Modular Seat Substrate Integrating Guides and Terminals
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Solution Overview
Problem
Existing vehicle seat assemblies face challenges in providing comprehensive occupant support, comfort, and integrating multiple functional features while managing packaging, manufacturing, and assembly complexities.
Innovation Solution
A modular seat substrate with integrated guides for suspension wires, air bladders, and electrical terminals, which distributes occupant loads and integrates pneumatic articulation and wiring systems, allowing for preassembly of subcomponents to reduce assembly time and enhance modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a modular seat substrate with integrated guides, air bladders, and electrical terminals is used, then assembly time is reduced and manufacturing efficiency is improved, but device complexity increases due to integration of multiple functional features
Solution Approach 1:
The patent integrates multiple functional components (guides for suspension wires, air bladders for comfort, electrical terminals for connectivity, and retainers for structural support) into a single seat substrate assembly. This merging of previously separate components into one integrated unit reduces the number of assembly steps and overall assembly time, while the modular design allows for standardized manufacturing processes that mitigate the complexity increase.
Solution Approach 2:
The seat substrate is designed as a multi-functional component that simultaneously provides structural support (through retainers), suspension guidance (through integrated guides), pneumatic comfort (through air bladders), and electrical connectivity (through integrated terminals). This multi-functionality eliminates the need for multiple separate components, reducing assembly time while the standardized interface design helps manage the inherent complexity through universality.
2Reliability
If multiple functional features are integrated into the seat substrate, then occupant support and comfort are improved, but manufacturing cost increases
Solution Approach 1:
By combining multiple functional features (guides, air bladders, electrical terminals, retainers) into a single integrated seat substrate, the patent reduces the total number of parts that need to be manufactured, stored, and handled. This consolidation can reduce overall manufacturing costs despite the increased complexity of each integrated unit, as it eliminates the need for multiple separate manufacturing processes and reduces assembly operations.
Solution Approach 2:
The seat substrate is designed with pre-integrated features (molded-in guides, pre-attached air bladders, and pre-positioned electrical terminals) that are prepared during the substrate manufacturing process itself. This preliminary integration of multiple functions into the base substrate reduces the need for subsequent assembly operations and secondary manufacturing steps, thereby reducing overall manufacturing costs while maintaining reliable occupant support.
3Productivity
If a modular design with preassembled subcomponents is used, then assembly repeatability is improved, but initial device complexity increases
Solution Approach 1:
The seat assembly is divided into modular subcomponents (seat substrate, backrest assembly, cushion assembly, armrest assemblies) that can be independently manufactured and tested. Each module contains integrated features (guides, air bladders, electrical terminals) that are standardized across different configurations. This segmentation enables consistent manufacturing processes for each module, improving assembly repeatability while the standardization of interfaces reduces the perceived complexity of the modular system.
Solution Approach 2:
Multiple subcomponents are preassembled with their respective features (guides attached to substrate, air bladders connected to retainers, electrical terminals wired to harnesses) before final assembly. This preliminary assembly of subcomponents ensures consistent positioning and connection, improving repeatability of the final assembly process. The standardized preassembly procedures reduce variability and improve manufacturing consistency across production batches.
Data Source
AI summary
A substrate is mounted to a vehicle seat frame, to provide a support surface for an occupant. The seat substrate is formed with a pair of guides to receive a pair of suspension wires of a vehicle seat suspension for translation of the pair of suspension wires within the pair of guides and to distribute an occupant load from the pair of suspension wires to the substrate. An air bladder is fastened to a plurality of retainers on the substrate. A first plurality of terminals is mounted to the substrate for electrical connection to a wire harness. A second plurality of terminals is mounted to the substrate, each in electrical communication with one of the first plurality of terminals, for electrical connection to a plurality of electrical devices in the vehicle seat assembly.