Recliner mechanism for seat assembly and method of manufacturing

A method for manufacturing a recliner heart may include supporting a guide plate of the recliner heart with a first support member, positioning a first block onto the guide plate opposite the first support member, positioning a second block in a recess of the guide plate, and applying a force to the first block. The second block may be disposed in the recess such that a gap is formed between the guide plate and the second block. A force may be applied to the first block such that material of the guide plate moves into the gap formed between the guide plate and the second block.

FIELD

The present disclosure relates to a recliner mechanism for a seat assembly and a method of manufacturing the recliner mechanism.

BACKGROUND

Vehicle seats often include a recliner heart that can rotate a seatback relative to a seat bottom. A hand lever can be rotated to move the recliner heart between a locked position preventing relative rotation between the seatback and the seat bottom and an unlocked position permitting relative rotation between the seatback and the seat bottom. When in the locked position, tolerances between components of the recliner heart may continue to allow for movement of the seatback relative to the seat bottom, which affects the perceived quality of the seat by a user, for example. The present disclosure provides a recliner heart and a method for reducing tolerances between components of the recliner heart, therefore, restricting movement of the seatback relative to the seat bottom when the recliner heart is in the locked position.

SUMMARY

In one form, the present disclosure provides a method for manufacturing a recliner heart. The method may include supporting a guide plate of the recliner heart with a first support member, disposing a first block onto the guide plate opposite the first support member, disposing a second block in a recess of the guide plate, and applying a force to the first block. The second block is disposed in the recess such that a gap is formed between the guide plate and the second block. A force is applied to the first block such that material of the guide plate moves into the gap formed between the guide plate and the second block.

In some configurations, the guide plate includes a first boss. The first boss is supported by the first support member and the first block is disposed onto the first boss.

In some configurations, the gap is formed between the first boss of the guide plate and the second block.

In some configurations, the force is applied to the first block via a press.

In some configurations, the method includes disposing a third block onto a second boss of the guide plate.

In some configurations, the method includes supporting the second boss opposite the third block with a second support member.

In some configurations, the second block is disposed between the first and third blocks.

In some configurations, the method includes applying a force to the third block such that material of the second boss moves into another gap formed by the second boss and the second block.

In some configurations, the recess has a first width before the forces are applied to the first and third blocks and a second width after the forces are applied to the first and third blocks. The first width is wider than the second width.

In some configurations, the force is applied to the third block via a second press.

DETAILED DESCRIPTION

With reference toFIGS. 1-3, a recliner assembly10is provided that may be incorporated into a vehicle seat assembly18having a seatback22and a seat bottom24. The seatback22and seat bottom24may include a seatback frame26and a seat bottom frame28respectively. The seat assembly18may be positioned in a vehicle20, as shown inFIG. 1. The recliner assembly10may include a first recliner mechanism12, a second recliner mechanism13, a cross member14, and a hand lever16(or release lever).

The first and second recliner mechanisms12,13may be operable in a locked state preventing relative rotation between the seatback22and the seat bottom24and an unlocked state permitting relative rotation between the seatback22and seat bottom24among an upright position (FIG. 1), a rearward reclined position (FIG. 2) and a forward dump position (not shown). As shown inFIG. 5, the first recliner mechanism12may include a first bracket30, a second bracket32, a recliner heart (or locking mechanism)34, an outer coil spring46, an inner coil spring48, and a hub50.

As shown inFIGS. 4 and 5, the first bracket30may include a generally round main body37and a pair of mounting lobes31that extend outward from the main body37. The main body37may include a central aperture35and a tab42. The mounting lobes31may include a plurality of apertures33through which fasteners (not shown) may extend to securely attach the first bracket30to the seat bottom frame28of the seat assembly18.

As shown inFIG. 5, the second bracket32may be generally rectangular and may include a plurality of apertures41, and a central aperture44through which the cross member14extends. Fasteners (not shown) may extend through the plurality of apertures41to securely attach the second bracket32to the seatback frame26of the seat assembly18.

With reference toFIG. 5, the recliner heart34may be mounted to the first and second brackets30,32and may include a guide plate38, a ratchet plate45, a cam52, a plurality of pawls54, a connector disk56, a plurality of coil springs58, a control ring60, and an encapsulation ring64. The recliner heart34may be operable to lock the first recliner mechanism12, thus preventing relative rotation between the seatback22and the seat bottom24, and to also unlock the first recliner mechanism12, thus permitting relative rotation between the seatback22and seat bottom24.

The guide plate38may be mounted to the first bracket30. With references toFIGS. 4-8, the guide plate38may be a generally round, flat disk with a central aperture39(FIGS. 5 and 6), a plurality of bosses43(FIGS. 4 and 6-8) and first recesses47(FIG. 6). Each first recess47is disposed between two of the plurality of bosses43(FIG. 6) and includes a width W1(FIG. 6).

The ratchet plate45may be a generally round, flat disk and may include a central aperture65and a cylindrical recess67(FIG. 5). The cylindrical recess67may include a plurality of teeth69(FIG. 4) disposed on an inner diameter defining the cylindrical recess67. The second bracket32may be welded and/or otherwise suitably fixed to the seatback22and the ratchet plate45to attach the ratchet plate45to the seatback22. The ratchet plate45may be mounted to the guide plate38with the cylindrical recess67disposed substantially concentric with outer radii of the bosses43. The encapsulation ring64has a U-shaped cross-section and may be disposed generally around the peripheries of the ratchet plate45and the guide plate38to rotatably couple the ratchet plate45to the guide plate38.

The plurality of pawls54may be radially disposed around the central aperture39on the guide plate38and may be slidably mounted within the first recesses47of the guide plate38(FIG. 4). An edge of each pawl54may include a plurality of teeth57adapted for meshing engagement with the teeth69of the ratchet plate45. Each pawl54may also include a latch72at an end opposite the teeth57.

The cam52may be a generally round disk having an aperture59and a plurality of radial latch protrusions61arranged around the aperture59. The cam52is rotatable relative to the pawls54and the ratchet plate45such that the latch protrusions61can selectively engage the latches72of the pawls54to move the pawls54out of engagement with the teeth69of the ratchet plate45(i.e., into the unlocked state).

The connector disk56is engaged with the cam52and the hub50. The connector disk56may include a disk portion88(FIG. 5) and an extrusion90(FIGS. 4 and 5) extending perpendicularly from the disk portion88. The disk portion88may have a plurality of flanges92extending therefrom. Each flange92is engaged with a corresponding one of the coil springs58disposed in a second recess93. Because each flange92is engaged to the corresponding spring58, the connector disk56rotationally biases the cam52in a manner that causes the latch protrusions61to force the pawls54radially outwardly into the locked state, whereby the teeth57of the pawls54engage the teeth69of the ratchet plate45.

The extrusion90of the connector disk56is engaged with the hub50and the cam52such that rotation of the hub50(which is caused by rotation of the hand lever16) causes rotation of the cam52to move the pawls54radially into and out of engagement with the teeth69of the ratchet plate45.

The outer coil spring46may exert a torsional force that biases the first recliner mechanism12toward a locked state. The outer coil spring46may wrap around the hub50and engage the first bracket30and the hand lever16. The inner coil spring48may extend around the cross member14and may engage the first and second brackets30,32to rotationally bias the seatback22toward the upright position relative to the seat bottom24.

The hub50may extend through the length of the recliner heart34and may include a first end70and a second end71. The first end70may engage the hand lever16such that the hub50and the hand lever16are rotationally fixed to each other. A fastener36(e.g., a screw; shown inFIGS. 2, 3 and 5) may extend through the hand lever16and threadably engage the first end70of the hub50. The second end71may include an aperture73(FIG. 4) that receives and end of the cross member14. The cross-sectional shape of the aperture73generally corresponds to the cross-sectional shape of the cross member14such that the cross member14and the hub50are rotationally fixed relative to each other. To enable the seatback22to pivot relative to the seat bottom24, a user may pivot the hand lever16in a clockwise direction (relative to the view shown inFIG. 4) thus rotating the hub50(and consequently the cross member14). Accordingly, clockwise rotation of the cross member14causes the cam52to similarly rotate in a clockwise direction relative to the plurality of pawls54, overcoming a counterclockwise rotational bias of the outer coil spring46.

The structure and function of the second recliner mechanism13may be similar or identical to that of the first recliner mechanism12and, therefore, will not be described again in detail.

The cross member14may be a generally rectangular (e.g., square) profile and may extend in a cross-vehicle direction. The cross member14may connect the first recliner mechanism12to the second recliner mechanism13, and may transmit rotational motion of the first recliner mechanism12to the second recliner mechanism13to move the second recliner mechanism13between the locked and unlocked states simultaneously with motion of the first recliner mechanism12between the locked and unlocked states. That is, the cross member14transmits torque from the hand lever16to the second recliner mechanism13.

As shown inFIG. 3, the hand lever16may include a hub portion87and a handle portion89. The hub portion87may include a recess86. The recess86may include an aperture94(FIG. 5) through which the fastener36extends. The handle portion89may extend outward from the hub portion87and may be shaped to provide a comfortable gripping surface that a user can grip to actuate the hand lever16. The hand lever16may be securely attached to the first end70of the hub50, so that a rotational movement of the hand lever16causes the hub50(and consequently the cross member14) to rotate. This rotational movement may function to lock and unlock the seat recliner mechanisms12,13to selectively prevent and allow rotational motion of the seatback22relative to the seat bottom24.

With continued reference toFIGS. 6-8, a method for manufacturing the guide plate38of the recliner heart34will now be described in detail. The guide plate38can be casted or machined to relatively loose tolerance. Thereafter, the distance between the bosses43can be adjusted to reduce unwanted movement between it and other parts of the recliner heart34. As shown inFIGS. 7 and 8, the guide plate38of the recliner heart34is disposed on support members100a,100bduring the adjustment operation such that one boss43ais supported by the support member100aand another boss43bis supported by the support member100b.

As shown inFIGS. 7 and 8, a first rectangular-shaped impression block102is disposed on the one boss43aat or near an end thereof and a second rectangular-shaped impression block104is disposed on the another boss43bat or near an end thereof. The first impression block102is made of a metallic material (e.g., steel) and has a flat end106that contacts a surface108of the one boss43a. Similarly, the second impression block104is made of a metallic material (e.g., steel) and has a flat end110that contacts a surface111of the another boss43b. In some configurations, the ends of106,110of the blocks102,104, respectively, may be another shape (e.g., curved or tapered).

A third rectangular-shaped sizing block112may be disposed in one of the first recesses47(between the blocks102,104). In this way, a gap or space114is formed between an end116of the third sizing block112and a wall118of the one boss43aand a gap or space119is formed between another end120of the third sizing block112and a wall122of the another boss43b.

As shown inFIG. 8, a downward force (i.e., in direction Y) is applied on the first impression block102via a press124, for example, such that the first impression block102moves material from the one boss43ainwardly (i.e., in the X-direction) and into the gap114. Similarly, a downward force (i.e., in direction Y) is applied on the second impression block104via a press125, for example, such that the second impression block104moves material from the boss43binwardly (i.e., in the X-direction) and into the gap119. In this way, the width W1of the one of the first recesses47is reduced to width W2. It is understood that the press124may apply a force on the block102separately or simultaneously to the press125applying a force on the block104. Reducing the width of the first recesses47as described above reduces movement of the pawls54within the first recesses47when the recliner heart34locks the first and second recliner mechanisms12,13, which, in turn, restricts movement of the seatback22relative to the seat bottom24.

One benefit of the method for manufacturing a recliner heart as described above is the reduction in cost from not having to grind components of the recliner heart to meet specified tolerances. Another benefit of the method for manufacturing a recliner heart as described above is the speed in which the guide plate of the recliner heart may be manufactured (i.e., width of the recesses are sized). The sizing block can also be adjusted as necessary to account for part or material variances within the recliner heart. It should be understood that the method described above can also be used for guide plates for other configurations of recliner hearts/recliner mechanisms that may vary in structure.