Modular Seatback Inner Carrier for Fast, Precise Assembly
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Solution Overview
Problem
Traditional automotive seat assembly is complex and time-consuming, requiring hundreds of parts, and lacks a modularized process for seatback assembly that can be sourced independently of traditional assembly plants while maintaining structural integrity and aesthetic appeal.
Innovation Solution
A modularized seatback assembly system featuring an inner carrier module with side members, upper cross members, and access apertures, which couples with a seatback frame assembly using mounting slots and locator members, allowing for efficient assembly and alignment without traditional fasteners, and a back panel module that integrates with the inner carrier module for structural support and aesthetic cohesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional automotive seat assembly methods are used, then structural integrity is maintained, but assembly time and complexity increase significantly
Solution Approach 1:
The seatback assembly is divided into modular components: an inner carrier module with attachment features, a back panel module, and a seatback frame assembly. This segmentation allows independent manufacturing and streamlined assembly while reducing the overall number of parts needed compared to traditional methods.
Solution Approach 2:
Multiple attachment features (mounting slots, locator members, access apertures) are integrated directly into the inner carrier module as molded-in features. This merging of multiple functions into a single component reduces part count and simplifies the assembly process.
2Loss of time
If modularized assembly process is implemented, then assembly time is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The inner carrier module includes pre-formed molded-in attachment features (mounting slots, locator members, access apertures) that are created during the molding process. This preliminary action ensures precise geometric relationships are built-in, eliminating the need for post-assembly adjustments and ensuring consistent alignment.
Solution Approach 2:
The molded-in attachment features on the inner carrier module serve as intermediary elements that mediate between the back panel module and the seatback frame assembly. These features provide precise alignment and positioning, ensuring manufacturing precision is maintained throughout the modularized assembly process.
3Device complexity
If molded-in attachment features are used, then part count is reduced, but manufacturing complexity increases
Solution Approach 1:
The inner carrier module is designed as a universal component that performs multiple functions: structural support, attachment point for the back panel, alignment reference, and fastener access pathway. By making this single component multi-functional, the need for multiple separate parts is eliminated, and the molded-in features are justified by their multiple roles.
Data Source
AI summary
A seatback assembly includes an inner carrier module having an upper cross member. The upper cross member includes first and second mounting slots and first and second access apertures disposed therethrough. A seatback frame assembly includes an upper frame member with access apertures disposed therethrough. The inner carrier module is located to a front side of the seatback frame assembly when a locator member of the inner carrier module is received in a locating aperture of the seatback frame assembly. The access apertures of the inner carrier module are aligned with the access apertures of the seatback frame assembly when the two components are coupled together. Guide sleeves are received though the access apertures. A back panel module mounts to a rear side of the seatback frame assembly, wherein upper hook members of the back panel are partially received in the mounting slots of the inner carrier module.