Method for producing a rear wall of a seat backrest

Abstract

A method of manufacturing at least one of a vehicle seat structure, a vehicle seat and a vehicle seat bench. The method may include forming at least one back shell extending in a direction transverse to a direction of travel and having a front side relative to the direction of travel and a back side relative to the direction of travel, a frame structure, reinforcement ribs arranged on the front side of the back shell, absorption ribs arranged on the back side of the back shell, and structural insertion components arranged on the back shell and/or the frame structure. The forming includes molding at least the back shell and the frame structure as a one-piece integrated structural component.

Claims

1. A vehicle seat structure, comprising: one shell made of thermoplastic and extending in a direction transverse to a direction of travel and having a front side relative to the direction of travel and a back side relative to the direction of travel, wherein the shell has an overall flat and planar shape and the planar shape possesses no curvature, wherein the shell comprises an inner portion, an outer portion, and a frame structure made of thermoplastic; reinforcement ribs arranged on the inner portion and the outer portion of the front side of the shell; absorption ribs arranged on the inner portion and the outer portion of the back side of the shell; and structural insertion components arranged on the shell and/or the frame structure, wherein at least the shell and the frame structure are formed as a one-piece, integrated, thermoplastic structural component, wherein the shell and the frame structure are one-piece such that the frame structure surrounds and encloses the inner portion of the shell in the direction transverse to the direction of travel and separates the inner portion of the shell from the outer portion of the shell, wherein the reinforcement ribs and the absorption ribs each include a plurality of horizontal ribs and vertical ribs that intersect each other, wherein the reinforcement ribs surround the structural insertion components on the front side of the shell in the direction transverse to the direction of travel.

2. The vehicle seat structure of claim 1, wherein the reinforcement ribs abut the frame structure on the front side of the shell.

3. The vehicle seat structure of claim 1, wherein the frame structure extends circumferentially around the inner portion of the shell.

4. The vehicle seat structure of claim 1, wherein the structural insertion components are arranged in or on at least one of the shell or the frame structure and are encased at least partially by the thermoplastic material of the at least one of the shell or of the frame structure.

5. The vehicle seat structure of claim 1, wherein the horizontal ribs and the vertical ribs intersect each other along at least the inner portions of the front side and the back side of the shell.

6. The vehicle seat structure of claim 1, wherein the horizontal ribs and the vertical ribs intersect each other along at least the respective outer portions of the front side and the back side of the shell.

7. The vehicle seat structure of claim 1, wherein the horizontal ribs and the vertical ribs intersect each other along at least the respective inner portions and the respective outer portions of the front side and the back side of the shell.

8. The vehicle seat structure of claim 1, wherein the horizontal ribs intersect multiple of the vertical ribs, and the vertical ribs intersect multiple of the horizontal ribs.

9. The vehicle seat structure of claim 1, wherein the horizontal ribs and the vertical ribs within the inner portion and the outer portion are spaced closer together than ribs within the frame structure.

10. A vehicle seat structure, comprising: at least one shell extending in a direction transverse to a direction of travel and having a front side relative to the direction of travel and a back side relative to the direction of travel, wherein the shell has an overall flat and planar shape and the planar shape possesses no curvature, wherein the shell comprises an inner portion, an outer portion, and a frame structure; reinforcement ribs arranged on the inner portion and the outer portion of the front side of the shell; absorption ribs arranged on the inner portion and the outer portion of the back side of the shell; and structural insertion components arranged on the shell and/or the frame structure, wherein at least the shell and the frame structure are a one-piece, integrated, thermoplastic structural component, wherein the shell and the frame structure are molded such that the frame structure surrounds and encloses the inner portion of the shell in the direction transverse to the direction of travel and separates the inner portion of the shell from the outer portion of the shell, wherein the reinforcement ribs and the absorption ribs each include a plurality of horizontal ribs and vertical ribs that intersect each other, wherein the reinforcement ribs surround the structural insertion components on the front side of the shell in the direction transverse to the direction of travel.

11. The vehicle seat structure of claim 10, wherein the reinforcement ribs abut the frame structure on the front side of the shell.

12. The vehicle seat structure of claim 10, wherein the frame structure extends circumferentially around the inner portion of the shell.

13. A vehicle seat structure, comprising: at least one back shell extending in a direction transverse to a direction of travel and having a front side relative to the direction of travel and a back side relative to the direction of travel, wherein the shell has an overall flat and planar shape and the planar shape possesses no curvature, wherein the back shell comprises an inner portion, an outer portion, and a frame structure; reinforcement ribs arranged on the inner portion and the outer portion of the front side of the back shell; absorption ribs arranged on the inner portion and the outer portion of the back side of the back shell; and structural insertion components arranged on the back shell and/or the frame structure, wherein at least the back shell and the frame structure are molded to each other in a plastic to plastic manner by melting surfaces of the back shell and the frame structure and subsequently molding the back shell and the frame structure at those melted surfaces to form a one-piece, integrated, thermoplastic structural component, wherein the back shell and the frame structure are molded such that the frame structure surrounds and encloses the inner portion of the back shell in the direction transverse to the direction of travel and separates the inner portion of the back shell from the outer portion of the back shell, wherein the reinforcement ribs and the absorption ribs each include a plurality of horizontal ribs and vertical ribs that intersect each other, wherein the reinforcement ribs surround the structural insertion components on the front side of the back shell in the direction transverse to the direction of travel.

14. The vehicle seat structure of claim 13, wherein the reinforcement ribs abut the frame structure on the front side of the back shell.

15. The vehicle seat structure of claim 13, wherein the frame structure extends circumferentially around the inner portion of the back shell.

Description

(1) The invention is explained in detail using the attached schematic figures.

(2) In the figures:

(3) FIG. 1 schematically shows a rather large rest part of a divided seat rest back wall, e.g., in a division ratio of 60% relative to the entire backseat rest,

(4) FIG. 2 shows a smaller press part of a divided seat rest back wall, e.g., in a division ratio of 40% relative to the entire backseat rest,

(5) FIG. 3 schematically shows an imaginary section along the line A-A in FIG. 2,

(6) FIG. 4 schematically shows an imaginary section along the line B-B in FIG. 1,

(7) FIG. 5 schematically shows an imaginary section along the line C-C in FIG. 2,

(8) FIG. 6 schematically shows the larger rest part in FIG. 1 in a first front perspective view, and

(9) FIG. 7 schematically shows the larger rest part in FIG. 1 in a second rear perspective view.

(10) Parts corresponding to each other are provided with the same reference numerals in all figures.

(11) FIGS. 1 and 2 show a rather large and a smaller rest part. Together, these two rest parts form a seat rest back wall that is constructed asymmetrically divided. The division ratio of such a seat rest back wall is, for example, 60% to 40%.

(12) The rest parts shown in FIGS. 1 and 2 consist of a circumferential frame structure 1.1, 1.2 as well of the rack shell 2.1, 2.2 associated with the latter. These components form the supporting framework of the backrest and consist in the example of fiber-reinforced plastic, e.g., glass-fiber-reinforced plastic. Additional reinforcements of material with a greater strength such as, e.g., steel can be used at the spots where an elevated introduction of load is to be reckoned with. The corner connection area 3, that is the basis in the example for the upper connecting of the backrest part to the vehicle body is formed from a profile-like, structural support component 3.1 with a greater strength such as, e.g., steel, on which the plastic frame area 3.2, a partial area of the frame structure 1.2, is supported, that for its part is covered over in a roof-like manner by another profile-like structural cover part 3.3 with a greater strength. With this construction, also called sandwich construction, a high transfer of force can be achieved with a comparatively low use of material. In order to reduce the manufacturing and assembly expense the reinforcements can be directly integrated during the manufacturing process of the plastic structural parts in that they are also directly molded at the same time.

(13) Furthermore, FIG. 1 shows a loading opening 4 such as is customarily used today for stowing long transport material, e.g., skis. The flap that closes the loading opening 4 when not in use is not shown. In the open state of the loading opening 4 the area 4.1 is readily visible in this edge area in FIG. 7. It can also be provided here for aesthetic reasons to provide this area 4.1 with a coating such as, e.g., a textile or a surface structure such as, e.g., a pitting that can also be directly integrated into the manufacturing process in the presented seat structure construction.

(14) It can be seen in FIGS. 1 and 2 as well as 6 and 7 how the back shells 2.1 and 2.2 are reinforced with a plurality of horizontal ribs 5.1 and vertical ribs 5.2. It can furthermore be gathered from FIG. 4 that the ribs are arranged on both sides of the back shell 2.1. For reasons of presentation the back shell 2.2 is shown in the section A-A of FIG. 3 on the backside without ribbing which, however, is nevertheless present in this exemplary embodiment. While the reinforcement ribs 6.1 on the front side ensure great rigidity of the back shell, the absorption ribs 6.2 on the backside have the task of reducing elevated energy such as occurs, e.g., in a crash by their intrinsic deformation.

(15) Another special rib shaping is apparent from FIG. 1 and FIG. 6. A V-rip 7, that is, a rib with a V-shaped formation is formed in a one-piece manner on the back shell 2.1 below the area on which the safety belt is mounted on the vehicle seat structure. This shaping also has the task of improving the flow of force since the occurrence of elevated introduction of load into the structure must be reckoned with particularly in this area.

(16) A vertically extending web with trim conduit 8 can be recognized in FIG. 1 and along the imaginary section B-B shown in FIG. 4. The fastening means of the seat covering, also not shown, can be readily attached to this web. The web with trim conduit 8 preferably consists of metal, especially preferably of steel, which has in particular advantages regarding the transfer of force and rendering it shatterproof. The web with trim conduit 8 is connected to a first web connection 9.1, for example, integrally, by molding with the material of the plastic back shell 2.1 in the upper area of the backrest. To this end the area to be molded has perforations through which the plastic melt flows. Due to its flat design, forces are transferred in a laminar manner into bordering areas, which results in a lesser loading of the structural components. The second web connection 9.2 is preferably integrated in the same manner into the plastic back shell 2.1 in the lower area of the backrest.

(17) Another feature of the vehicle seat structure in accordance with the invention is shown in FIGS. 1 and 4 in the lower area. At least one trim hook 10 but preferably at least two more trim hooks 10 are formed in one piece on the front side of the back shell 2.1. The seat cover (not shown) can be attached on these hooks, again with suitable fastening means.

(18) FIG. 3 shows a possibility in the lower area of the vehicle seat structure of how the hat-shaped frame structural part 1.2, that is open on one side, can be closed in a flush, aligned manner relative to the back shell 2.2 with a covering profile 11. To this end the covering profile 11 is, e.g., pressed in or adhered in or connected by other suitable plastic connection methods such as, e.g., ultrasound welding, to the back shell 2.2. Ribbing is arranged on the backside of the backshell 2.2 and the covering profile 11 also has such ribbing.

(19) FIG. 5 shows a detail in accordance with an imaginary section line C-C on an enlarged scale that describes a possibility for degrading a load peak caused, e.g., by a crash and thus minimizing the entire load for the vehicle structure. A bush 13 pressed into a rest pivot bearing area 12 of the vehicle seat structure is paired with its outside diameter with the receiving bore of the rest pivot bearing area 12 in such a manner, e.g., with a transitional fit, that the bush 13 can move out of the bearing position in case of an occurring, elevated load in the direction R to an extent that is not critical for safety before it is securely held with suitable structure locking parts (not shown). In this manner at least a part of the loading energy is converted into movement.

(20) Other attached structural parts of metals or non-metals can be integrated into the vehicle seat structure or into parts of it by the previously described, direct molding, as can be seen in the example of the armrest receptacle 14, or they are connected by connection means 16 such as, for example, screws to the vehicle seat structure. This method of construction is represented using the belt connection structural component 15.

LIST OF REFERENCE NUMERALS

(21) 1.1, 1.2 frame structure 2.1, 2.2 back shell 3 corner connection area 3.1 structural support component 3.2 plastic frame area 3.3 structural cover part 4 loading opening 4.1 area 5.1 horizontal ribs 5.2 vertical ribs 6.1 reinforcement ribs 6.2 absorption ribs 7 V-rib 8 web with trim conduit 9.1 first web connection 9.2 second web connection 10 trim hook 11 cover profile 12 rest pivot bearing area 13 bush 14 armrest receptacle 15 belt connection structural component 16 connection means R direction