Modular Vehicle Seat Assembly With Snap-Fit Back and Cushion Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle seats are complex and costly to manufacture and install, making them difficult to adapt to various vehicles and consumer preferences.
Innovation Solution
A modular seat system with snap-fit assemblies for the seat back and cushion modules, featuring clips, tabs, and channels for easy assembly, and integrated components like a blower and airflow channels for comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If vehicle seats include many comfort and aesthetic features, then consumer demand for high quality seats is met, but manufacturing complexity and costs increase
Solution Approach 1:
The seat is divided into modular components including a seat back module with a back carrier, a seat cushion module with a cushion carrier, and a frame assembly. Each module can be independently manufactured and assembled, reducing overall manufacturing complexity while maintaining diverse comfort and aesthetic features through modular variation
Solution Approach 2:
The back carrier and cushion carrier are designed as universal base structures that can accommodate multiple different back trim covers and cushion trim covers with varying comfort and aesthetic features. The standardized carrier designs allow the same structural component to support multiple product variations
2Adaptability or versatility
If vehicle seats are designed with complex features, then comfort and aesthetics are improved, but ease of installation deteriorates
Solution Approach 1:
The seat system is segmented into pre-assembled modules (back module with back carrier and trim cover, cushion module with cushion carrier and trim cover) that can be manufactured separately and then quickly installed together using standardized snap-fit connections, simplifying the installation process despite complex features
Solution Approach 2:
The snap-fit assembly mechanism allows the modules to self-align and self-secure during installation. The back carrier and cushion carrier automatically engage with the frame assembly through snap-fit connections without requiring additional fasteners or complex alignment procedures
3Ease of operation
If vehicle seats are made modular for easy installation, then ease of installation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The snap-fit connections are designed with specific dimensional parameters including flexible tabs that can deflect within controlled ranges, and receptacles with tolerance ranges that accommodate normal manufacturing variations. The flexible tabs can bend to accommodate slight misalignments during assembly, reducing the stringency of precision requirements
4Adaptability or versatility
If vehicle seats use integrated components for comfort features, then comfort is improved, but device complexity increases
Solution Approach 1:
Comfort features are segmented into separate attachable components such as blowers that can be mounted on the back carrier, and airflow channels that can be integrated into the cushion carrier. This allows the base modular structure to remain simple while comfort features can be added or removed based on specific vehicle requirements
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
Facilitates cost-effective, easy installation and adaptation to different vehicles, while maintaining comfort and aesthetic features.
Implementation Method 1
the clip may be configured to flex to facilitate rotation of the back carrier about the lower cross member
Implementation Method 2
at least one of the first tab and the second tab may be configured to flex during assembly of the seat back module to the back frame
Data Source
AI summary
A seat for a vehicle may have a frame, a seat back module and a seat cushion module. The frame may have a back frame and a lower structure. The seat back module may have a back trim cover coupled to a back carrier. The seat cushion module may have a cushion trim cover coupled to a cushion carrier. A process for assembling the seat is also provided.