Support assembly, vehicle seat with facility and removal function, and method for manufacturing

Abstract

The invention relates to a support assembly, a vehicle seat with a convenient access function and a method for manufacturing the support assembly. The invention relates to a support assembly (16) for a vehicle seat (10) having a convenient access function, comprising a transmission mechanism (28), in particular an oscillating transmission mechanism for adjusting the inclination of a seat back (14), having a hollow wheel extending along a central axis (M) in an axial direction (A), according to the invention, a journal (22) having a bearing surface (24) for pivoting the seat back (14) is formed on an end wall (35) of the hollow wheel, said journal forming, with the hollow wheel, an integral bearing hollow wheel (26) which is formed in particular by means of cold extrusion with subsequent cutting-type reworking. High stability is achieved with small tolerances by means of the integral construction.

Description

Technical Field

[0001] The invention relates to a support assembly for a vehicle seat with an easy entry and exit function, such a vehicle seat and a method for producing such a support assembly. Background Art

[0002] Seats with an easy entry / exit function facilitate access to rear seats, such as the second or third row. To access seats in the front area or even in the third row, the seat backrest of the front seat is tilted down (the so-called easy entry / exit function). In addition to this tilting mechanism, the seat backrest is typically equipped with a conventional tilt adjustment mechanism. To tilt the seat backrest, a locking mechanism is unlocked, allowing the backrest to pivot about its bearings and thus tilt down. A drive mechanism with a transmission, typically a swing-type transmission, is typically designed for conventional tilt adjustment.

[0003] To achieve these functions—on the one hand, tilting the seat backrest and on the other hand, conventional inclination adjustment—various solutions for bearing assemblies are known on the market. In these solutions, the transmission for adjusting the inclination, in particular a swivel transmission, has an outer wheel extending along the central axis and in the axial direction and configured as a hollow wheel. This outer wheel typically has an internal toothing that meshes with the outer toothing of the inner wheel. Two such bearing assemblies are usually mounted opposite each other on the vehicle seat and connected to each other via a synchronizing shaft, also known as a reclining shaft.

[0004] A bearing region of a backrest component for supporting a seat backrest is usually connected to this ring gear in the axial direction.

[0005] Another solution combined Figure 4 Diagrammatically illustrated. This figure shows a half-section of the internal gear 2 extending in the axial direction A along the central axis M. The internal gear 2 is designed as a stamped part, in which a stepped ring 4 is stamped out of an initially approximately disk-shaped component and slightly offset in the axial direction A. The stepped ring 4 is connected to the remaining components in a form-fitting manner via a toothing 6. A support ring 7 is formed on this stamped, axially displaceable ring 4 as a support area. A backrest component 8 is supported on this support area and is secured in the axial direction by a welded axial stop 9.

[0006] Both solutions have disadvantages especially in terms of stability, in particular in terms of adequate crash safety. Figure 4The variant shown in FIG2 shows the weak structure caused by stamping and, in particular, the fact that the toothing has only a small material thickness in the connection area between the stamped and axially displaceable ring 4 and the remaining external components. Due to manufacturing constraints, the support width is also limited. Furthermore, due to the welded axial stop 9 and the weld seam required for this, an undesirable axial gap exists for supporting the backrest component 8.

[0007] The bearing diameter is generally limited by the separately welded bearing component in the first variant. Increasing the bearing diameter to increase stability leads to increased costs and, for example, poorer tolerances regarding the concentricity of the welded bearing component relative to the ring gear, which is detrimental to overall quality. This variant also has a large axial extension, which is disadvantageous when installation space is limited. Summary of the Invention

[0008] Based on this, the object of the present invention is to specify a support assembly for a vehicle seat with an easy entry and exit function, such a vehicle seat, and a method for producing such a support assembly with high stability.

[0009] According to the present invention, this object is achieved by a support assembly for a vehicle seat with an easy entry and exit function, the support assembly comprising a transmission mechanism, in particular a pivoting transmission mechanism for adjusting the inclination of a seat portion, in particular a seat backrest, wherein the transmission mechanism comprises a hollow gear extending axially along a central axis, the hollow gear generally forming the outer gear of the transmission mechanism. A journal having a bearing surface for pivotally supporting the seat backrest is formed on the end wall of the hollow gear, the journal and the hollow gear forming a one-piece supporting hollow gear.

[0010] The object is also achieved by a vehicle seat having such a support assembly, which is designed for easy entry and exit. The seat backrest is, in particular, pivotally mounted on the seating part via the support assembly. Typically, two such support assemblies are mounted opposite each other laterally on the vehicle seat.

[0011] Finally, the object is also achieved by a method for producing such a bearing assembly, in which a one-piece bearing ring is produced, which has an end wall with a journal with a bearing surface integrally formed thereon.

[0012] The advantages and preferred embodiments explained below with respect to the support assembly can also be applied to the vehicle seat and / or the method in the same manner. The same applies in reverse, that is, the advantages and preferred embodiments explained below with respect to the method or the vehicle seat can also be applied to the support assembly in the same manner.

[0013] This supporting ring gear thus has a dual function and forms part of the gear mechanism, in particular the outer wheel, for adjusting the inclination, wherein the axle journal is simultaneously formed by the integral component. The supporting ring gear has, in particular, an internal toothing on its inner side, which meshes with the external toothing of the inner wheel of the gear mechanism in the assembled state.

[0014] The integral integration of the bearing function into the ring gear achieves a particularly high degree of stability. In this context, "integral" refers to a one-piece design, meaning that multiple components are not subsequently joined together, for example, by welding or other material-locking connections. In particular, a common joint structure of materials forms the integral bearing ring gear. In particular, a stamping process is unnecessary for forming the geometry of the integral bearing ring gear, particularly for forming the journals, since this process results in material separation and weakening.

[0015] The supporting ring gear is usually produced here from a metal, in particular one with high hardness, such as steel.

[0016] The design as a one-piece component offers significantly more design freedom, which can be fully utilized due to the particularly stable construction. Compared to stamped hollow gears, as described at the outset, weak areas can be avoided. With this one-piece component, the bearing diameter can also be easily selected without incurring additional costs. Furthermore, the one-piece design allows for high tolerance accuracy even with large bearing diameters.

[0017] In a suitable embodiment, the one-piece support ring gear is designed as a monolithic component, more specifically, as a cold-extruded component. The cold-extruded method allows the one-piece support ring gear to be manufactured from a hard material with high rigidity, resulting in particularly good mechanical stability. The cold-extruded method is preferred over alternative production methods for forming a monolithic component, such as casting or 3D printing, although these alternative production methods are generally also contemplated.

[0018] In this type of mass-forming, particularly cold extrusion, a raw component with a predetermined geometry is produced from a disk-shaped blank, for example, as a starting component, by mass-forming it in an extrusion process, usually without external heating of the blank. The raw component already has at least approximately the desired geometry of a bearing ring with a particularly conical initial bearing journal formed on the end wall. The raw component itself is thus already designed as a ring gear, particularly with an internal toothing on the inside and with the initial bearing journal on the end wall. During this extrusion process, the material flows, thereby forming the geometry. A die is used in the extrusion process, which defines the desired geometry of the raw component and into which the raw component is pressed.

[0019] Due to manufacturing constraints, the shaping of the initial component takes into account certain edge conditions, for example, so that the material can flow into the desired areas and, in particular, so as not to cause damage in the internal joint structure, such as (micro)cracks, etc. Sharp edges or strong deflections can therefore have a negative impact on the quality of the initial component produced.

[0020] Therefore, in a practical design, as described above, a starting component is first formed during the manufacturing method, the shape of which only resembles the desired final shape of the bearing ring. This particularly concerns the design of the journal with the bearing surface, which is particularly critical due to tolerances. As described above, initially, only a starting journal with an oversized portion is formed at the location of the subsequent journal, the oversized portion being particularly conical and thus tapering. This starting journal is then re-machined by cutting, thereby removing material and thus producing the bearing surface.

[0021] The bearing surface is thus generally formed by chip-removing machining of the original journal and, therefore, also of the journal. Chip-removing machining generally refers to a manufacturing method in which material is mechanically removed. Chip-removing machining particularly refers to turning, in particular rounding. Grinding also belongs to chip-removing machining.

[0022] In a suitable embodiment, the journal is stepped in the direction of the center axis, wherein a support ring is formed adjacent to the bearing surface and is set back radially inwards from the bearing surface. This support ring is preferably also formed by machining.

[0023] In a suitable embodiment, an axial locking element, in particular a locking ring for axially locking a seat component supported on an axle journal, is attached to this support ring, or more precisely to its circumferential surface. The seat component, in particular the backrest component, in particular an annular flange designed in the manner of an adapter, is fastened to this annular flange.

[0024] This multi-step design of the journal is made possible by a three-dimensional, monolithic component, in particular produced by reshaping. The particular advantage of the additional support ring, which forms the front end of the supporting ring in the axial direction, is that it achieves particularly high precision in axial positioning, thereby enabling a support that is as close to the axial direction as possible. The retaining element is hereby fixed to the support ring in an orientation-fixed manner, in particular by welding, wherein the weld seam is formed in particular between the retaining element and the support ring, or more precisely, in the radial gap between these two components. This achieves a high degree of axial positioning accuracy. The retaining element rests in particular on the axial, annular end wall of the journal, which forms the step between the bearing surface and the circumferential surface of the support ring and connects these two surfaces to one another in the radial direction.

[0025] In a preferred embodiment, the end wall is formed smoothly and without recesses on the inner side of the bearing ring facing away from the journal. This inner side thus forms a flat surface oriented perpendicular to the axial direction in a preferred embodiment. This measure achieves a particularly high stability. This smooth design is particularly effective for Figure 4 This is not possible with the described known designs using a stamped hollow gear and a further formed bearing ring, since the bearing ring is formed by stamping out a central sub-region, so that the bearing region is necessarily designed only as a hollow ring. In contrast, the entire bearing region, i.e., the journal, is now designed as a single piece and, in particular, does not have a cavity and is therefore not designed as a hollow journal.

[0026] In a preferred embodiment, the bearing ring gear generally has no weak areas. This is understood to mean that in the transition region to the journal, the wall thickness does not fall below the (minimum) wall thickness of the end wall in the region radially spaced from the journal. The minimum wall thickness (which to some extent defines a reference for possible weak areas) is measured radially spaced from the journal and particularly in the radially outermost region of the end wall, after which an axially extending, typically bushing-like section (the inner wall of which forms the internal toothing) is connected to the end wall.

[0027] The particular advantage of the integral design is, of course, that, for example, Figure 4 In contrast to the stamped hollow gear explained at the outset with respect to the prior art, no weak points are formed in this transition region to the journal (such as would be produced by axial displacement of the stamped component due to manufacturing limitations).

[0028] In a preferred embodiment, the bearing surface forms a bearing diameter greater than 40 mm, and in particular greater than 45 mm. For example, the bearing surface has a bearing diameter of up to 55 mm, and preferably 47 mm. By designing the component as a single piece, such a large bearing diameter can be achieved in a particularly simple design without risking adverse tolerance effects. The large bearing diameter results in a high overall stability and, therefore, also a high crash safety.

[0029] The support assembly also has a releasable locking mechanism that prevents the seat back from pivoting about the axle journal and can be released when necessary, i.e., to implement the easy entry and exit function. This locking mechanism is often simply referred to as a lock and is typically present in such easy entry and exit seats. It is actuated, for example, by a cable mechanism.

[0030] In an expedient embodiment, a shaft, more precisely a synchronizing shaft, which serves to synchronize the rotational position with the opposing second bearing assembly, is also guided through the internal gear.

[0031] When the vehicle seat is installed, two opposing bearing assemblies are therefore connected to one another by means of such a synchronized shaft, also referred to as a reclining shaft. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Next, embodiments of the present invention will be explained in more detail with the aid of the accompanying drawings, in which:

[0033] Figure 1 shows a simplified side view of a vehicle seat;

[0034] Figure 2 shows a cross-sectional view of the support assembly;

[0035] Figure 3 An enlarged view is shown in the region of the bearing ring of the bearing assembly; and

[0036] Figure 4 A known bearing assembly is shown. DETAILED DESCRIPTION

[0037] exist Figure 1The vehicle seat 10 is shown in a greatly simplified form in FIG. This vehicle seat comprises a seating part 12 and a seat back 14 which is pivotally mounted on the seating part 12 via two opposing support assemblies 16 arranged at the edges. The vehicle seat 10 is mounted on a rail system 17 for longitudinal adjustment. The vehicle seat 10 can be equipped with an easy entry and exit function and can be tilted forward in the direction of the seating part 12 along the double arrow as a supplement to the normal inclination adjustment of the seat back 14. For this purpose, a locking mechanism 18 for releasing the pivotability is released. This locking mechanism 18 is known in principle and is known in the art. Figure 2 The area is formed by the dotted rectangle.

[0038] In order to allow the seat back 14 to pivot, the backrest component 20 is supported at the journal 22 in a manner that allows it to swing on a radial support surface 24 (annular surface) of the journal 22. The support surface 24 defines a support diameter d, which is particularly greater than 45 mm. In the embodiment, a support bushing 25 is also provided for support, into which the backrest component 20 is inserted. The support bushing 25 is configured to be U-shaped when viewed in a half-section. The backrest component 20 is an adapter configured in the form of a flange, and the remaining components of the seat back 14 are fastened to the adapter.

[0039] The journal 22 is part of a one-piece, cold-extruded bearing ring 26. This part forms the outer gear of a gear mechanism 28, which is usually designed as a pendulum gear mechanism, also known as a pendulum fitting. For this purpose, the bearing ring 26 has a typically cylindrical bushing 30, which has an internal toothing 32 on its inner surface. An inner gear 34 with a corresponding external toothing meshes with this inner toothing.

[0040] The bushing portion 30 is delimited in the axial direction A by an end wall 35 extending in the vertical direction, from which the journal 22 emerges. The journal is generally annular in shape.

[0041] The supporting ring gear 26 generally extends in the axial direction A along a central axis M. The supporting ring gear 26 is arranged concentrically with respect to this central axis M.

[0042] The supporting ring gear 26 forms a central, bushing-like bearing section 36 as a component of the integral supporting ring gear 26, through which a synchronizing shaft 38 is passed in the exemplary embodiment. In the installed state, this synchronizing shaft connects the two opposing supporting assemblies 16 to one another and ensures a consistent rotational position of the two supporting assemblies 16.

[0043] The synchronizing shaft 38 is guided through a separate shaft bushing 40 , which is inserted into the bushing-like bearing section 36 .

[0044] The backrest component 20 is stopped in the axial direction A by an axial stop element 42, which is in particular designed as an annular disk. The axial stop element 42 is fixed to the shaft journal 22, more precisely to the end-side support ring 44, more precisely by a weld 46. This weld is formed on the radial circumference of the support ring 44 between this support ring and the stop element 42. As a result, a high axial positioning accuracy of the stop element 42 can be achieved, and the backrest component 20 is therefore supported axially without play.

[0045] The integral structure of the supporting ring gear 26 also allows good Figure 3 See the enlarged image:

[0046] The supporting ring gear 26 is formed as a one-piece component in the exemplary embodiment from the following components:

[0047] A radially outer bushing part 30 with an internal toothing 32, an opposite and radially inner bushing-like bearing section 36, an end wall 35 connecting the bushing part 30 and the bearing section 36 to one another, and a journal 22 extending from the end wall 35 in the axial direction A. Overall, an annular cavity is formed between the bushing part 30 and the bearing section 36, in which cavity the inner wheel 34 is arranged.

[0048] The journal 22 is designed in a stepped manner, with a first step, which begins at the end wall 34 and has the bearing surface 24. A second step, on which a support ring 44 is formed, adjoins the first step, set back radially inwards, and the retaining element 42 is mounted on the circumferential surface of the support ring. This retaining element, in particular, rests directly on a radially extending annular surface that connects the circumferential surface to the bearing surface 24.

[0049] The one-piece support ring gear 26 is designed, in particular, as a cold-extruded component and subsequently re-machined by cutting. This manufacturing method achieves a particularly strong and stable structure. It should be emphasized that the support ring gear 26 has no weak areas, that is, in particular, no material thinning in the transition area 48 from the end wall 35 to the journal 22. This transition area is understood to be the area of ​​the end wall 35 that directly adjoins in the radial direction.

[0050] The end wall 35 preferably has a constant, constant thickness D in the embodiment. It should be emphasized that this thickness D does not change in the transition region 48 as in the connection region 48. Figure 4 As in the case of the explained known embodiment.

[0051] It should also be emphasized that the entire journal 22 is solid and not designed as a hollow element with an internal cavity. In a preferred embodiment, the inner side 50 of the end wall 35 facing away from the journal 22 has no recess extending into the journal 22. This inner side 50 is in particular designed as a flat surface that extends continuously in the radial direction from the bearing section 36 to the bushing part 30.

[0052] To produce the supporting ring gear 26, proceed as follows:

[0053] First, from a blank (not shown in detail here), in particular in the form of a disk and in particular a perforated disk, a raw component 52 is formed by integral shaping, more precisely in particular by cold stamping, in which the journal 22 is not yet formed, but only the raw journal 54, in particular tapering conically, is formed. Figure 3 As shown by the hatched conical sub-region in FIG. In the original component 52 , the other contours of the supporting ring gear 26 are preferably already formed, ie, in particular the contours with the bushing part 30 and the supporting section 36 , the inner toothing 32 and the smooth inner side 50 .

[0054] The shaded conical sub-region is subsequently removed by chip-cutting remachining, in particular by turning, so that a stepped design of the journal 22 with the bearing surface 24 and the support ring 44 is obtained.

[0055] Reference Signs List

[0056] 2 hollow wheel

[0057] 4 rings

[0058] 6 teeth

[0059] 7 support ring

[0060] 8 backrest components

[0061] 9Axial stop structure

[0062] 10 vehicle seats

[0063] 12 Ride section

[0064] 14 Seat back

[0065] 16 support components

[0066] 17-track system

[0067] 18 locking mechanism

[0068] 20 backrest components

[0069] 22 journal

[0070] 24 support surfaces

[0071] 25 support bushing

[0072] 26 supporting hollow wheel

[0073] 28 transmission mechanism

[0074] 30 bushing part

[0075] 32 internal teeth

[0076] 34 inner wheel

[0077] 35 end wall

[0078] 36 support sections

[0079] 38 Synchronous shaft

[0080] 40 shaft bushing

[0081] 42 axial stop element

[0082] 44 support ring

[0083] 46 welding department

[0084] 48 Transition Area

[0085] 50 inside

[0086] 52 original components

[0087] R, M central axis

[0088] A axial direction

[0089] dSupport diameter

[0090] D Wall thickness

Claims

1. A support assembly (16) for a vehicle seat (10) with an easy entry and exit function, the support assembly comprising a transmission mechanism (28), in particular a swing transmission mechanism for adjusting the inclination of a seat backrest (14), the transmission mechanism comprising a hollow wheel extending in an axial direction (A) along a central axis (M), characterized in that A journal (22) having a support surface (24) for pivotally supporting the seat back (14) is formed on the end wall (35) of the hollow wheel, and the journal and the hollow wheel form an integral supporting hollow wheel (26).

2. Support assembly (16) according to the preceding claim, characterized in that The one-piece supporting ring gear (26) is designed as a one-piece formed component and in particular as a cold-extruded component.

3. A support assembly (16) according to any one of the preceding claims, characterized in that The bearing surface (24) is formed by machining the journal (22).

4. A support assembly (16) according to any one of the preceding claims, characterized in that The journal (22) is designed to be stepped in the direction of the center axis (M) and forms a recessed support ring (44) adjoining the bearing surface (24).

5. Support assembly (16) according to any one of the preceding claims, characterized in that An axial locking element (42) for axially locking a seat component (20) supported on the journal (22) is fastened to the circumferential surface of the support ring (44).

6. Support assembly (16) according to any one of the preceding claims, characterized in that The end wall (35) is formed smoothly and without recesses on the inner side (50) of the supporting ring gear (26) facing away from the axle journal (22).

7. Support assembly (16) according to any one of the preceding claims, characterized in that The bearing ring gear (26) has no weak areas and the end wall (35) radially spaced apart from the journal (22) has a particularly minimum wall thickness (d), which is not fallen below in a transition region (48) radially directly adjacent to the journal.

8. Support assembly (16) according to any one of the preceding claims, characterized in that The bearing surface (24) forms a bearing diameter (D) greater than 40 mm and in particular greater than 45 mm.

9. Support assembly (16) according to any one of the preceding claims, characterized in that A releasable locking mechanism (18) is formed, which prevents the seat back (14) from being pivotable about the journal (22).

10. Support assembly (16) according to any one of the preceding claims, characterized in that A shaft, in particular a synchronization shaft (38) for synchronization with an opposing second bearing assembly (16), is guided through the bearing ring gear (26).

11. A vehicle seat (10) with an easy entry and exit function, comprising a seating portion (12) and a seat back (14) mounted in a swingable manner at the seating portion, the vehicle seat having a support assembly (16) according to any one of the preceding claims.

12. Method for producing a bearing assembly (16) according to any one of the preceding claims, wherein: A one-piece supporting ring gear (26) is produced, which has an end wall (35) with a journal (22) formed thereon, the journal having a supporting surface (24).

13. A method according to the preceding claim, in which, in order to construct the supporting hollow wheel (26), a blank, in particular a disk-shaped blank, is first subjected to a one-piece reshaping, in particular a cold stamping reshaping, thereby forming a raw component (52), which has a raw journal, in particular a cone, at the end wall, which has an oversized portion, at which material is removed by subsequent chip-cutting remachining and the supporting surface (24) is produced.

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