Modular Vehicle Seat Assembly Using Preassembled Modules
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Solution Overview
Problem
Current vehicle seat assembly methods are time-consuming and complex, involving hundreds of parts, making it difficult to deliver and assemble cost-efficient seats with desired features using a limited number of preassembled modular components.
Innovation Solution
The method involves assembling a vehicle seat using preassembled modules, including a front seatback module, rear seatback module, seat module, and headrest module, which are coupled to a seat frame and seatback frame to form a fully integrated seat assembly, allowing for efficient and cost-effective construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ground-up assembly method is used, then complete seat assembly can be achieved, but assembly time and complexity increase significantly
Solution Approach 1:
The seat assembly is divided into distinct modular components: seatbacks (with frames and upholstery), cushions, and headrests. Each module is preassembled separately with its fasteners and components, then integrated into the final seat assembly. This segmentation reduces assembly time and complexity by allowing parallel production and simplifying the integration process.
Solution Approach 2:
The patent applies preliminary action by preassembling complete seatback modules, cushion modules, and headrest modules before final integration. Each module comes pre-equipped with necessary fasteners and components, so that when they are integrated into the final seat assembly, minimal additional assembly steps are required. This preliminary preparation significantly reduces the time and complexity of the final assembly process.
2Productivity
If preassembled modular components are used, then assembly efficiency improves, but number of modules to manage increases
Solution Approach 1:
The patent merges multiple components into integrated modules. For example, each seatback module combines the frame, upholstery, and fasteners into a single preassembled unit. Each cushion module integrates the cushion, cover, and associated components. This merging reduces the total number of separate parts that need to be managed during assembly, while still maintaining the benefits of modular construction for improved assembly efficiency.
Data Source
AI summary
A method of assembling a vehicle seat assembly is provided. The method comprises the steps of providing a preassembled front seatback module and a seatback frame. The method further includes assembling a seatback assembly by coupling the front seatback module to a preassembled rear seatback module around and interconnected to the seatback frame. The method further includes providing a preassembled seat module and pivotally coupling the seat module to the seatback assembly. The assembly method further includes coupling the seat module to a seat frame, and further coupling a preassembled headrest module to an upper portion of the seatback assembly.