Vehicle Seat Back Panel With Welded Feature Integration

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Solution Overview

Problem

Existing methods for manufacturing vehicle seat back panels are labor-intensive and require manual processes to attach additional features like storage pockets or design elements, which are time-consuming and inefficient.

Innovation Solution

A method involving a stack of materials with an adhesive layer between an upper and lower layer, where additional panel members are welded into the back panel during manufacturing, eliminating the need for manual attachment methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual processes are used to attach additional features like storage pockets or design elements, then flexibility in adding features is maintained, but labor intensity and time consumption increase significantly

Engineering Contradiction:

Improveability to add featuresVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent divides the back panel into distinct layers (upper layer, lower layer, intermediate layer) with specific zones designed for different functions. Additional panel members are integrated into specific recesses or cutouts in the upper layer, allowing modular addition of features while maintaining automated manufacturing of the base structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent pre-forms recesses or cutouts in the upper layer material during the initial manufacturing process, and positions additional panel members within these pre-prepared zones before final assembly. This preliminary preparation enables automated integration of additional features without requiring manual attachment operations during production.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If manual attachment methods like sewing are used for additional panel members, then feature integration is achieved, but manufacturing complexity and labor costs increase

Engineering Contradiction:

Improvefeature integrationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the manufacturing of the back panel and additional panel members into a single integrated process. Multiple panel members are simultaneously welded to the lower layer and intermediate layer in one automated operation, merging what would traditionally be separate assembly steps into a unified manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces manual mechanical attachment methods (sewing, stapling, gluing) with automated welding technology. The welding process uses heat and pressure to fuse panel members to the layer structure, eliminating the need for manual labor and complex multi-step attachment procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If additional panel members are attached after back panel manufacturing, then feature customization is possible, but production time and labor requirements increase

Engineering Contradiction:

Improvecustomization capabilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent maintains continuous automated manufacturing flow by integrating the attachment of additional panel members into the primary welding process. The back panel and additional features are manufactured in one continuous operation without interruption or transfer to manual workstations, eliminating idle time and maintaining production rhythm.

Inventive Principle:

Principle #20Continuity of useful action

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 approach streamlines the manufacturing process by integrating additional features like pockets or design elements directly into the back panel, reducing labor costs and enhancing production efficiency.

Implementation Method 1

an adhesive layer (7) arranged between the upper layer (3) and the lower layer (5) and fixing the upper layer (3) to the lower layer (5)

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

welding the stack to form a one piece back panel comprising a lower layer (5), an adhesive layer (7), an upper layer (3) and at least one additional member (9)

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11833944B2Back panel for a vehicle seat

Publication Date: 2023.12.05 ADIENT US LLC

AI summary

A back panel for a vehicle seat is described. The back panel may have an upper layer, a lower layer supporting the upper layer, an adhesive layer arranged between the upper layer and the lower layer and fixing the upper layer to the lower layer, and at least one additional panel member welded to the lower layer.