Car Seat Lumbar Support Unit Simplified Structure
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Solution Overview
Problem
Conventional car seat lumbar support units have reduced responsive performance and increased manufacturing costs due to complex structures and power transmission issues, particularly with drive cables and multiple components in a narrow space.
Innovation Solution
A simplified structure using a first and second elevating unit with motors, transfer screws, and nut members, along with a rotary cylinder, allows independent operation of upper and lower brackets, directly transmitting rotational force for improved responsiveness and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power connection is made through a drive cable between the elevating bracket and motor, then the structure can be connected, but responsive performance is reduced
Solution Approach 1:
The patent extracts and eliminates the drive cable from the power transmission system. Instead of using a cable to transmit power from the motor to the elevating bracket, the invention integrates the power transmission directly through the motor's driving shaft and gear mechanism, removing the intermediate cable component that caused responsiveness issues.
Solution Approach 2:
The patent introduces a gear as an intermediary mechanism between the motor and elevating bracket. The gear transmits power directly from the motor's driving shaft to the elevating bracket through meshing teeth, providing a more responsive and reliable power transmission path compared to flexible cable connection.
2Reliability
If many components such as a worm gear are used to change power transmission direction, then power connection is achieved, but manufacturing costs and structure complexity are increased
Solution Approach 1:
The patent merges the power transmission direction change function into the motor assembly itself. The motor's internal gear mechanism and the elevating bracket's gear are designed to mesh directly, combining what would have been separate components (motor, worm gear, bracket) into an integrated unit that reduces part count and manufacturing complexity.
Solution Approach 2:
The motor assembly is designed to perform multiple functions: generating rotational power, changing power transmission direction through its gear mechanism, and directly driving the elevating bracket. This multi-functional design eliminates the need for separate dedicated components like worm gears, reducing manufacturing costs.
3Volume of moving object
If a narrow space is used for component arrangement, then the lumbar support fits the seat, but component arrangement becomes difficult without interruption
Solution Approach 1:
The patent employs a nested arrangement where the gear is positioned inside the motor housing, and the elevating bracket is integrated with the motor assembly. This nesting allows multiple components to occupy overlapping or adjacent spaces efficiently, fitting the lumbar support mechanism into a compact form factor suitable for car seat integration.
Solution Approach 2:
The lumbar support mechanism is segmented into distinct functional modules: the motor assembly (with integrated gear), the elevating bracket, and the curved band. This segmentation allows each component to be optimized for its specific function and arranged in a compact, non-interfering manner within the narrow available space.
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 solution enhances product reliability and responsiveness by simplifying the structure and reducing manufacturing costs, enabling precise and efficient adjustment of the seat back curvature in a car seat lumbar support unit.
Implementation Method 1
performs an elevating operation of an upper bracket relative to a lower bracket, which determines a degree of curvature of a seat back by using a first motor, a first transfer screw, and a first nut member
Data Source
AI summary
A car seat lumbar support unit performs an elevating operation of an upper bracket relative to a lower bracket which determines a degree of curvature of a seat back by using a first motor, a first transfer screw, and a first nut member (first elevating unit) that are easily designed and manufactured, and performs an elevating operation of the lower bracket and the upper bracket which determines a curved position of the seat back by using a second motor, a second transfer screw, and a second nut member (second elevating unit), wherein a rotary cylinder is organically coupled so that the first elevating unit and the second elevating unit are independently operable without being restricted by each other.