Vehicle seat

A vehicle seat (10) includes an improved seat frame member (14) used as a seat back, a recliner mechanism connection (16) and a vehicle seat track actuator mechanism (18). The seat back frame member (14) includes a side frame member (30) having a side frame structural member (32) preferably made from a relatively high strength steel and a stiffening insert member (42) to provide strength and rigidity to the recliner mechanism connection (16) and to reduce the overall mass of the vehicle seat frame member and thereby the vehicle seat (10). The seat frame member (14) further includes a recliner mechanism (34) welded to the side frame structural member (32) preferably utilizing a shaped laser weld pattern (40). The vehicle seat track actuator mechanism (18) includes a bar (56), first and second pivot pins (62, 64) and connectors (70).

BACKGROUND

The present disclosure relates generally to improvements to a seat structure. More particularly the present disclosure relates to improvements relating to a seat frame and process for making the seat frame, a track for adjusting the position of the seat and an actuator for a latch for locking the track in position.

It is generally known to provide adjustable seats and in particular adjustable vehicle seats. Further, it is generally known to provide an adjustable track assembly for adjusting the fore—aft position of the vehicle seat within the vehicle. Such track assemblies are known for use in providing fore-aft adjustment to vehicle seats such a “captain's chair” or other type of vehicle seats. The linear adjustable vehicle seat allows an occupant to obtain a more comfortable seating position and to provide space behind or in front of the vehicle seat to assist in entering and exiting the vehicle. Further, latch mechanisms are generally known for locking the vehicle seat position at a plurality of locations. Further, recliner latch mechanisms are known for providing adjustability to the seat back. Such latch mechanisms are generally known as pawl and positive engagement latch-type devices and mechanisms.

There remains a continuing need to provide improved seats having lower mass and the same strength or even an improved (increased) strength and performance for the above that provide greater performance than compared to the known seats.

SUMMARY

An exemplary embodiment of the present disclosure relates to an improved seat back frame member and recliner mechanism connection. The seat back frame member includes, inter alia, a side frame member having a side frame structural member preferably made from a relatively high strength steel and a stiffening insert member to provide strength and rigidity to the recliner mechanism connection and reduce the mass of the vehicle seat back frame member and thereby the vehicle seat. The seat back frame member further includes a recliner mechanism for providing pivotable adjustment of the seat back of the vehicle seat. The recliner mechanism is welded to the side frame structural member preferably utilizing a C-shaped laser weld pattern to further strengthen the recliner mechanism connection.

According to an alternate embodiment, the seat may include a seat track assembly and a vehicle seat track actuator mechanism. The vehicle seat track actuator mechanism includes, inter alia, a bar, first and second pivot pins and connectors. The connectors are fastened to the distal ends of the first and second pivot pins and secure the pivot pins into holes located on movable track members of the seat track assembly. The vehicle seat track actuator mechanism is designed for operating a latch mechanism to unlock the latch mechanism and release the movable track members so they may move with respect to the base (stationary track members) and thereby move the vehicle seat in the fore and aft directions.

DETAILED DESCRIPTION

Referring generally toFIGS. 1 through 21, a vehicle10having a vehicle seat12having an improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18are shown according to exemplary embodiments. The improved seat back frame member14and recliner mechanism connection16are designed to improve the performance of the seat back frame14and vehicle seat12by increasing the strength of the seat frame14and the recliner mechanism connection16without unnecessarily increasing the weight of the seat12. The seat track actuator18mechanism is configured for actuating a latch mechanism20for selectively controlling the position of the vehicle seat12relative to the interior of the vehicle10. It should be noted that the improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18and methods described herein may be used in a variety of applications and vehicle seat systems (e.g., front seats, second or third row seats, bucket seats, bench seats, etc. for automobiles, trucks, vans, SUVS, trains, airplanes, boats, etc.) and other non-vehicle seat applications wherein it would be desirable to utilize an improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18of the type disclosed herein (e.g., theatre seats, doctors' chairs, etc.).

Referring now toFIG. 1, a vehicle10is shown according an exemplary embodiment. The vehicle10includes one or more vehicle seats12provided for an occupant of the vehicle10. One exemplary embodiment of a vehicle seat structure12is shown inFIG. 2. While the vehicle10shown is a 4-door sedan, it should be understood that the seat12may be used in a mini-van, sport utility vehicle or any other means in or by which someone travels or something is carried or conveyed for any market or application including everything from office seating and transportation to planes and space travel and everything in between. The vehicle seat12shown includes a seat back22, a seat base24, and a connection member or recliner16coupled to the seat back22and the seat base24. The vehicle seat12further may include a head restraint26and base portion28. The head restraint26extends upward from the seat back22and is configured to restrain the head of an occupant during an impact. The base portion (e.g. track assembly)28couples the seat12to the vehicle body and may be configured to allow the seat12to be selectively positioned (manually or motor driven) relative to the vehicle body.

Referring now in particular toFIGS. 1 through 11there is disclosed a pair of vehicle seat side members30having a unique construction. In particular, each side frame member30is a mirror image of the other, so the current description will be given for a single side frame member30. It should be understood that the side frame member30is a part of a seat back frame member14having a plethora of additional devices, mechanisms and items added to the seat back frame14including an upper (and possibly lower) cross frame members, a suspension member, a foam cushion and a seat cover, none of which are currently shown in the FIGURES.

The side frame member30includes a side frame structural member32as is generally known. The side frame structural member32is generally flat, formed (commonly stamped but may be produced using any known or appropriate forming process) metallic member. The side frame structural member32is preferably made from relatively high-strength steel appropriate for the intended application of a vehicle seat12. The side frame member further preferably includes a recliner mechanism34for providing pivotable adjustment of the seat back22of the vehicle seat12.

As best shown inFIGS. 3,6and9, the recliner mechanism34is disclosed as a round heart-type recliner mechanism as is generally known in the vehicle seat applications. The round heart-type recliner mechanism34has a base plate36to be secured to the seat base24and a moving plate (or tooth)38shown secured to the side frame structural member32. As best shown inFIGS. 4,7and10, the recliner mechanism34is welded (albeit indirectly as explained below) to the side frame structural member using a laser welding process utilizing a C-shaped (also known as a staple) laser weld pattern40. In particular, four, evenly and angularly spaced, C-shaped welds40are provided. It should be understood that other shapes of laser welding may be used and fewer or more welds may be utilized.

FIGS. 4,7and10show alternate, inboard side views of the side seat frame member30. As best shown inFIG. 7, the side seat frame member30further includes a stiffening insert member42used in connecting the round heart-type recliner mechanism with the side frame structural member32. The insert member42is generally a planar member that fits within the inboard side of the side frame structural member32and has a first, upper end having a generally square end and a second, lower end having a generally rounded shape complementary with the outline of the round heart-type recliner mechanism34. The stiffening, insert member42further includes a pair of laterally located, extension flanges44extending in a direction substantially perpendicular to the general planar portion and from the first, upper end toward the second, lower end and to at least a point below the upper C-shaped, laser weld seam46. It has been determined that the laterally located, extension flanges need not extend beyond the upper C-shaped laser weld seams since beyond about that location, the laterally located, extension flanges provide very limited stiffening to the side frame structural member32.FIG. 11shows a cross-section further detailing the connection of the stiffening insert member42, the round heart-type recliner mechanism34and the side frame structural member32.

Utilizing the stiffening insert member42in connecting the round heart-type recliner mechanism34and the side frame structural member32as disclosed makes it possible to have a sufficiently high-strength connection between the round heart-type recliner mechanism34and the side frame structural member32without having to further thicken the entire side frame structural member32and thereby having added, unnecessary mass. The stiffening insert member42may alternatively also include stiffening projections48extending in-board as an upset in the general planar area such as shown inFIGS. 4 and 7. The stiffening projections48further extend from a location proximate the first, upper end to a location above the connection area of the C-shaped, laser welds40. Two stiffening projections48are shown located laterally from a general centerline of the stiffening insert member42.

Referring now toFIGS. 12 through 21and in particular toFIG. 12, a known actuator (or release system)18for use with a seat track assembly28to support the vehicle seat12is shown. The actuator18operates a latch mechanism20to unlock the latch mechanism20and release the movable track member50to allow it to move with respect to a base (typically a second track member)52. When the actuator18is released, typically a biasing member (such as a spring)54in the latch mechanism20, forces the latch mechanism20to reengage and lock the movable track member50with respect to the base52. The actuator18ofFIG. 12includes a pivotable bar56(generally referred to as a towel bar in a vehicle seat application) having a generally U-shaped configuration including contours for providing installation in the vehicle seat12and track assembly28. The actuator18includes a cross member58having a round, rod shape that is coupled to the sides or legs of the bar56and then inserted in the track members50,52to pivot the towel bar56. The cross member58is typically a stiff, metallic material and takes up space underneath the vehicle seat12.

FIGS. 13 and 14show an actuator18for use with a seat track assembly28to support the vehicle seat12according to one exemplary embodiment. The actuator18is designed for operating a latch mechanism20to unlock the latch mechanism20and release the movable track member50to allow it to move with respect to a base52. The actuator18is movable from a latch position to an unlatched position against the force of a biasing member54such as a spring in the latch mechanism20or other force generating mechanism. Similar toFIG. 12, the latch mechanism20locks the movable track member50with respect to the base or stationary track member52. The track assembly28has first and second rail members50,52and typically the vehicle seat12is supported on the movable track member50. The actuator18includes a bar (or towel bar)56having a generally U-shaped configuration including contours for providing installation in the vehicle seat12and track assembly28. The bar56of the actuator18is pivoted with respect to the seat track assembly28in a hole60in the movable track member50. The bar56of the actuator18includes first and second pivot pins62,64located on the first and second sides66,68of the U-shaped bar56for insertion in the holes60in the respective track rail members50. The first and second pivot pin62,64each include a connector or bushing70located close to their distal ends that attach the pivot pins62,64to the hole60in the track rail members50and thereby provide a pivot location and a connector70for securing the bar56to the track assembly28.

FIG. 15shows the pivot pin62,64of the bar56of the actuator18of the vehicle seat12. The pivot pin62,64is a generally cylindrically-shaped member having a first circumferential extension member (or collar)72located in a central region and first circumferential groove74located at a distanced spaced from circumferential extension member72and close to the one end of the pivot pin62,64inserted into the hole60in the movable track50. The pivot pin62,64is attached to the bar56at a second location spaced from the circumferential extension member72. The connector70attaches the pivot pin62to the track rail member50.

FIGS. 16 through 21show the connector70used to attach the pivot pin62,64to the track rail member50. The connector70is a generally cylindrical bushing member and includes a first pair of oppositely located grooves76extending from a first end of connector70along the wall of the body portion of the cylinder78. The connector70is inserted into at least one hole60of at least one track rail member50(this allows the connectors70to be shipped with the rail assemblies). The connector70further includes a first pair of displaceable extension member (or wings)82that protrude outward and can be flexed inward and allow the pivot pin62,64and connector70to be inserted into the hole60in the track rail member50and to thereby be connected (or snapped into) the track rail member50. The displaceable extension members82expand outward once the connector70is inserted into the hole60in the track rail member50to prevent the connector70from detaching from the track rail member50. The one end of the pivot pin62,64is inserted in the connector70and the grooves76allow the body portion of the cylinder78to flex outward over the end of the pivot pin62,64until the end reaches the groove74of the pivot pin62,64and an inwardly extending lip80in the one end of the connector70is located in the groove74. The connector70traps the pivot pin member62,64to the track rail assembly28when a force is applied to the actuator18to unlock the latch mechanism20.

For purposes of this disclosure, the term “coupled” means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

The construction and arrangement of the elements of the improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18shown is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed. For example, the while improved seat back frame member14and recliner mechanism connection16and the improved vehicle seat track actuator mechanism18described herein are shown as being used in combination with a vehicle seat12, such improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18may also be suitable for use with track assemblies used in other seat applications. Further, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. It should be noted that the elements and/or assemblies of the improved seat back frame member14and recliner mechanism connection16and an improved vehicle seat track actuator mechanism18may be constructed from any of a wide variety of materials that provide sufficient strength or durability in any of a wide variety of colors, combinations and suitable materials. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the scope of the present disclosure which is limited only by the understanding of a person of ordinary skill in the art.