Frame structures for vehicle seats

Embodiments of the present invention may include a frame structure for a vehicle seat having two frames, a pile portion, and a section modulus reducing configuration. The two frames extend in a specific direction. At the pile portion, the two frames abut each other in a direction perpendicular to the specific direction and connected to each other. The section modulus reducing configuration is formed at an edge portion in the specific direction of the pile portion, and is configured to achieve a reduction in section modulus.

This application claims priority to Japanese patent application serial number 2013-28754, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention relate to a frame structure for a vehicle seat. Preferably, the frame structure has two frames extending in a specific direction and integrally connected together.

2. Description of the Related Art

Japanese Laid-Open Patent Publication No. 2012-218665 discloses a frame structure for a vehicle seat. The frame structure has a side frame for a seatback. The side frame has a side frame main body formed of a thin steel plate and a sub frame formed of a thick steel plate, with the two frames being connected to each other in the height direction. The side frame main body and the sub frame are butt-welded to each other in the height direction. Another frame is passed astride the side frame main body and the sub frame. Since another frame is provided between the side frame main body and the sub frame, it is possible to suppress an abrupt change in the section modulus between them.

As a result, a reduction in structural strength is prevented, and the bonding strength for the side frame main body and the sub frame is enhanced. It should be noted, however, that end portions of frames differing in thickness are butt-welded to each other. Thus, it is rather difficult to perform positioning of the frame which makes the structure difficult to produce.

Therefore, there is a need in the art for a frame structure light in weight and providing high strength and easy to produce.

SUMMARY OF THE INVENTION

According to an aspect of the invention, a frame structure for a vehicle seat has two frames, a pile portion, and a section modulus reducing configuration. The two frames preferably extend in a specific direction. At the pile portion, the two frames abut each other in a direction perpendicular to the specific direction and are connected to each other. The section modulus reducing configuration is formed at an edge portion in the specific direction of the pile portion, and is configured to achieve a reduction in section modulus.

Thus, the change in section modulus caused between the pile portion and a region off the pile portion is small. The two frames abut each other in a direction perpendicular to the specific direction in which they extend, and are connected together. Thus, the frame structure is of a simple construction. In this construction, the reduction in structural strength accompanying an abrupt change in section modulus is suppressed. As a result, it is possible to achieve compatibility between the reduction in weight resulting from the reduction in section modulus and the securing of the requisite strength. Thus, it is possible to form a frame structure that can be easily produced.

According to another aspect of the invention, the two frames may have different mechanical strengths. The section modulus reducing configuration may be formed at an edge portion of the frame having a higher mechanical strength. Thus, it is possible to effectively reduce the section modulus of the edge region in the specific direction of the pile portion. It is possible to more effectively reduce the change in section modulus generated between the pile portion and a region apart from the pile portion.

According to another aspect of the invention, the section modulus reducing configuration may be provided by a cutout portion formed at the edge portion of at least one of the frames. Thus, the section modulus reducing configuration can be formed simply and easily. The section modulus reducing configuration helps to achieve an overall reduction in the weight of the frame structure.

DETAILED DESCRIPTION OF THE INVENTION

An example of a frame structure for a vehicle seat will be described with reference toFIGS. 1 to 7. As shown inFIG. 1, the frame structure is applicable to a seat1of an automobile. The seat1has a seatback2, a seat cushion3and a headrest6. The seatback2is connected to the rear portion of the seat cushion3. The seat cushion3is connected to a vehicle floor. The headrest6is attached to the top portion of the seatback2.

As shown inFIG. 1, the lower end portions of the right and left sides of the seat back2are connected to the rear end portions of the right and rear sides of the seat cushion3, respectively, via recliners4. The recliners4connect the seatback2and the seat cushion3to each other such that they are able to rotate or lock in position. As a result, the seatback2may be freely tilted in the seat longitudinal direction with respect to the seat cushion3, and can be locked at each of various positions. That is, it is possible to adjust the backrest angle of the seatback2with respect to the seat cushion3.

As shown inFIG. 1, each recliner4is normally maintained in a state (locked state) in which the backrest angle of the seatback2is fixed. An operation lever4A to be pulled up is provided at a vehicle-outer-side side portion (the right-hand side inFIG. 1) of the seat cushion3. Through the operation of the operation lever4A, the locked state of both recliners4is collectively released. As a result, the locked state is switched to a state in which the backrest angle of the seat back2can be freely adjusted. Spiral springs5are respectively hooked over the right and left sides of the seatback2and the seat cushion3. When adjusting the backrest angle, the spiral springs5bias the seatback2forward to a position where it touches the back of a seated occupant. This biasing raises the seatback2. At the time of adjustment of the backrest angle, the seatback2moves in conformity with the back of the seated occupant. As a result, the backrest angle can be adjusted simply and easily. The recliners4are basically of the same structure as those disclosed, for example, in Japanese Laid-Open Patent Publication No. 2011-116303.

The seat1is equipped with a three-point type seatbelt device (not shown) for constraining a body of the seated occupant. The seatbelt device has a retractor (not shown) and a belt guide2B. The retractor is provided inside the seatback2and is configured to take up webbing. The belt guide2B is provided at a shoulder portion on the vehicle outer side of the seatback2. The webbing is pulled out of the retractor, and is extracted from the belt guide2B to the front side of the seatback2. A tip portion of the webbing is fastened to the vehicle-outer-side side portion of the seat cushion3. A tongue plate, through which the webbing is passed, is provided halfway through the pulled out webbing. The occupant pulls the webbing by utilizing the tongue plate, and attaches the tongue plate to a buckle provided on the vehicle-inner-side (left-hand side inFIG. 1) portion of the seat cushion3. As a result, the webbing crosses the chest and the waist of the occupant. The seatbelt device is of the same basic structure as that disclosed, for example, in Japanese Laid-Open Patent Publication 2011-131697.

When a front portion of the vehicle undergoes collision or the like, inertial force may cause the occupant to receive a strong impact throwing him towards the front side of the seat. In the construction in which the seatbelt device is provided on the seatback2, a strong tensile force toward the seat front side is applied to the webbing supporting the occupant. The shoulder portion at the vehicle-outer-side of the seatback2(the belt guide2B) constituting an extraction port of the webbing can be pulled. As a result, the seatback2receives a strong tensile force. The force will strive to push and bend the seatback2toward the seat front side around connecting points supported by the recliners4. In order that the side frame21may not easily undergo bending deformation, the frame structure is endowed with the following high structural strength construction.

As shown inFIGS. 1 and 4, the seatback2has a reverse U-shaped back frame20. The back frame20has side frames21and22, and an upper pipe23. The side frames21and22are formed as vertically elongated plates, and constitute the frameworks of the right and left side portions of the seatback2. The upper pipe23bridges the upper end portions of the side frames21and22. The upper pipe23is horizontally elongated, and constitutes the framework of the upper side portion of the seatback2. The side frames21and22are vertically elongated. The side frames21and22are formed by cutting a steel plate material.

As shown inFIGS. 1 and 4, the upper pipe23is a round steel tube. The vehicle-inner-side end portion of the upper pipe23is formed through downward bending of the steel tube. A portion shaped into a semi-circular configuration is formed at the upper end portion of the side frame22. The vehicle-inner-side end portion of the upper pipe23is butt-welded to the inner peripheral surface of that portion. As a result, the upper pipe23is connected to the side frame22firmly and integrally. The vehicle-outer-side end portion of the upper pipe23extends straight in the width direction of the seat. A semicircular hole21A6is formed at the upper end portion of the side frame21. The vehicle-outer-side end portion of the upper pipe23is butt-welded to the inner peripheral surface (upper surface) of the semicircular hole21A6. The belt guide2B is welded to the vehicle-outer-side end portion of the upper pipe23, and the belt guide2B is welded to the side frame21. Thus, the upper pipe23is connected to the side frame21firmly and integrally.

As shown inFIGS. 2 and 3, the belt guide2B has a passing hole2B3, a front leg portion2B1, and a rear leg portion2B2. The passing hole2B3expands upwardly from the lower end of the belt guide2B. The upper pipe23is passed through the passing hole2B3in the width direction of the seat. The front leg portion2B1and the rear leg portion2B2are respectively brought into contact with a front wall portion21A1and a rear wall portion21A2of a rectangular tubular frame21A of the side frame21. The upper pipe23and the right and left side edge portions of the passing hole2B3, which contact each other, are arc-welded together. The front leg portion2B1and the front wall portion21A1are arc-welded to each other, and the rear leg portion2B2and the rear wall portion21A2are arc-welded to each other. As a result, the upper pipe23and the side frame21are connected to each other firmly and integrally.

Each of the side frames21and22exhibits an arcuately curved configuration. The upper region of each of the side frames21and22is situated on the rear of the lower region in the seat. The side frames21and22have portions supporting the waist of the occupant from both outer sides, and these portions protrude largely forward. As a result, the side frames21and22can firmly support the body around the waist of the occupant from both outer sides. The rear portions of the side frames21and22are recessed. This provides a larger space around the knees of an occupant seated in the rear.

In producing the side frame22as shown inFIG. 1, a thin steel plate of a thickness of 1.2 mm is cut in an arcuately curved configuration. After this, the edge portions on the front and rear of the side frame22(flange portions22A and22B) are bent toward the seat inner side. A recliner4is connected to the outer surface of the lower region of the side frame22. The seat cushion3has a cushion frame30equipped with a side frame32. The side frame22is connected to the inner surface of the side frame32through the intermediation of the recliner4.

As shown inFIGS. 2 and 3, the side frame21has the rectangular tubular frame21A and a thick plate frame21B. The rectangular tubular frame21A is formed by bending a thin steel plate having preferably a thickness of 1.2 mm into a rectangular tubular configuration. The thick plate frame21B is formed of a thick steel plate having preferably a thickness of 4 mm, and is connected to the lower portion of the rectangular tubular frame21A.

In producing the rectangular tubular frame21A, a thin steel plate is cut so that the rectangular tubular frame21A extends vertically. After this, the thin steel plate is bent into a rectangular sectional configuration so that both ends thereof contact each other.

Both ends of the configuration are then integrally bonded together through laser welding, and the rectangular tubular frame21A is formed having a closed sectional configuration. As a result, the rectangular tubular frame21A can exhibit high structural strength against bending and torsion.

After this, the rectangular tubular frame21A is bent backwards into an arcuate configuration through further press work. The steel plate constituting the rectangular tubular frame21A is a high tensile steel plate exhibiting high structural strength against bending and torsion. A high strength material exhibits rather low ductility. Thus, when the high strength material of a rectangular tubular configuration is bent arcuately, wrinkles, fractures, etc. can be generated at the bent portion.

As shown inFIGS. 2 and 7, recessed lines21A2a,21A3a, and21A4aare respectively formed in an inner side wall portion21A3, an outer side wall portion21A4, and a rear wall portion21A2prior to the press work. The recessed lines21A2a,21A3a, and21A4aare recessed toward the interior of the tube of the rectangular tubular frame21A, and extend in a longitudinal direction of the rectangular tubular frame21A. The rear wall portion21A2, the inner side wall portion21A3, and the outer side wall portion21A4are compressed by bending the rectangular tubular frame21A arcuately. The recessed lines21A2a,21A3a, and21A4acan disperse the compressive forces of each wall portion. As a result, the recessed lines21A2a,21A3a, and21A4acan suppress the generation of wrinkles, fractures or the like on surfaces of the wall portions21A2to21A4. As a result, the rectangular tubular frame21A can be smoothly curved into an arcuate configuration.

As shown inFIG. 2, the rectangular tubular frame21A has a seam21A5between the edge portions. The seam21A5extends straight in the height direction along a center line in the width direction of the front wall portion21A1. The front wall portion21A1faces towards the front, and only receives an in-plane stress in the tensile direction when the rectangular tubular frame21A is bent arcuately. The rear wall portion21A2, the inner side wall portion21A3, and the outer side wall portion21A4, all receive an in-plane stress in the compressing direction. Therefore, they are all difficult to bend. Conversely, the front wall portion21A1can be bent relatively smoothly. The recessed lines21A2a,21A3a, and21A4aare only formed in the intermediate regions in the height direction of the arcuate portions of the rear wall portion21A2, the inner side wall portion21A3, and the outer side wall portion21A4. No recessed lines are formed in the upper region and the lower region. Such lines are preferably straight and not arcuate.

As shown inFIGS. 2 and 3, the thick plate frame21B is a thick steel plate that is thicker and of a higher structural strength than the plate of the rectangular tubular frame21A. The thick plate frame21B contacts the lower portion of the rectangular tubular frame21A and is bonded thereto through welding. More specifically, the upper region of the thick plate frame21B contacts the lower region of the inner side wall portion21A3. The upper edge portion of the thick plate frame21B and the rectangular tubular frame21A which contact each other are bonded together through arc welding. The lower edge portion of the inner side wall portion21A3and the thick plate frame21B which contact each other are bonded together through arc welding.

The thick plate frame21B has, at the front and rear edge portions, a front flange portion21B1and a rear flange portion21B2, respectively, formed through bending in the width direction of the seat. The flange portions21B1and21B2contact the front wall portion21A1and the rear wall portion21A2, respectively, of the rectangular tubular frame21A. The edge portions of the flange portions21B1and21B2are bonded to the front wall portion21A1and the rear wall portion21A2, respectively, through arc welding.

As shown inFIGS. 2 and 3, the seam21A5is formed at the center in the width direction of the front wall portion21A1of the rectangular tubular frame21A. The front flange portion21B1extends beyond the seam21A5in the width direction so as to cover the seam21A5. The tip portion of the flange portion21B1is integrally bonded to the front wall portion21A1through arc welding. In performing the arc welding, the arc-welded portion is caused to extend upwardly from a position at a preferable distance of 7 mm or more from the lower end portion of the front wall portion21A1so that the lower end portion of the front wall portion21A1formed of a thin steel plate may not melt under the heat of the welding.

In a state in which the front flange portion21B1covers the seam21A5of the front wall portion21A1, the thick plate frame21B is welded to the front wall portion21A1. The thick plate frame21B extends the seam21A5and is bonded to the rectangular tubular frame21A. Thus the thick plate frame2113holds the rectangular tubular frame21A from the inner side of the seam21A5while the thick plate frame21B is bonded to the front wall portion21A1at the outer side of the seam21A5. A lower end portion21A5aof the seam21A5is covered with the front wall portion21A1of the thick plate frame21B. Since the lower end portion21A5aof the seam21A5consists of a thin steel plate, it may melt from the heat during laser welding. In this structure, however, the portion possibly subjected to melting is covered with the thick plate frame21B. Thus, it is possible to prevent a reduction in the structural strength of the rectangular tubular frame21A.

As shown inFIGS. 2 and 3, the thick plate frame21B contacts the inner side wall portion21A3. The front flange portion21B1strides across the seam21A5, and the tip portion thereof is integrally welded to the thick plate frame21B. The rear flange portion21B2is integrally welded to the rear wall portion21A2. As a result, the thick plate frame21B strongly constrains the rectangular tubular frame21A so as to prevent the rectangular tubular frame21A from undergoing deformation in the direction in which the seam21A5could be torn apart (the width direction). Loads in various directions input to the side frame21pass the rectangular tubular frame21A and the thick plate frame21B. These loads are appropriately transmitted via the region of high structural strength without passing the melted-down lower end portion21A5aof the seam21A5.

The belt guide2B is connected to the upper end portion of the rectangular tubular frame21A. The belt guide2B is mounted to the rectangular tubular frame21A so as to extend on both sides of the seam21A5in the width direction. The belt guide2B has the front flange portion21B1. The front flange portion21B1is integrally connected to the rectangular tubular frame21A on both sides of the seam21A5. The front leg portion2B1of the belt guide2B contacts the front wall portion21A1of the rectangular tubular frame21A. The front leg portion2B1has portions extending from right and left edge portions toward the seat rear side. The portions contact the inner side wall portion21A3and the outer side wall portion21A5b, and are integrally connected to the rectangular tubular frame21A by arc welding. As a result, in the rectangular tubular frame21A, an upper end portion21A5bof the seam21A5is covered by the front leg portion2B1of the belt guide2B. Since the upper end portion21A5bof the seam21A5is formed of a thin steel plate, it may be melted down at the time of laser welding. The front leg portion2B1covers the portion that may be melted down. Thus, it is possible to prevent a reduction in the structural strength of the rectangular tubular frame21A.

The front leg portion2B1of the belt guide2B contacts the front wall portion21A1. The belt guide2B strongly constrains the rectangular tubular frame21A so as to prevent the rectangular tubular frame21A from undergoing deformation in the direction in which the seam21A5may be torn apart (the width direction). Loads in various directions may be input to the upper pipe23and the side frame21. The loads pass the rectangular tubular frame21A and the belt guide2B. The loads are appropriately transmitted via the region of high structural strength without passing the upper end portion21A5bof the seam21A5. This upper end portion21A5bof the seam21A5may be subject to melting.

The recliner4is connected to the outer side surface of the thick plate frame21B. The recliner4is connected to the inner side surface of the side frame31of the cushion frame30. The recliner4is connected to the thick plate frame21B, so that, as compared with the construction in which the recliner4is connected to the thin steel plate, it is possible to provide a higher connection strength. When a large load is input to the seatback2, the lower end side region of the side frame21receives the largest bending load. It is possible to effectively enhance the structural strength of the lower end side region of the side frame21due to the thick plate frame21B.

As shown inFIG. 2, the thick plate frame21B has a surface that contacts the inner side wall portion21A3. A recess (cutout portion)21B4is formed at the center of the upper edge portion of the surface. The recess21B4is cut downwardly in a recessed configuration. The recess21B4helps to reduce the change in section modulus generated in the boundary region between the connection portion and the non-connecting portion.

They differ in that the connecting portion connects with the rectangular tubular frame21A and the thick plate frame21B while the non-connecting portion does not connect with them. The recess21B4has step side surfaces extending toward the bottom surface thereof. The side surfaces are inclined surfaces inclined at an angle larger than a right angle. The inclined configuration of the recess21B4helps to further reduce the change in section modulus generated in the above-mentioned boundary region.

The lower region of the side frame21is particularly subject to the load of a bending moment. The requisite structural strength of the lower region is secured by the thick plate frame21B. There is involved an abrupt change in section modulus between the connection portion, which connects the rectangular tubular frame21A and the thick plate frame21B, and the non-connecting portion. Due to the above-described structure, however, it is possible to broadly receive the input load by the structure as a whole without involving any local stress concentration. Thus, the vehicle-outer-side side frame21exhibits high structural strength. When the side portion of the vehicle suffers collision, the vehicle-outer-side side frame21may receive a large load from the vehicle outer side. In this case, the side frame21can broadly receive the load with the entire structure without involving any local stress concentration. As a result, it is possible to increase the period of time that elapses until the side frame21is bent in a buckled fashion. That is, in the present structure, the lightweight rectangular tubular frame21A formed of a thin steel plate and the high-strength thick plate frame21B formed of a thick steel plate are appropriately combined with each other. As a result, it is possible, in the present structure, to attain compatibility between a reduction in weight and the securing of the requisite strength.

The recess21B4is formed at the center of the upper edge portion of the thick plate frame21B. On both sides of the recess21B4, there is provided a front portion21B5and a rear portion21B6. As a result, when a large load in the longitudinal direction is input to the seatback2, it is possible to support the lower end portion of the rectangular tubular frame21A from below with a strong force by the front portion21B5and the rear portion21B6of the thick plate frame21B.

The rectangular tubular frame21A is of a closed sectional configuration and exhibits high structural strength. The rectangular tubular frame21A and the recliner4contact and are connected to the same surface (outer side surface) of the thick plate frame21B. The rectangular tubular frame21A and the recliner4are arranged at the same position in the width direction. As a result, the installation space in the width direction in which the three members are arranged is reduced. An armrest support bracket26for attaching an armrest device (not shown) is integrally connected to the outer side wall portion21A4of the rectangular tubular frame21A (SeeFIGS. 1, 4, and 5). Since the rectangular tubular frame21A is of a closed sectional configuration, the strength with which the armrest support bracket26is supported is high.

As shown inFIGS. 1 and 4, in addition to the upper pipe23, two reinforcing pipes24and25are provided between the side frames21and22. The reinforcing pipes24and25are formed by bending round steel tubes in a crankshaft-like fashion. The reinforcing pipe24bridges between the intermediate portions of the side frames21and22. The reinforcing pipe25bridges between the lower portions in the height direction of the side frames21and22. The reinforcing pipe24has a flattened plate-like vehicle-inner-side end portion. The end portion contacts the bent flange portion22B on the rear edge of the side frame22from the seat rear, and is integrally connected therewith. The vehicle-outer-side end portion of the reinforcing pipe24is passed through the inner side wall portion21A3and the outer side wall portion21A4of the rectangular tubular frame21A constituting the side frame21. The portions connected together by passing through are firmly integrated with each other through welding.

The reinforcing pipe25has a vehicle-inner-side end portion to be passed through the side frame22. The portion passed through is firmly integrated with the side frame22by welding. The vehicle-outer-side end portion of the reinforcing pipe25is passed through the connecting portion of the rectangular tubular frame21A and the thick plate frame21B constituting the side frame21. The portions connected together by passing through are firmly integrated with each other through welding (SeeFIG. 6). The vehicle-outer-side end portion of the reinforcing pipe25is passed through a round hole21B3formed in the thick plate frame21B and a semicircular hole21A7formed at the lower end portion of the rectangular tubular frame21A. The portions connected together by passing through are firmly integrated with each other through welding. The reinforcing pipes24and25are mounted to the back frame20in a ladder-like fashion so as to enhance the structural strength of the back frame20against bending or torsion.

The frame structure has two frames (the rectangular tubular frame21A and the thick plate frame21B) extending in a specific direction (the seat height direction). The two frames contact each other in a direction (the width direction of the seat) perpendicular to said specific direction and are bonded together. There is a pile portion where the two frames contact each other and are piled together. There is formed, at an edge region in said specific direction of the piled portion (the upper edge portion of the thick plate frame21B), a section modulus reducing configuration (the recess21B4). The section modulus reducing configuration may help to achieve a reduction in section modulus.

Thus, the change in section modulus generated between the piled portion and the region off the piled portion is reduced. The frame structure has a simple construction in which the two frames contact each other in a direction perpendicular to the specific direction in which they extend. The construction does not involve a reduction in structural strength causing an abrupt change in section modulus. It is possible to attain compatibility between a reduction in weight accompanying a reduction in section modulus and the securing of the requisite strength. Thus, it is possible to form a frame structure that can be easily produced.

The two frames connected to each other (the rectangular tubular frame21A and the thick plate frame21B) include a high strength frame exhibiting higher mechanical strength (the thick plate frame21B) and a low strength frame exhibiting lower mechanical strength (the rectangular tubular frame21A). The high strength frame has a section modulus reducing configuration (the recess21B4) at an edge portion thereof. The section modulus reducing configuration may effectively reduce a predefined position. The predefined position may be an edge portion of a pile portion piling the two frames. The lower strength frame extends from the edge portion.

Instead of the structure ofFIGS. 1 to 7, the seat1may have a structure as shown inFIGS. 8 and 9. The seat1may have the same members as those of the members ofFIGS. 1 to 7. The same members are indicated by the same reference numerals. A description of the same members will be left out. A vehicle may have a rear seat for three persons in the rearmost row. The rear seat may be divided in a proportion of 6:4. A larger one of the divisional seat may be the seat1. The seat1may be a seat for two persons. The seat1integrally has, at the vehicle-inner-side side portion thereof, the construction of a central seat1A having a small lateral width.

The seat1has the reverse U-shaped back frame20. The back frame20has the vehicle-inner-side side frame21. A back frame20A constituting the inner framework of a seatback2A of the central seat1A is integrally connected to the side frame21. The back frame20A is supported by the side frame21in a cantilever-like fashion. Thus, the side frame21is preferably strong enough to support the back frame20A. The construction of the side frame21is substantially the same as that of the side frame21described above.

Instead of the structure ofFIGS. 1 to 7, the seat1may have a structure as shown inFIG. 10. As shown inFIG. 10, a thick plate frame21B has a surface contacting a rectangular tubular frame21A. Two front and rear recesses (a front recess21B7and a rear recess21B8) are formed at an upper edge of the surface. The recesses (cutouts) have a downwardly cut-out configuration. The recesses help to reduce the change in section modulus generated in the boundary region between the rectangular tubular frame21A and the portion to which the thick plate frame21B is connected. Between the recesses, there is formed a central portion21B9. The central portion21B9has step side surfaces extending toward the bottom surfaces of the recesses. The side surfaces are inclined surfaces of an angle larger than the right angle. The inclined configuration of the recesses help to further reduce the change in section modulus generated in the above-mentioned boundary region.

While the embodiments of invention have been described with reference to specific configurations, it will be apparent to those skilled in the art that many alternatives, modifications and variations may be made without departing from the scope of the present invention. Accordingly, embodiments of the present invention are intended to embrace all such alternatives, modifications and variations that may fall within the spirit and scope of the appended claims. For example, embodiments of the present invention should not be limited to the representative configurations, but may be modified, for example, as described below.

The frame structure for a vehicle seat is applicable to any of automotive seats including a driver's seat, a passenger seat next to the driver's seat, and rear seats. The frame structure is applicable to vehicle seats other than those found in automobiles such as those found on a train, railroad car, etc. The frame structure is applicable to a seat for various vehicles such as an aircraft and a ship.

As described above, the frame structure is applicable to the seatback of a vehicle seat. Alternatively, the frame structure is applicable to other seat components such as a seat cushion and a headrest. The frame structure is applicable to various reinforcing structures with which a vehicle seat is provided, such as a slide rail, an ottoman, and a seat lifter. The present frame structure is applicable to a frame structure in which two frames extending in a specific direction are integrally connected to each other.

As described above, the specific direction in which the two frames extend may be the seat height direction. Alternatively, the specific direction may be any other direction such as the seat longitudinal direction or the width direction. The two frames extend in the same direction (specific direction) and have a portion contacting each other in a direction perpendicular to the specific direction. One or both of the frames may be bent halfway and extend in a direction different from the specific direction.

As described above, the two frames may be connected to each other by arc welding. Alternatively, the two frames may be connected to each other by laser welding, or some other fastening method. As described above, the direction in which the two frames abut each other may be a direction perpendicular to the specific direction in which the two frames extend. One of the two frames may be connected to an intermediate portion of the other. That is, one may extend in the specific direction longer than the other, and may contact with and connect to the intermediate portion of the other. In this case, it is desirable to form a section modulus reducing configuration at both edge portions of the pile portion where the two frames contact and connect with each other.

As described above, the two frames (the rectangular tubular frame21A and the thick plate frame21B) preferably differ from each other in mechanical strength. The section modulus reducing configuration is formed at the edge portion of the high strength frame. The high strength frame exhibits higher mechanical strength. The edge portion may be the upper edge portion of the thick plate frame21B. Alternatively, the two frames may have the same level of mechanical strength. In such a construction, the section modulus reducing configuration may be formed at an edge portion at either one or both of the frames. Alternatively, the section modulus reducing configuration may be formed at the edge portion of the frame of lower mechanical strength. The section modulus reducing configuration may be formed by partially thinning the edge portion of one frame. Alternatively, the section modulus reducing configuration may have a portion bent so as to achieve a reduction in section modulus. Finally, the section modulus reducing configuration may have a hole, groove or wave shape which has a plurality of bent portions.