CROSS-REFERENCE TO RELATED APPLICATION

[0001] This PCT patent application claims the benefit of U.S. Provisional Patent

Application Serial No. 61 /375,204 filed August 19, 2010, entitled "One Piece Rear Back," the entire disclosure of the application being considered part of the disclosure of this application, and hereby incorporated by reference.

Background

[0002] The present invention relates to vehicle seats and more specifically, the back panel for second and third row seats wherein the panel or structural frame is formed out of a single stamped sheet of steel and eliminates the need for a tubular steel outer frame.

[0003] Vehicle manufacturers typically form the structural frame of second and third row seats using a perimeter tube that is welded to various brackets and a stamped panel that extends between the perimeter tube to provide structural rigidity to the seat. These seat designs are expensive to manufacture in time and materials and are typically relatively heavy. Some manufacturers have attempted to eliminate perimeter tubes and have stamped multiple panels and then welded them together along with various welded reinforcing brackets and bars welded thereto for structural rigidity. These double-stamped panels are also time-consuming and expensive to manufacture and therefore there is a desire for a reduced cost and mass structural members for rear vehicle seats, specifically the second and third row seats.

Summary

[0004] The present invention relates to vehicle seats and more specifically, the back panel for second and third row seats wherein the panel or structural member is formed out of a single stamped sheet. [0005] The present invention uses a single stamped panel sheet of steel and through careful addition of stamped geometric designs forming ribs or raised members allows for a lightweight structural member formed from a thin sheet of steel, typically 0.4 mm to 0.6 mm, without the additional need for welded brackets, perimeter tubes or other structural supports. The panel may also be formed using fairly standard steel compositions such as 1008 or 340 XF steels.

Brief Description of the Drawings

[0006] FIG. 1 illustrates a front perspective view of a structural member for a 60% rear vehicle seat;

[0007] FIG. 2 is a front perspective view of a structural member for a 40% rear vehicle seat;

[0008] FIG. 3 is a rear plan view of the structural member of FIG. 1 ;

[0009] FIG. 4 is a rear plan view of the structural member in FIG. 2;

[0010] FIG. 5 is a side view of the structural member in FIGS. 1 and 3.

Description

[0011] The present invention is generally directed to a structural member 10 or panel as illustrated in FIGS. 1-5. The structural member 10 is generally formed from a single sheet of stamped metal leaving a base plane 12 and creating a raised pattern 14 across a back surface 13. The raised pattern 14 may include multiple levels of height from the base plane 12. The structural member 10 also includes a top rail 20 which includes headrest locators 16 and a side rail 18 extends around the rest of the perimeter.

[0012] The pattern illustrated in the Figures forming the raised pattern 14 allows the structural member 10 to be formed as a low cost, low mass product. More specifically, the structural member 10 may meet the various current seat standards such as FMVSS 202A, ECE 17 Cargo Retention, and other structural requirements. This may all be accomplished using a single sheet of standard steel such as a 1008 or 340 XF steel of relatively thin proportions, specifically 0.4 mm to 0.6 mm. By eliminating the brackets, exterior members and using a standard steel of thinner proportions than normal, the present invention reduces material costs as well as the weight of the seat. The reduced weight of a seat is particularly important in reducing the overall weight of the vehicle and therefore improving the fuel economy of the vehicle. In addition, manufacturing costs are reduced through the use of the one piece design. More specifically, the design of the raised pattern 14 reduces costs and mass by optimizing the geometry to allow the use of thinner than standard gauge steel materials.

[0013] As illustrated in FIGS. 1-4, the structural member has different patterns if it is the 60% seat portion, specifically illustrated in FIGS. 1 and 3 or the 40% seat portion, specifically illustrated in FIGS. 2 and 4. It should be noted that the 60% pattern may be applied to seats that are 50% and larger of the rear seat and the 40% pattern may be applied to seats that are 50% or less of the overall rear seats, that are split seats.

[0014] The similar features of structural members of the 60% and 40% pattern will be first described. The structural member 10 is stamped to have a raised pattern 14 extending from a base plane 12. After being stamped, the structural member has an outer perimeter 30 formed from a base edge 32, an inner edge 34, an outer edge 36 and a top edge 38. The base edge 32 and inner edge 34 and top edge 38 are substantially straight, although some variations may occur. The outer edge 36 has a lower straight edge 40, a curved outer edge 42 and an upper outer edge 44. The size, shape, and configuration of the outer edge 36 may vary depending on the vehicle, and it is expected that in most circumstances the outer edge 36 will extend outwardly with the curved outer edge 42, but in some configurations, the outer edge 36 will be straight without the curved outer edge 42. [0015] Proximate to the base edge 32, an attachment area 48 may be configured to have various holes and in some embodiments, additional hinge plates 50 to couple the structural member 10 and thereby the seat portions to a seat base or to a vehicle. The size, shape, and configuration of this attachment area 48 may vary depending upon the type of vehicle and intended functionality of the seat.

[0016] Each of the structural members 10 includes an outer perimeter rib 52 that extends circumferentially and approximately proximate to the outer perimeter 30. It should be noted that the top rail 20 is disposed between the outer perimeter rib 52 and the upper edge 38. The outer perimeter rib 52 generally includes a base perimeter portion 54, an inner perimeter portion 60, an outer perimeter portion 62, and an upper perimeter portion 70. The base perimeter portion 54 generally includes a central member 55 that is substantially aligned with the base edge 32. The base perimeter portion 54 also generally includes an outer base angle portion 56 and an inner base angle portion 58. The inner base angle portion 58 and outer base angle portion 56 are angled to provide clearance for hinge plates 50 located in the lower edge attachment area 48. Variations in the size, shape,

configurations, and angles of the base perimeter portion 54 are expected.

[0017] It should be noted that the upper perimeter portion is slightly recessed or in closer proximity to the base plane than the inner perimeter portion 60 as well as the outer perimeter portion 62. The upper perimeter portion 70 generally extends substantially across a majority of the width of the structural member proximate to the top rail 20. Due to the reduced height of the upper perimeter portion 70 relative to the rest of the outer perimeter rib 52, additional rib members 72 extending from the top rail and approximately

perpendicular to the top rail 20 and upper perimeter portion 70 may be added. For the 40% structural member, at least one such reinforcing rib member 72 extends from the top rail 20 between the headrest holes 68 across the upper perimeter portion 70 into a raised rib, although it may also extend to the base plane 12 in some embodiments.

[0018] As illustrated in FIGS. 1 and 3, for the 60% portion, the reinforcing rib members 72 are included with at least one being disposed between the headrest holes 16 and another reinforcing rib member 72 outward of the outward headrest hole 16 and wherein at least two of the reinforcing rib members 72 that extend from the top rail 20 to the base plane 12 are located substantially on each side of a latch member 22. As illustrated in FIGS. 2 and 4, an additional reinforcing rib member 72 is located on both the 40% and 60% member proximate to the latch member 22. Due to the size, shape and configuration of the structural members around the latch member 22, the reinforcing rib member 72 located proximate to the latch member 22 is substantially reduced in size. Although these rib members 72 may be stamped from the steel back surface, in some embodiments the reinforcing rib member may be welded from the top rail across the upper perimeter portion 70.

[0019] The outer perimeter portion 62 extends generally from the base perimeter portion 54 and specifically from the outer base angle portion 56 upward toward the top rail 20. The outer perimeter portion 62 generally includes a lower straight portion 64 extending upwardly to join an outward curved portion 66 and into a transition portion 68 which causes the outer perimeter portion 62 to actually flow into the top rail 20 instead of the reduced height of the upper perimeter portion 70. The upper perimeter portion 70 extends to meet the transition portion 68. The actual size, shape, and configuration of the outer perimeter portion 62 may vary to match the size, shape, and configuration of the vehicle in which the structural member is placed.

[0020] The structural member 10 has so far been described with substantially similar features with only minor variations between the 60% structural member 10 ^' and the 40% structural 10 ^" . The 60% structural member 10 ^' and the reinforcing ribs or raised portions 14 thereon bounded by the outer perimeter rib 52 will now be described and the raised portions 14 on the 40% structural member 10 ^" bounded by the outer perimeter rib will be later described below. The 60% structural member 10 ^' includes a triangular rib portion 80 formed approximately centered between the inner perimeter portion 60 and lower straight portion 64. The triangular rib portion 80 includes generally a lower leg 84 substantially aligned with the base perimeter portion 54 and an inner leg 86 and outer leg 88 extending therefrom to an apex 82. As illustrated in FIG. 3, the apex 82 is substantially aligned with the latch member 22. An apex rib 90 extends from the apex vertice 82 upward to the upper perimeter portion 70 and the latch member 22 is located on the apex rib 90. The triangular rib portion 80 is illustrated generally as an equilateral triangle, although some variations may occur. The structural member 10 ^' also includes connecting ribs that extend from the intersection of the lower leg 84 and inner leg 86 in a first lower vertice 83 as well as the lower leg 84 and outer leg 88 in a second lower vertice 85. These connecting ribs 92 extend from the triangular rib portion 80 to the intersection between the outer base angle portion 56 and the outer perimeter portion 62 as well as the intersection between the inner base angled base 58 and inner perimeter portion 60. A pair of cross ribs, specifically a first cross rib 96 and a second cross rib 98, each extend approximately from the upper inner corner of the structural members as well as the upper outer corner of the structural members toward respectively the inner leg 86 and outer leg 88 of the triangular rib portion 80. More specifically, one of the cross ribs 96, 98 extends approximately from the intersection of the inner perimeter portion 60 and upper perimeter portion 70 of the outer perimeter rib 52 while the other of the cross ribs 96, 98 extends proximately from the intersection of the upper perimeter portion 70 and the transition portion 68 to the outer leg 88. More specifically, each of the cross ribs is aligned as if they were in an approximately x-pattem although they never specifically cross each other, if the cross ribs 100 were extended, they would form an x-pattern with the opposing end intersecting each of the outer base angle portion 56 and inner base angle portion 58. It should be noted that the inner leg 86 of the triangular rib portion 80, including one of the connecting ribs 92 extending toward the inner base angle portion 58 and the outer perimeter portion 62 on one of the cross ribs 100 generally forms a second triangular shape 102, which is similar to the first triangular shape formed on the base plane by the triangular rib 80. Likewise, the apex rib 92, one of the cross ribs 100 extending from the inner leg 86 of the triangular rib portion 80 and the upper perimeter portion 70 form an upper inner triangular shape 104 on the base plane 12. Due to the outwardly curved portion 60 of the outer perimeter portion 62, including the transition portion 68, two additional reinforcing ribs 1 10 are added which extend from one of the cross ribs 100 specifically to cross rib extending from the outer leg 88 of the triangular rib portion 80 toward the transition portion 68. One of the additional reinforcing ribs extends between the cross rib and the intersection of the outer curved portion 66 and lower straight portion 64 of the outer perimeter portion 62 while the other of the additional reinforcing ribs 1 10 extends generally from the cross rib 100 to the intersection of the apex rib 90 with the upper perimeter portion 70. The last described additional reinforcing rib 1 10 generally forms a triangular shape referred herein as the outer apex triangular shape 106 with the additional reinforcing rib, cross rib and apex rib 90 as its outer bounds.

[0021] The structural raised pattern 14 of the 40% structural member 10 ^" will now be described. As described above, the 40% structural member 10 ^" generally includes an outer perimeter portion 62 with one variation on the outer perimeter portion 62 as compared to the 60% structural member 10 ^' . On the outer perimeter rib 52, specifically the inner perimeter portion 60, a recessed, enlarged latch mounting area 120 is provided, whereas the latch on the 60% structural member 10 ^' is located on the apex rib 90. However, the latch mounting area 120 will have a less height from the base plane 18 than the inner perimeter portion 60, yet still has greater height from the base plane 18 than the upper perimeter portion 70. Extending from the intersection of the primary portion 124 of the inner portion 60 with the latch mounting area 120 is a primary cross rib 130 that extends downward and outwardly to the intersection with the outer base angle portion 56. Extending from the primary cross rib 130 are a plurality of perpendicular ribs 132 each defining a recessed portion 134 therebetween, specifically a first perpendicular rib 140, 142, 144, 146 and 148, respectively. The perpendicular ribs 132 include generally at least one rib intersecting the upper perimeter portion, at least one rib intersecting the outer perimeter portion, at least one rib intersecting the inner perimeter portion and at least one rib intersecting the base perimeter portion 54 specifically the inner base angle portion 58. As illustrated in FIGS. 2 and 4, an additional perpendicular rib is provided extending from the primary cross rib 130 to approximately the intersection of the upper perimeter portion 70 and outer perimeter portion 62 specifically the intersection between the transition portion 68 and upper perimeter portion 70. Therefore, three perpendicular ribs 132 may extend from the cross rib 130 outwardly and upwardly while two perpendicular ribs 132 extend from the cross rib downwardly and inwardly.

[0022] In addition, the design of the raised pattern 14 in combination with the top rail 20 reduces costs and mass by integrating the headrest locaters 16 and the related support features directly into the panel 10 eliminating the additional steps of welding brackets which add cost and weight. The structural member 10 may allow for various headrest locations including outboard and center headrest designs. The structural member 10 through minor variations of the raised pattern 14 illustrated in the Figures may be used with other proportions of seats than the illustrated 60/40 percent split configuration. The raised patterns illustrated in FIGS. 1 and 3 are particularly optimal for a 60% split configuration seat. The raised patterns 14 in FIGS. 2 and 4 are particularly optimal for a 40% split configuration seat. Of course, variations of the illustrated raised pattern may vary as the height or width of the seat structural member 10 is changed. The patterns may be used with minor variations or 50/50 percent split rear seats or 100 percent rear seats.

[0023] As the height or width of the vehicle structural member 10 is increased, generally the width and height of the raised pattern 14 increases proportionally. By increasing the width and height of the raised pattern 14, structural integrity is maintained.