REAR SEAT BACKREST WITH LIGHTWEIGHT ALUMINUM BACK PANEL

Abstract

A vehicle seat assembly is provided including a back panel formed of an aluminum alloy material that is stamped to form an aluminum alloy stamped back panel. The aluminum alloy stamped back panel has a periphery and with fastening locations inwardly of the periphery. A backrest frame is provided comprising steel tubes. A plurality of fastening connections fix the back panel to the backrest frame at the fastening locations. A process is provided for forming a vehicle seat assembly including stamping an aluminum alloy sheet to form an aluminum alloy, stamped, back panel with a periphery and with fastening locations inwardly of the periphery, providing a backrest frame comprising steel tubes, providing a plurality of steel fasteners and fixing the aluminum alloy stamped back panel to the backrest frame with the fasteners at the fastening locations.

Claims

1. A vehicle seat assembly comprising: a back panel comprising an aluminum alloy stamped to form an aluminum alloy stamped panel with a periphery and with fastening locations inwardly of the periphery; a backrest frame comprising steel tubes; and a plurality of fastening connections fixing the back panel to the backrest frame at the fastening locations, wherein each fastening connection comprises: a panel passage opening through said aluminum alloy stamped panel; a fastener formed of steel and comprising a fastening head and a fastener shaft with an end fixed to one of the steel tubes of the backrest frame, the fastening head extending radially outwardly from the fastener shaft and including a contact surface mechanically engaging a surface of the aluminum alloy stamped panel, the fastening head cooperating with the fixed fastener shaft end to clamp the aluminum alloy stamped panel to the backrest frame.

2. A vehicle seat assembly according to claim 1, wherein the aluminum alloy stamped panel comprises a U-channel provided along at least a portion of the periphery with planar regions and raised stamped portions provided inwardly of the periphery.

3. (canceled)

4. A vehicle seat assembly according to claim 1, wherein the fastener shaft comprises a friction welded end, friction welded to said one of the steel tubes of the backrest frame.

5. A vehicle seat assembly according to claim 1, wherein the fastener shaft comprises a resistance welded end, resistance welded to said one of the steel tubes of the backrest frame.

6. A vehicle seat assembly according to claim 1, wherein: the fastener comprises a rivet; each fastening connection further comprises a steel tube passage opening through said one of the steel tubes of the backrest frame; the fastener shaft passes through the panel passage opening and the steel tube passage opening; and the rivet has a terminated end including a contact surface mechanically engaging a surface of the said one of the steel tubes of the backrest frame, whereby the rivet clamps the clamp the aluminum alloy stamped panel to the backrest frame.

7. A vehicle seat assembly according to claim 1, wherein the aluminum alloy is in the 5000 series or the 6000 series with a T0-T5 tempering.

8. A vehicle seat assembly according to claim 1, wherein the aluminum back panel has a thickness of between 0.95-0.75 mm

9. A vehicle seat assembly according to claim 1, wherein the aluminum back panel is between 0.87 and 0.67 Kg and preferably about 0.72 Kg.

10. A process for forming a vehicle seat assembly, the process comprising the steps of: stamping an aluminum alloy sheet to form an aluminum alloy stamped back panel with a periphery and with fastening locations inwardly of the periphery; providing a backrest frame comprising steel tubes; providing a plurality of steel fasteners; fixing the aluminum alloy stamped back panel to the backrest frame with the fasteners at the fastening locations by forming the fastening connection comprising: forming a panel passage opening through said aluminum alloy stamped panel; providing a fastener formed of steel comprising a fastening head and a fastener shaft; fixing an end of the fastener shaft to one of the steel tubes of the backrest frame with the fastening head extending radially outwardly from the fastener shaft with a contact surface mechanically engaging a surface of the aluminum alloy stamped panel with the fastener head cooperating with the fixed fastener shaft end to clamp the aluminum alloy stamped panel to the backrest frame.

11. A process according to claim 10, wherein the aluminum alloy stamped panel comprises a U-channel provided along at least a portion of the periphery, with planar regions and raised stamped portions provided inwardly of the periphery.

12. (canceled)

13. A process according to claim 10, wherein the step of fixing comprises friction welding the fastener shaft end to said one of the steel tubes of the backrest frame wherein the fastener shaft friction welded end is friction welded to said one of the steel tubes of the backrest frame.

14. A process according to claim 10, wherein the step of fixing comprises resistance welding the fastener shaft end to said one of the steel tubes of the backrest frame wherein the fastener shaft end is resistance welded to said one of the steel tubes of the backrest frame.

15. A process according to claim 10, wherein the step of fixing further comprises: providing the fastener as a rivet; forming a steel tube passage opening through said one of the steel tubes of the backrest frame; passing the fastener shaft through the panel passage opening and the steel tube passage opening; terminating a rivet shaft end including the contact surface mechanically engaging a surface of the said one of the steel tubes of the backrest frame, whereby the rivet clamps the clamp the aluminum alloy stamped panel to the backrest frame.

16. A process according to claim 10, wherein the aluminum alloy is in the 5000 series or the 6000 series with a T0-T5 tempering.

17. A process according to claim 10, wherein the aluminum back panel has a thickness of between 0.95-0.75 mm

18. A process according to claim 10, wherein the aluminum back panel is between 0.87 and 0.67 Kg and preferably about 0.72 Kg.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In the drawings:

[0024] FIG. 1 is a front view of an aluminum back panel according to the invention;

[0025] FIG. 2 is a partial sectional view taken along line II-II of FIG. 1;

[0026] FIG. 3 is a perspective view of a vehicle seat according to the invention, showing the vehicle seat in a use position and without trim and without foam;

[0027] FIG. 4 is a perspective view of the vehicle seat of FIG. 3, showing the vehicle seat in a folded forward position and again without trim and without foam;

[0028] FIG. 5 is a perspective front view showing a back frame and back panel assembly according to the invention;

[0029] FIG. 6 is a partial sectional view taken along line VI-VI of FIG. 5;

[0030] FIG. 7 is a perspective rear view showing the back panel of FIG. 5, indicating the fastener openings with adjacent opening peripheral back surface of the back panel;

[0031] FIG. 8 is a perspective view showing a sample aluminum back panel portion and sample steel tube back frame portion fixed together with a fastener which is resistance welded to the sample steel tube back frame portion and with a flanged fastener head mechanically clamping the sample aluminum back panel portion to the sample steel tube back frame portion;

[0032] FIG. 9 is a sectional view of the connected parts of the view of FIG. 8;

[0033] FIG. 10 is a perspective view showing a resistance welding process with a sample aluminum back panel portion and a sample steel tube portion connected by a resistance welded fastener;

[0034] FIG. 11 is a schematic sectional view showing a friction welded fastener that is friction welded to a back frame steel tube with a flanged fastener head mechanically clamping the aluminum back panel;

[0035] FIG. 12A is a side view showing a stage of a friction welding joining process;

[0036] FIG. 12B is a side view showing another stage of a friction welding joining process;

[0037] FIG. 12C is a side view showing another stage of a friction welding joining process;

[0038] FIG. 12D is a side view showing another stage of a friction welding joining process;

[0039] FIG. 13A is a schematic side view showing a stage of a rivet joining process;

[0040] FIG. 13B is a schematic side view showing another stage of a rivet joining process;

[0041] FIG. 13C is a schematic side view showing another stage of a rivet joining process; and

[0042] FIG. 13D is a schematic side view showing another stage of a rivet joining process.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] Referring to the drawings, FIG. 1 shows an aluminum alloy back panel generally designated 10. The back panel 10 is formed with one stamping to provide a U-channel 12 along a substantial portion of a periphery of the back panel 10. The U-channel 12, particularly adds rigidity and stiffness to the overall structure of the back panel 10. The one stamping also provides raised portions including raised ribs 14 and raised circular regions 16. These raised portions 14 and 16 are provided with intervening planar regions 18. Fastening locations 40, preferably in the form of rivet through holes or pilot through holes are provided in some of the raised portions. The through holes 40 are particularly indicated in FIG. 7.

[0044] The back panel 10 is provided as part of a backrest frame (seat back frame) assembly with a steel tubular frame 30. The seat back frame assembly is a part of a backrest frame 4 and is provided in combination with vehicle seat parts to provide a vehicle seat generally designated 2.

[0045] The steel tubular frame 30 is comprised of lateral steel frame tubes 32 and backrest horizontal steel frame tube 34. A vehicle seat with a similar backrest steel tube frame is disclosed in International Patent Application PCT/US2017/016170, filed Feb. 2, 2017, which is incorporated by reference herein in its entirety.

[0046] A recliner arrangement 50 and a side bracket 58 with recliner pivot 54 connect to the back panel 10 and steel tubular frame 30 of the backrest frame assembly. The recliner arrangement 50 includes a recliner/fold forward fixture 52. The fixture 52 provides reclining adjustment of the backrest 4. The fixture 52 pivots the back panel 10 and steel tubular frame 30 of the backrest frame assembly to allow the backrest 4 to be set in any of a plurality of recliner positions and an upright position. The fixture 52 also allows a forward pivoting of the backrest 4 to a fold flat position. The robust and rigid nature of the back panel 10 allows the back panel 10, in the fold flat position, to function as a cargo load floor. The vehicle seat 2 also includes a cross tube 56 connecting the recliner arrangement 52 the side bracket 58. A seat cushion frame 60 is connected to the side bracket 58 and recliner arrangement 52 and is in turn also connected to vehicle floor bracket 62 via position adjustment track 66 and 68. Although a particular vehicle seat 2 is disclosed, the back panel 10 and steel tubular frame 30 frame assembly maybe used with other vehicle seat configurations.

[0047] As can be seen in FIG. 5, the back panel 10 and steel tubular frame 30 frame assembly forms a unitary rigid back frame assembly structure based on a combination of steel (steel alloy) components 32, 34 and aluminum (aluminum alloy) back panel 10. Each lateral steel frame tube 32 and each horizontal steel frame tube 34 is mechanically connected by a fastener 20 to the back panel 10. The fasteners 20 each pass through a respective one of the fastening locations/openings 40. Each of the horizontal frame tubes 34 is mechanically connected to the fasteners 20 by welding or by a rivet connection as discussed below. Each fastener 20 includes a flange fastener head 22 to mechanically fasten the back panel 10 to the steel tubes 32 and 34 of the steel tube frame 30. The plurality of fastening locations or through openings 40 are pre-formed in the back panel 10. These may be formed during stamping or during a subsequent drilling process. The fasteners 20, mechanically connected to the backrest steel tube frame 30, extend through the fastening locations 40 with the fastening head 22 of the fastener 20 extending radially outwardly of the fastening locations. The fastening heads contact an opening peripheral back surface of the back panel 10. This provides a clamping together of the backplane 10 and the backrest steel tube frame 30. The clamping action provided by the engagement of the fastening head 22 and the surface of the back panel 10 allows the fastener 20 to be formed of steel. In particular, the clamping mechanical connection provided by the fastener had 22 avoids the need for a welding or bonding of the aluminum alloy/magnesium alloy back panel 10 to the steel tube frame 30 or to the steel fastener 20.

[0048] The welded fastener 20, 20 includes a fastener shaft 25, 25 (FIG. 9, FIG. 11) extending from the fastener head 22, 22. The fastener shaft 25, 25 may be advantageously welded to the tubes 32 and 34 to provide a steel/steel weld connection 24, 24. In the alternative, tubes 32 and 34 may be provided with rivet through openings for a rivet fastener 20. The rivet fastener 20 has a rivet shaft 25 that passes through both the opening 40 of the aluminum backplane 10 and also trough a formed rivet through opening 95 in the steel respective tubes 32 and 34. The fastening end of the shaft 25 of the rivet fastener 20 is expanded to form an expanded end 29 providing a mechanical holding at a inner tube wall side of tubes 32 and 34 and at the opposite back side of the back panel 10.

[0049] The aluminum back panel 10 is preferably an aluminum alloy of the 5000-6000 series with T0-T6 tempering. For example, the aluminum back panel 10 advantageously is aluminum alloy 5754 T0. Other particularly suitable aluminum alloys are aluminum alloy 6021-6022 T0. The back panel 10 preferably has a thickness in the range of 0.95-0.75 mm (+/0.05 mm). Such an aluminum alloy material and thickness are particularly advantageous with regard to stamping. The back panel 10 is provided with good rigidity and stiffness with raised ribs 14, circular portion 16, intervening planer regions 18 and U-channel 12. The U-channel 12 advantageously extends around corners of the aluminum back panel 12 and is advantageous with regard to providing trim clearance. The pattern of raised and planar portions may be varied to provide rigidity and stiffness characteristics.

[0050] The aluminum alloy back panel 10 provides particular advantages. The aluminum back panel 10 has a lower mass compared to typical thin, steel back panel. Advantageously, the back panel 10 itself is between 0.87 and 0.67 Kg and preferably about 0.72 Kg. The aluminum back panel 10 is still quite thin based on a preferred material thickness <0.95 mm. This allows a conventional stamping process to be used to provide a structure comparable to a steel alloy back panel. Further, the aluminum alloy back panel 10 meets the same regulatory and automotive customer requirements as the steel back panel. Table I below provides a comparison as to attributes:

TABLE-US-00001 TABLE I Aluminum Back Attribute Steel Back panel panel Comment Material Type HSLA (High Strength Aluminum Alloy, Matching Stiffness Low Alloy) Steel 5754-T0 5000-6000 series T0-T6 Tempering Material 0.55-0.45 mm 0.95-0.75 mm Matching Stiffness Thickness (+/0.05 mm) (+/0.05 mm) Mass for 0.95 Kg 0.72 Kg Approximately 25% Typical Single Reduction in mass Occupant Seat Back Panel Technical Stamping Formability Stamping Formability Aluminum Back Attributes Carpet Channel Carpet Channel panel Technical Load Floor Strength Load Floor Strength Attributes must be Regulatory Requirements Regulatory Equal or Better than Requirements Steel Connection Welding Connections Connection between Between Back Laser, according to the Dissimilar materials, Panel & Steel RSW, invention Aluminum Back Back frame GMAW panel & Steel Back frame

[0051] The back panel 10 and the steel tube back frame 30 may advantageously be fixed together to form the back frame with steel fasteners 20 and 20 that are welded with the steel tube back frame 30 to form a steel to steel/steel weld 24, 24. This is a steel/steel weld connection 24, 24 that allows the back panel 10 to be clamped to the back frame 30. As noted above, the clamping action is provided by the fastener head 25, 25 being pressed on an opening peripheral back surface 42 surrounding each through opening 40. Two types of steel/steel welds 24, 24 are believed to be particularly advantageous. Resistance welding is discussed below with reference to steel fastener 20 and friction welding is discussed below with reference to steel fastener 20.

Resistance Weld Fastener

[0052] FIG. 10 shows a sample aluminum back panel portion 10 and a sample steel tube portion 30. As discussed above, the back panel 10 includes a pilot opening 40 formed in advance. FIG. 10 shows the fastener 20 being spot welded to a tube 32/34 sample profile portion 30. The process includes applying pressure via resistance weld upper electrode 70 and resistance weld lower electrode 72. In practice, the resistance weld lower electrode 72 presses against an opposite tube wall and the current flows around the tube 32/34. The square tubing 32/34 does allow for the necessary clamping pressure to be applied at the opposite tube wall, with the current flowing around the tube to form the weld 24. With the electrodes 70 and 72 applying clamping pressure, the back panel 10 is clamped underneath head 22 of the fastener 20. The rectangular shape back frame tube members 32/34 are also steel. The resulting weld 24 is a steel/steel weld as shown in FIG. 8 and FIG. 9. The resistance weld technology (RSW) is typical used in sheet to sheet welding applications. RSW is utilized according to the invention to weld a fastener 20 to the back frame tube member 32/34 and to also clamp an aluminum back panel 10 underneath the head 22 of the steel fastener 20 to fully form the connection joint.

Friction Weld Fastener

[0053] FIG. 11 schematically shows a connection joint formed with a fastener 20 that is friction welded to the square or rectangular profile tubing 32/34 of the tube back frame 30. As discussed above, the back panel 10 includes a pilot opening 40 formed in advance. The diameter size of the pilot opening may be selected such that the friction welding process pushes some of the material surrounding the opening 40 to interact and provide a better connection with the fastener head 22. The deformed aluminum material of the peripheral back surface 42, in the region of the opening 40, is shown in the sectional view of FIG. 11, also showing a friction welded fastener 20 friction welded to a back frame steel tube 30. The flanged fastener head 22 is pressed during the friction welding process to provide a mechanical clamping the aluminum back panel 10 with the tube frame 30.

[0054] The friction welding process uses a driving bit 80 which rotates and applies force to the fastener 20, with the aluminum back panel 10 in contact with the tube frame 30 and the tube frame 30 backed by anvil 82. As indicated in FIG. 12A, a pressing force is applied from each of the anvil 82 and the driving bit 80 as the driving bit 80 is rotated. This causes the fastener 20 to penetrate into the aluminum back panel 10, through the pilot hole 40. As shown in FIG. 12B, the fastener 20, under the force and action of the driving bit 80, pushes some aluminum material and cleans the contact surface with steel tube frame 30 to activate or initiate welding. Friction welding proceeds without penetration into the steel tube frame 30 as shown in FIG. 12C and with pressing as shown in FIG. 12 D. The back frame member 30 is again formed of steel and has a rectangular or square profile. Energy created by rotation of fastener 20, generates friction between fastener 20 and the back fame member 30 with the friction generating heat energy, which welds the fastener 20 to the back frame member 30. The aluminum back panel 10 is clamped underneath the head 22 of the steel fastener 20 and the joint is fully formed. The process provides a particularly advantageous connection joint with the friction welded fastener 20 having a steel/steel weld 24 with the steel tube frame 30 and mechanically clamping the aluminum back panel 10 to the steel tube frame 30.

Blind Rivet Connection

[0055] According to a further alternative, a rivet fastener 20 is used to form the mechanical connection joint between the aluminum back panel 10 and the steel tube back frame 30. As shown in FIG. 13, there is first a mechanical drilling operation of the steel tube 30. The steel tube back frame 30 and the back panel 10 are positioned relative to each other. A rivet through hole 95 is drilled with a drill 91 that is connected to a robot drill tool 90. The drill tool may be part of a robot tool head. The tool head of the robot also includes a robot rivet insertion tool/rivet tool 94 to insert a rivet fastener 20. The tool head is switched to the robot rivet insertion tool/rivet tool 94, as shown in FIG. 13C to insert the rivet 20 as shown in FIG. 13B. In a blind rivet operation, the tool 94 stakes (cuts off) the rivet 20 to the undersurface of the steel back frame 30. As can be seen in FIG. 13C, the rivet tool 94 pulls the pigtail 99 of the blind rivet fastener 20, changing the shape at the end 29, while closing the gap between the aluminum back panel 10 and the steel tube back frame 30. This expands the rivet blind end 29 of the rivet fastener 20 and then the mandrel 99 is snapped off. FIG. 13D shows the riveting with the pigtail 99 snapped off at the rivet head by the pulling force of the rivet tool 94, such that the connection joint is fully formed. The riveting process according to the invention is particularly advantageous using such a robot tool wherein essentially all of the steps (the four steps of FIG. 13A-13D) are performed by the same tool head, which indexes from a drilling to a riveting operation. The rivet assembly is inserted into the hole 95 drilled through the parts to be joined and a specially designed tool is used to draw the mandrel into the rivet.

[0056] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

LIST OF REFERENCE CHARACTERS

[0057]

TABLE-US-00002 2 vehicle seat 4 backrest 10 back panel 12 U-channel 14 rib raised portion 16 circular raised portion 18 planar region 20, 20, 20 fastener 22, 22, 22 fastener head 24, 24 fastener welded end 25, 25, 25 fastener shaft 29 rivet blind end 30 backrest steel tube frame 32 lateral steel frame tube 34 horizontal frame tube 40 fastener weld site/through hole, opening 42 peripheral back surface 50 recliner arrangement 52 recliner/fold forward fixture 54 recliner pivot 56 cross tube 58 side bracket 60 seat cushion frame 62 vehicle floor bracket 66 position adjustment track 68 position adjustment track 70 resistance weld upper electrode 72 resistance weld lower electrode 80 driving bit 82 anvil 90 robot drilling tool 91 drill 94 robot pulling tool 95 drilled hole 99 rivet pigtail