Modular Seat Recliner Handle Pulley for OTF and Non-OTF Assembly
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Solution Overview
Problem
Existing remote handle assemblies for automotive seat recliner mechanisms are costly and complex due to unique components for OTF and non-OTF versions, with the main pulley often decoupled from the handle spline, increasing manufacturing complexity and cost.
Innovation Solution
A remote handle assembly with a modular pulley arrangement that includes common components for both OTF and non-OTF versions, where the spline shaft is decoupled from the OTF pulley, reducing complexity and cost by using a single pulley system with a torsion spring to bias the pulley and spline shaft into engagement, allowing for a unified design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the main pulley is decoupled from the handle spline to enable power actuator operation, then the one touch feature (OTF) functionality is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The main pulley is designed to serve dual functions: it acts as both the operational pulley for manual handle operation and as the engagement point for the power actuator cable. This eliminates the need for separate decoupling mechanisms while enabling both OTF and non-OTF functionality through a single unified component design.
Solution Approach 2:
The patent combines the main pulley and handle spline into a single integrated assembly where the main pulley is fixedly coupled to the handle spline. This merging eliminates the complexity of decoupling mechanisms while maintaining the ability to achieve OTF functionality through the power actuator's direct engagement with the integrated pulley-spline assembly.
2Adaptability or versatility
If unique components are customized for each design application (OTF and non-OTF versions), then specific functionality is achieved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The remote handle assembly is designed with universal components that can serve both OTF and non-OTF applications. The main pulley, handle spline, and release cable assembly are configured to function in both modes without requiring version-specific customization, thereby simplifying manufacturing while maintaining functional adaptability.
Solution Approach 2:
The system incorporates a movable indicator component that can be positioned to indicate different operational states (OTF or non-OTF). This dynamic element allows a single static assembly design to accommodate different functional configurations without requiring physical customization of the core components.
3Adaptability or versatility
If multiple unique components are used for different seat assembly applications, then specific design requirements are met, but the quantity of components and cost increase
Solution Approach 1:
The patent employs a universal set of components including the main pulley, handle spline, release cable, and housing that can be configured for different seat assembly applications. By designing these components with standardized interfaces and dimensions, the same component set serves multiple design requirements, reducing the total number of unique parts needed across different vehicle models and seat configurations.
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
The solution reduces component costs and manufacturing complexity by using common parts for both OTF and non-OTF versions, while maintaining functionality and ease of assembly.
Implementation Method 1
A remote handle assembly with a modular pulley arrangement that includes common components for both OTF and non-OTF versions, where the spline shaft is decoupled from the OTF pulley, reducing complexity and cost by using a single pulley system with a torsion spring to bias the pulley and spline shaft into engagement
Data Source
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AI summary
A remote handle assembly for selectively unlocking a component in a seat assembly for an automotive vehicle comprises a rear housing having a boss, a spline shaft pivotally coupled to the boss around an axis of rotation, and a pulley pivotally coupled to the boss around the axis of rotation. The spline shaft includes a cam surface and a pulley channel extending circumferentially around the axis of rotation. The spline shaft is pivotable between an unactuated position and an actuated position. The pulley includes an engagement surface and an upper pulley channel extending circumferentially around the axis of rotation. The pulley is pivotable between a second unactuated position and a second actuated position. The pulley is spaced between the spline shaft and the rear housing. The upper pulley channel in the pulley axially aligns with the pulley channel in the spline shaft. The cam surface of the spline shaft is configured to frictionally engage with the engagement surface on the pulley as the spline shaft rotates towards the actuated position.