resolves the conflict between operational ease and structural integrity.
4Ease of manufacture
If warning symbol is not intuitively associated with actuating handle, then manufacturing simplicity is maintained, but user understanding of unsafe status becomes less effective
Solution Approach 1:
The patent uses a flag with distinct color changes (typically red when unlocked, green when locked) that is visually integrated with the actuating handle. This color-based visual feedback system intuitively communicates the occupancy safety status to users without complicating the manufacturing process, as the flag is a simple visual indicator that can be incorporated into the existing handle design.
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 the mass and part count of seatbacks while improving structural integrity and safety by allowing single-operation welding and providing an intuitive warning mechanism for occupancy safety through the latch system's ergonomic design.
Implementation Method 1
at least one welding stitch connects the bracket to one of the first or second panels, the at least one welding stitch included in the laser welding stitch pattern
Data Source
AI summary
A vehicle seatback includes: a first panel; a second panel coupled to the first panel so that a welding stitching pattern is exposed, each welding stitch of the welding stitching pattern accessible from a common direction; and a bracket, wherein at least one welding stitch included in the welding stitch pattern connects the bracket to one of the first or second panels. A vehicle latch system includes: a housing at a first edge of a movable vehicle seatback with a handle to assume an extended position outside the housing in which a flag on the handle is presented, and a retracted position inside the housing in which the flag is not presented; a latch configured for placement at a second edge of the movable vehicle seatback, the second edge opposite the first edge; and a cable connecting the handle and the latch to each other.