Recliner Adjuster Compact Welding Locking Strength
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Solution Overview
Problem
Conventional recliner adjusters face challenges in reducing size while maintaining locking strength, leading to increased weight and manufacturing costs due to the caulking method used to hold the base member and rotary arm together, and difficulties in assembling the memory mechanism with precise clearance.
Innovation Solution
The recliner adjuster incorporates a guide bracket, internal gear, cam, lock gears, and a mounting ring with a flat annular and cylindrical side portion to reduce size without compromising locking strength, using laser welding or CO2 welding for assembly, and includes a spring retainer and spiral spring for biasing the seat back, allowing for adjustable inclination and memory function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base member and rotary arm are held together by caulking a portion of the ring member, then the locking strength is maintained, but the outer diameter of the base member increases and the size cannot be reduced
Solution Approach 1:
The patent replaces the conventional caulking method with a welding method to join the ring member to the base member. This substitution allows for a more compact design as welding provides superior joint strength without requiring the additional material thickness needed for caulking, thereby reducing the outer diameter while maintaining locking strength.
Solution Approach 2:
The patent changes the joining method from mechanical (caulking) to thermal (welding), which fundamentally alters the connection parameters. Welding enables a stronger, more compact joint that reduces the overall dimensions of the base member while maintaining or improving the locking strength compared to caulking.
2Ease of manufacture
If the mounting ring is mounted on both the reclining mechanism and memory mechanism with predetermined minimum clearance, then proper assembly is achieved, but this cannot be easily accomplished by caulking
Solution Approach 1:
The patent replaces caulking with welding for mounting the ring member, which provides superior precision and control over clearance dimensions. Welding allows for more accurate positioning and tighter tolerances compared to caulking, making it easier to achieve the predetermined minimum clearance between the reclining mechanism and memory mechanism.
Solution Approach 2:
The patent changes the joining process parameters from those suitable for caulking to those optimized for welding. This includes adjusting positioning fixtures, welding sequences, and dimensional tolerances to achieve the precise clearance requirements that are difficult to accomplish with caulking methods.
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
This design effectively reduces the size and weight of the recliner adjuster while maintaining locking strength, enhancing manufacturing efficiency and cost-effectiveness, and allows for precise adjustment and memory functionality.
Implementation Method 1
The cylindrical side portion of the mounting ring is joined to the guide bracket or the internal gear by laser welding or CO2 welding.
Implementation Method 2
The cylindrical side portion of the mounting ring is joined to the guide bracket or the internal gear by laser welding or CO2 welding.
Implementation Method 3
An outer peripheral surface of the other of the guide bracket and the internal gear is held in sliding contact with an inner surface of the cylindrical side portion of the mounting ring to thereby radially position the other of the guide bracket and the internal gear.
Implementation Method 4
a cam interposed between the guide bracket and the internal gear, a pair of lock gears radially slidable in association with an operation of the cam
Data Source
AI summary
A recliner adjuster includes a guide bracket to be fixed to one of a seat cushion and a seat back that can pivot with respect to the seat cushion, an internal gear to be fixed to the other of the seat cushion and the seat back, a cam interposed between the guide bracket and the internal gear, a pair of lock gears radially slidable in association with an operation of the cam, and a mounting ring for assembling the guide bracket and the internal gear together with the cam and the pair of lock gears interposed therebetween. The mounting ring has a flat annular portion and a cylindrical side portion joined to one of the guide bracket and the internal gear. An outer peripheral surface of the other of the guide bracket and the internal gear is held in sliding contact with an inner surface of the cylindrical side portion of the mounting ring to thereby radially position the other of the guide bracket and the internal gear.