Seat Back Adapter Carrier for Modular Frame Reuse

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Solution Overview

Problem

Modern motor vehicle seating assemblies face challenges in providing comfort, function, and versatility while maintaining cost-effectiveness and reducing complexity.

Innovation Solution

The introduction of an adapter carrier system that allows for interchangeable forward soft trim carrier assemblies and corresponding seat back panel and closeout assemblies, all adapted to a common seat back frame, enabling various unique seat back assembly configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional high volume seat back frames are used with fixed configurations, then manufacturing costs are reduced and production efficiency is improved, but adaptability and versatility are limited

Engineering Contradiction:

Improveseat back configuration adaptabilityVSAvoidseating assembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The seat back assembly is divided into distinct modular components: the common seat back frame, interchangeable forward soft trim carrier assemblies, and corresponding seat back panel and closeout assemblies. Each module can be independently manufactured and then assembled in different configurations, enabling versatility while maintaining production efficiency through standardized frame reuse.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The common seat back frame is designed as a universal base structure that can accommodate multiple different forward soft trim carrier assemblies and seat back panel combinations. This multi-functional frame serves as a platform for various seat back configurations, achieving adaptability without requiring multiple specialized frames for different vehicle models or trim levels.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple unique seat back configurations are created with dedicated frames, then adaptability and customer value are improved, but manufacturing costs and production complexity increase

Engineering Contradiction:

Improveseat back configuration varietyVSAvoidmanufacturing cost and production efficiency

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single common seat back frame design serves multiple purposes across different vehicle models and trim levels by accommodating various interchangeable forward soft trim carrier assemblies and seat back panels. This universal frame reduces the total number of unique frame parts needed, lowering manufacturing costs and inventory requirements while maintaining the ability to offer diverse seat back configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The modular design allows individual components such as forward soft trim carriers and seat back panels to be easily removed, replaced, or upgraded independently of the common frame structure. This enables flexible configuration changes without scrapping the entire seat back assembly, reducing waste and allowing recovery of the common frame for reuse in different applications.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If traditional seat back frames are modified to accommodate multiple configurations, then adaptability is improved, but structural integrity and reliability may be compromised

Engineering Contradiction:

Improveinterchangeable configuration capabilityVSAvoidframe structural integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The interchangeable components are designed as self-contained modules (forward soft trim carrier assemblies and seat back panels) that attach to the common frame through standardized interfaces. This segmentation allows the frame to maintain its original structural integrity while accommodating different configurations through properly engineered attachment points that preserve load paths and structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The common seat back frame acts as an intermediary structure between the interchangeable forward soft trim carriers and seat back panels. It provides a stable, structurally sound platform with standardized mounting interfaces that ensure reliable connections while allowing configuration changes without compromising the overall structural integrity of the seat back assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12208716B2Flexible upper frame adapter for traditional back frame and seat back assemblies

Publication Date: 2025.01.28 FORD GLOBAL TECH LLC

AI summary

A motor vehicle seating assembly includes a conventional common seat back frame, a plurality of forward soft trim carrier assemblies each having a unique configuration, a plurality of corresponding seat back panel and closeout assemblies, and an adapter carrier coupled with the common seat back frame and disposed between the forward soft trim carrier assembly and the corresponding seat back panel and closeout assembly. The adapter carrier includes a composite upper portion and a pair of depending frame attachment brackets coupled with a lower inboard and outboard lateral side of the composite upper portion of the adapter carrier. The pair of depending frame attachment brackets are coupled with a pair of opposed lateral side rails of the common seat back frame. The adapter carrier has a unique configuration corresponding with one of the plurality of forward soft trim carrier assemblies and the seat back panel and closeout assemblies.