Universal Seat Back Support Member for Modular Assembly

Solution Overview

Problem

Conventional seat assemblies, particularly sport seats, are costly due to their specialized design and limited component standardization, which increases production costs and reduces modularity.

Innovation Solution

A seat back support member with a primary substrate and secondary substrate is designed to fit standard seat back frames, incorporating a pair of receptacles for posts to support both the back and head of an occupant, allowing for interchangeable components and reduced costs by using common parts across different seat styles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional specialized design is used for sport seats, then comfort and support are improved, but production costs increase and modularity decreases

Engineering Contradiction:

Improvecomfort and supportVSAvoidproduction costs

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The seat back frame is designed as a universal component that can be used across different seat styles and configurations. The standardized frame with consistent post locations and dimensions allows the same frame to support various seat cushion designs, head restraints, and adjustment mechanisms, thereby reducing production costs while maintaining comfort and support functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The seat assembly is divided into modular components including the seat back frame, seat cushion, head restraint, and adjustment mechanisms. This segmentation allows each component to be manufactured independently using standardized interfaces, enabling mass production of common parts while allowing customization of specific features to maintain comfort and support.

Inventive Principle:

Principle #1Segmentation

2Reliability

If specialized design is used for sport seats, then performance is improved, but component standardization decreases

Engineering Contradiction:

ImproveperformanceVSAvoidcomponent standardization

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The seat back frame is designed as a universal component that can be used across different seat styles and configurations. The standardized frame with consistent post locations and dimensions allows the same frame to support various seat cushion designs, head restraints, and adjustment mechanisms, thereby reducing production costs while maintaining comfort and support functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The seat assembly incorporates adjustable components that allow dynamic configuration while maintaining standardized interfaces. The adjustment mechanisms enable users to modify seat position, recline angle, and head restraint height, providing performance optimization for different users while relying on standardized frames and mounting points for consistency and reliability.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If interchangeable components are implemented, then modularity is improved and costs reduced, but assembly complexity may increase

Engineering Contradiction:

Improvecost reduction and modularityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The seat assembly is divided into modular components including the seat back frame, seat cushion, head restraint, and adjustment mechanisms. This segmentation allows each component to be manufactured independently using standardized interfaces, enabling mass production of common parts while allowing customization of specific features to maintain comfort and support.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized interfaces and mounting points are pre-designed and pre-positioned on the seat back frame, including predetermined locations for post mounting, cushion attachment, and head restraint installation. This preliminary preparation of standardized connection points simplifies the assembly process by eliminating the need for custom fabrication or complex alignment procedures during assembly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10661691B2Integrated seat back support member for seat assemblies

Publication Date: 2020.05.26 LEAR CORP

AI summary

A seat assembly is provided with a seat back support member with a primary substrate received upon an upper cross member and a pair of side members of a seat back frame to support a back of an occupant. A pair of receptacles is formed through the primary substrate to receive a pair of posts that extend from the upper cross member of the seat back frame. A secondary substrate extends from the primary substrate to support a head of the occupant. A method of assembling a seat assembly determines whether the seat assembly comprises one of an adjustable head restraint assembly and an integrated head restraint. The adjustable head restraint assembly is assembled upon the pair of posts in response or a seat back support member with a pair of apertures formed therethrough is assembled upon the upper cross member with the pair of posts received in the pair of apertures.