HYDROFORMED SEATBACK FRAME
An automotive seat assembly comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.
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1. Field of the Invention
The invention relates to a hydroformed seatback frame.
2. Background Art
A hydroformed seatback frame is disclosed herein. Examples of electrical hydroformed seat components are disclosed in U.S. Pat. Nos. 6,352,311; 6,957,796; 5,564,785; 5,437,498; 5,452,941; 5,845,382; and 5,988,756 as well as published Application No. 2004/0135411.
SUMMARY OF THE INVENTIONIn accordance with at least one aspect of the present invention, an automotive seat frame assembly is provided. In at least one embodiment, the automotive seat frame assembly comprises an automotive seatbottom frame connected to an automotive seatback frame. The automotive seatback frame includes a hydroformed hollow metal tube having a cross-section which varies in shape along its length. In this embodiment, the hydroformed hollow metal tube has a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a traverse section extending between the respective top ends of the first and second support sections.
In accordance with at least another aspect of the present invention, an automotive seatback frame is provided for use with an automotive seat having a seatbottom and seatbottom frame, a seatback and seatback frame. The automotive seatback frame includes a hydroformed hollow metal tube having a cross-section which varies in shape along its length. In this embodiment, the hydroformed hollow metal tube has a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a traverse section extending between the respective top ends of the first and second support sections.
In accordance with yet another aspect of the present invention, an automotive seat assembly is provided. The automotive seat assembly includes an automotive seatbottom and an automotive seat back. The automotive seatbottom includes an automotive seatbottom frame, an automotive seatbottom cushion supported on the automotive seatbottom frame and an automotive seatbottom cover covering the automotive seatbottom frame and automotive seatbottom cushion. The automotive seatback includes an automotive seatback frame, an automotive seatback cushion supported on the automotive seatback frame and an automotive seatback cover covering the automotive seatback frame and the automotive seatback cushion. The automotive seatback frame is connected to the automotive seatbottom frame. Furthermore, the automotive seatback frame includes a hydroformed hollow metal tube having a cross-section which varies in shape along its length. In this embodiment, the hydroformed hollow metal tube has a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a traverse section extending between the respective top ends of the first and second support sections.
While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosures should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The following descriptions are merely exemplary in nature and are in no way intended to limit the invention, its application, or its uses.
Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring to
The hydroformed automotive seatback frame 15 shown in
The hydroformed automotive seatback frame 15 has a cross-section that varies along its length. This varying cross section can facilitate attachment of items to the hydroformed automotive seatback frame 15 as well as attachment of the hydroformed automotive seatback frame 15 to the automotive seat bottom frame 10. The cross sectional variations can also provide structural reinforcement at desired locations along the automotive seatback frame. Moreover, the seatback frame 15 is relatively resistant to bending and twisting compared with conventional seatback frames that either have varying cross sections but which are not hollow, or which are hollow but do not have varying cross sections.
While the seatback frame 15 may be made of any suitable metal, in at least one embodiment, the hydroformed seatback frame 15 is made of SAE 050XF steel. In at least one embodiment, the seatback frame 15 has a rear load strength to weight ratio of at least 3.0 KN/Kg, in at least another embodiment of at least 3.16 KN/Kg, and in at least yet another embodiment of at least 3.25 KN/Kg. In at least one embodiment, the seatback frame has a rear load strength to weight ratio of approximately 15% greater than the rear load strength to weight ratio of a standard stamped steel construction rear seat back made of the same material, in another embodiment of approximately 20% greater, and in yet another embodiment approximately 25% greater.
In at least one embodiment, the hydroforming mold can be configured to punch and/or extrude holes in the hydroformed automotive seatback frame 15 during molding. This can permit the relatively easy insertion of appendages, such as a headrest into the hydroformed automotive seatback frame 15 and/or the fastening of the hydroformed automotive seatback frame 15 to the automotive seat bottom frame 10. This can be done using a mold designed with punches in desirable locations. During the hydroforming process, after the hollow metal blank has been formed, and before the pressure of the fluid is reduced, the punch, in cooperation with the fluid, is able to punch or extrude holes as desired in the surface of the hollow metal tube. This can save time and reduces cost by permitting a one-step manufacturing process.
The hydroformed automotive seatback frame 15 illustrated in
As illustrated in
A first distinct cross-sectional geometry of the embodiment illustrated in
Attachment of the exemplary hydroformed automotive seatback frame 15, illustrated in
A second distinct cross-sectional geometry of the exemplary hydroformed automotive seatback frame 15 illustrated in
A third distinct cross-sectional geometry of the embodiment shown in
A fourth distinct cross-sectional geometry of the embodiment shown in
In the embodiment of the hydroformed automotive seatback frame 15 depicted in
It is desirable that the thickness of its walls remain relatively constant. Traditional high pressure hydroforming methods can result in attenuated wall thicknesses at curved areas of the hydroformed product. One way to ensure consistent wall thickness is to use a pressure sequence hydroforming process. According to this process, the hollow metal blank is placed in the mold cavity and the mold is partially closed causing some deformation of the blank. The hollow portion of the blank is then filled with fluid that is maintained within the hollow portion of the blank at a low pressure. The cavity is then closed completely. As the die closes completely, the walls of the blank are supported internally by the fluid. Once the die is completely closed, the internal fluid pressure is increased to finish forming the product and also to provide backup for punching holes. This method of low pressure hydroforming is fully disclosed in U.S. Pat. No. 6,397,449 to Mason et al., the disclosure of which is herein incorporated by reference. Use of the pressure sequence hydroforming process minimizes attenuation of wall thickness around curves and corners.
The embodiment of the hydroformed automotive seatback frame 15 shown in
In another aspect of the invention, a method of making an automotive seat frame is disclosed. According to this aspect of the invention, an automotive seatbottom frame 10 is provided, a hydroformed automotive seatback frame 15 including a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the top ends of the first and second support sections is provided, and the automotive seatbottom frame is connected to the automotive seatback frame.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Claims
1. An automotive seat frame assembly comprising:
- an automotive seatbottom frame; and
- an automotive seatback frame connected to the seatbottom frame, the seatback frame comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.
2. The automotive seat frame assembly of claim 1 wherein the hydroformed hollow metal tube comprises a wall having substantially uniform thickness along its entire length.
3. The automotive seat frame assembly of claim 2 wherein the cross-sectional shape of the hydroformed hollow metal tube is formed using a low pressure hydroforming process.
4. The automotive seat frame assembly of claim 1 wherein the bottom ends of the vertical support sections have a cross-sectional shape that facilitates connection of the seatback frame to the seatbottom frame.
5. The automotive seat frame assembly of claim 4 wherein the cross-sections of the respective bottom ends of the first and second vertical support sections have a shape that corresponds with the shape of the seatbottom frame at the location where the seatback frame is connected to the seatbottom frame.
6. The automotive seat frame assembly of claim 5 wherein the cross-sections of the respective bottom ends of the first and second vertical support sections are shaped to be received by, or be received within, the seatbottom frame connecting the seatback frame to the seatbottom frame.
7. The automotive seat frame assembly of claim 1 wherein a portion of at least one of the vertical support sections has a generally triangular cross-section.
8. The automotive seat frame assembly of claim 7 wherein the triangular cross-section is at a location of the at least one vertical support section where the at least one of the vertical support sections will bear the highest load during a rear impact.
9. The automotive seat frame assembly of claim 1 wherein the transverse section has a front side and wherein at least a portion of the front side is depressed to form a recess large enough to receive a person's neck.
10. The automotive seat frame assembly of claim 1 wherein the transverse section is adapted to receive a headrest.
11. The automotive seat frame assembly of claim 10 wherein the transverse section has a top side and a bottom side, wherein the top side has a pair of holes and the bottom side has a pair of holes, and wherein the pair of holes in the top side are axially aligned with the pair holes in the bottom side to enable the transverse section to receive posts from a headrest.
12. The automotive seat frame assembly of claim 10 wherein the holes are extruded.
13. The automotive seat frame assembly of claim 1 wherein the respective bottom ends of the first and second support sections have a cross-sectional shape that allows the seatback frame to be connected to the seatbottom frame, wherein a portion of at least one of the vertical support sections has a generally triangular cross-section, wherein the transverse section has a front side having a recess large enough to receive a person's neck, and wherein the transverse section is adapted to receive a headrest.
14. An automotive seatback frame for use with an automotive seat having a seatbottom having a seatbottom frame, and a seatback having a seatback frame, the automotive seatback frame comprising:
- a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the top ends of the first and second support sections.
15. The automotive seatback frame of claim 14 wherein the automotive seatback frame is made from SAE 050XF steel and wherein the automotive seatback frame has a rear load strength to weight ratio of at least approximately 3.0 KN/Kg.
16. A method of making an automotive seat frame comprising the steps of:
- providing an automotive seatbottom frame;
- providing the automotive seatback frame of claim 14; and
- connecting the automotive seatbottom frame to the seatback frame.
17. An automotive seat assembly comprising:
- an automotive seatbottom comprising an automotive seatbottom frame, an automotive seatbottom cushion supported on the automotive seatbottom frame and an automotive seatbottom cover covering the automotive seatbottom frame and automotive seatbottom cushion;
- an automotive seatback comprising an automotive seatback frame, an automotive seatback cushion supported on the automotive seatback frame and an automotive seatback cover covering the automotive seatback frame and the automotive seatback cushion, the automotive seatback frame being connected to the automotive seatbottom frame;
- the automotive seatback frame comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.
18. The automotive seat assembly of claim 17 wherein the hydroformed hollow metal tube comprises a wall having substantially uniform thickness along its entire length.
19. The automotive seat assembly of claim 17 wherein the bottom ends of the vertical support sections have a cross-sectional shape that facilitates the connection of the seatback frame to the seatbottom frame.
20. The automotive seat assembly of claim 17 wherein a portion of at least one of the vertical support sections has a generally triangular cross-section, wherein the transverse section has a front side wherein at least a portion of the front side is depressed to form a recess large enough to receive a person's neck and wherein the transverse section is adapted to receive a headrest.
Type: Application
Filed: Mar 8, 2006
Publication Date: Sep 13, 2007
Applicant: LEAR CORPORATION (Southfield, MI)
Inventors: Vincent Adragna (New Hudson, MI), Eric Beaulieu (Farmington Hills, MI), Gary Greiner (Chesterfield, MI)
Application Number: 11/276,626
International Classification: A47C 7/02 (20060101);