Metal working – Method of mechanical manufacture – Structural member making
Reexamination Certificate
1998-01-28
2001-05-01
Echols, P. W. (Department: 3726)
Metal working
Method of mechanical manufacture
Structural member making
C297S452180, C148S690000
Reexamination Certificate
active
06223436
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to motor vehicle seats, and more particularly to a seat back frame.
BACKGROUND OF THE INVENTION
Typically, vehicle seat assemblies include a recliner mechanism which supports a substantially U-shaped seat back frame with a cross-member extending across the back frame, and head rest guide tubes extending through the back frame for supporting a head rest assembly. Normally, an aluminum back frame comprises a hollow aluminum tube bent into a U-shaped configuration. The tube is usually bent in an unheat-treated condition, and then heat-treated after bending, or alternatively, the tube is annealed locally for bending. The heat-treating operation adds substantial manufacturing, handling, and shipping costs to the assembly.
The prior art bent tubes are deformed in the upper bending corners and have thin walls in the attachment areas, which results in a high shear stress. The thin attachment areas require a splint or insert to be inserted therein to reduce the shear stress. Furthermore, for attachment of the head rest guide tubes, apertures must be bored through both sides of the back frame tube, which may be awkward and may unnecessarily increase manufacturing costs.
It is desirable to provide a seat assembly in which localized heat treatment is not required prior to bending the seat back frame, heat treatment after frame completion is not rigid, and in which structural integrity is enhanced and manufacturing costs are reduced.
DISCLOSURE OF THE INVENTION
The present invention overcomes the above-referenced shortcomings of prior art seat assemblies by providing a seat back frame in the form of an extruded solid aluminum I-beam which does not require heat treatment for bending, localized heat treatment prior to bending, or post-bending heat treatment.
More specifically, the present invention provides an apparatus for supporting a seat back in a vehicle, comprising an aluminum I-beam formed in a generally U-shaped configuration, and having opposing ends supported with respect to the vehicle. The I-beam forms a seat back frame for supporting a seat back.
The present invention further provides a method of manufacturing a vehicle seat back frame, comprising the following steps: a) extruding an aluminum I-beam comprising a center support positioned between first and second flanges extending the length of the I-beam; b) cutting the I-beam to a desired length; c) age-hardening the I-beam; and d) bending the I-beam into a substantially U-shaped configuration, such that the center support and first and second flanges cooperate to form an inwardly-facing channel and an outwardly-facing channel.
In a preferred embodiment, the assembly includes a cross-member extending across the U-shaped I-beam, with the cross-member attached to the I-beam at opposing ends by a pair of swaged nuts.
The present invention also provides a method for attaching a head rest guide tube to a seat back frame having a substantially flat section with an aperture formed therethrough. The method comprises inserting the guide tube into the aperture and swaging (also termed “swedging”) the guide tube on both sides of the flat section whereby to secure the guide tube within the aperture.
Accordingly, an object of the present invention is to provide an aluminum seat back frame which does not require specialized heat treatment for bending.
Another object of the present invention is to provide a vehicle seat back frame with improved structural integrity.
Yet another object of the present invention is to provide a vehicle seat back frame with reduced manufacturing costs.
The above objects and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
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Cook Sanford E.
Dudash Eugene S.
Fudale Kevin J.
Hensley L. Keith
Smitterberg Eric A.
Brooks & Kushman P.C.
Cozart Jermie E.
Echols P. W.
Lear Corporation
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