Recliner Mechanism Gap Ring Removal for Assembly Efficiency
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Solution Overview
Problem
Existing vehicle recliner mechanisms are time-consuming to manufacture and require complex processes.
Innovation Solution
A method involving the attachment of a gap ring between plates of a recliner mechanism, with an encapsulation ring positioned axially, where the gap ring is removed using heat or friction to create a clearance gap, allowing for faster and more reliable manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for recliner mechanisms, then assembly reliability may be maintained, but manufacturing time is excessive
Solution Approach 1:
The gap ring is pre-positioned between the first plate and encapsulation ring before final assembly. This preliminary positioning ensures proper clearance gap formation without requiring time-consuming adjustments during assembly, thereby reducing manufacturing time while maintaining assembly reliability through pre-planned clearance specifications.
Solution Approach 2:
The patent replaces traditional mechanical clearance adjustment methods with a thermal field approach. The encapsulation ring is heated to expand the gap ring material, causing it to shrink or deform and create the required clearance gap. This substitution eliminates time-consuming mechanical adjustments while ensuring consistent clearance dimensions, thus improving productivity without compromising reliability.
2Productivity
If clearance gap is formed by traditional methods, then manufacturing time is reduced, but assembly reliability deteriorates
Solution Approach 1:
The patent changes the physical state of the gap ring material through temperature variation. By heating the encapsulation ring, the gap ring material undergoes thermal expansion or deformation, which automatically creates the precise clearance gap. This parameter change (temperature) ensures consistent clearance dimensions without requiring manual adjustment, thereby maintaining both manufacturing efficiency and assembly reliability.
Solution Approach 2:
The heating process induces a phase transition or significant thermal deformation in the gap ring material. As the encapsulation ring is heated, the gap ring material transitions from a rigid state to a more compliant state, allowing it to shrink or deform and form the precise clearance gap. This phase transition ensures consistent clearance formation, improving both productivity and reliability simultaneously.
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 method reduces manufacturing time and enhances the reliability of recliner mechanisms by simplifying the process of creating clearance gaps, improving the assembly's performance and efficiency.
Implementation Method 1
the flange of the encapsulation ring is heated to remove at least the portion of the gap ring from between the flange and the rim
Implementation Method 2
heating the flange to dissolve or burn off the gap ring
Data Source
AI summary
A method for manufacturing a recliner mechanism may include movably attaching a first plate of a recliner heart to a second plate of the recliner heart, positioning a gap ring onto the first plate of the recliner heart, positioning an encapsulation ring around the first and second plates such that the gap ring is disposed axially between the first plate and the encapsulation ring, and removing at least a portion of the gap ring from between the first plate and the encapsulation ring to form a clearance gap between the first plate and the encapsulation ring.