An integrated rear seat for a vehicle and a method of assembling the same

Abstract

The whole automobile rear seat provided by the application comprises a rear seat cushion and a rear seat back connected with the rear seat cushion, and the two sides of the rear seat back are provided with seat rear side wings, and the seat rear side wings are internally provided with side wing air bag units, which can provide more accurate installation datum for air bag supports, ensure accurate positioning of air bag modules, effectively disperse and bear the huge impact force when the air bag is unfolded, avoid local stress concentration, ensure that the skeleton has no permanent plastic deformation at the moment of air bag detonation, effectively avoid secondary injury caused by deformation of vehicle body accessories, satisfy light weight reduction of seat side wings, greatly shorten the development cycle and reduce the cost.

Description

Technical Field

[0001] This invention belongs to the field of automotive passive safety component manufacturing technology. Specifically, this invention relates to an integrated automotive rear seat and its assembly method. Background Technology

[0002] As global automotive safety regulations continue to tighten, the 2025 version of the Chinese C-NCAP evaluation program, the 2026 European Union crash test standard, the stringent side impact test of the North American IIHS, and the new version of the Southeast Asian ASEAN NCAP regulations have all included side impact protection for second- and third-row rear passengers as core deduction items. The penetration rate of rear side airbag installation has increased to over 75% year by year. OEMs have put forward multiple hard indicators for the rear airbag installation frame: installation positioning tolerance ≤ 0.6mm, no permanent plastic deformation of the frame at the moment of airbag deployment, a 50% reduction in the structural modification cycle of vehicle model modification, an automated assembly qualification rate of ≥ 99.5% on the production line, a weight reduction of ≥ 80g for seat side wings, and no airbag loosening or displacement during long-term high and low temperature vibration.

[0003] Traditional rear seat side wing frame installation methods typically involve fixing the airbag bracket directly or via a connecting plate to the main frame of the seat back (usually a tubular or stamped part). This installation method has several drawbacks. First, as the main load-bearing structure, the manufacturing and assembly tolerances of the main frame are directly transmitted to the airbag bracket, affecting the final positioning accuracy of the airbag module. This may obstruct the airbag deployment path or interfere with interior trim components, affecting airbag deployment during a collision and reducing safety. Second, opening holes or welding connection points in the main frame may weaken its local strength or cause deformation upon airbag deployment, potentially leading to secondary injuries to rear passengers. Furthermore, once the airbag bracket's position is determined, its structure is tightly coupled to the main frame, making modifications extremely difficult and requiring a complete redesign of the entire backrest frame, resulting in poor design and modification flexibility. In summary, the traditional structural solution of directly attaching the airbag bracket to the seat main frame can no longer simultaneously meet all the above-mentioned requirements.

[0004] Therefore, in order to improve or solve at least one of the above problems, a one-piece automotive rear seat and its assembly method are provided that can provide a more accurate installation reference for the airbag bracket, ensure accurate positioning of the airbag module, effectively disperse and withstand the huge impact force when the airbag deploys, avoid local stress concentration, ensure no permanent plastic deformation of the frame at the moment of airbag deployment, effectively avoid secondary damage caused by deformation of vehicle body accessories, meet the requirements for lightweighting and weight reduction of the seat side wings, and greatly shorten the development cycle and reduce costs. Summary of the Invention

[0005] This invention addresses the aforementioned problems and aims to provide a one-piece automotive rear seat and its assembly method that offers a more accurate installation reference for the airbag support, ensures precise positioning of the airbag module, effectively disperses and withstands the enormous impact force during airbag deployment, avoids localized stress concentration, ensures no permanent plastic deformation of the airbag frame at the moment of airbag deployment, effectively prevents secondary injuries caused by deformation of vehicle body accessories, meets the requirements for lightweighting and weight reduction of the seat side wings, and significantly shortens the development cycle and reduces costs. To achieve the above objectives, the technical solution adopted by this invention is as follows: The present invention provides an integrated rear seat for automobiles, characterized by including a rear seat cushion and a rear seat back connected to the rear seat cushion, with rear seat side wings on both sides of the rear seat back and side wing airbag units inside the rear seat side wings.

[0006] The integrated rear seat of an automobile provided by the present invention may also have the following features: the rear seat back includes a backrest frame and a rear seat cushion disposed on the backrest frame; a seat back panel is provided on the side of the backrest frame away from the rear seat cushion; and the rear side wing of the seat is connected to the backrest frame.

[0007] The integrated rear seat of a car provided by the present invention may also have the following features: the rear side wing of the seat includes a side wing shell and a side wing foam disposed in the side wing shell, and the side wing shell is also provided with a side wing skin.

[0008] The integrated rear seat of a car provided by the present invention may also have the following features: a side wing mounting bracket is provided on the side wing shell, one side of the side wing mounting bracket is connected to the side wing shell, and the other side of the side wing mounting bracket is connected to the backrest frame.

[0009] The integrated rear seat of a car provided by the present invention may also have the following features: the side airbag unit includes an airbag bracket and an airbag module disposed on the airbag bracket, the airbag bracket is connected to a fixing component, and the fixing component is connected to the backrest frame and the side airbag foam.

[0010] The integrated rear seat of a car provided by the present invention may also have the following features: the fixing component includes a steel wire frame and a first connecting piece and a second connecting piece disposed on the steel wire frame, the first connecting piece being connected to the airbag bracket and the second connecting piece being connected to the side wing mounting bracket.

[0011] The integrated rear seat of an automobile provided by the present invention may also have the following features: the fixing assembly further includes a third connecting piece and a fourth connecting piece disposed on the wire frame, the third connecting piece being connected to the side wing foam, and the fourth connecting piece being connected to the side wing foam; the fixing assembly further includes a fifth connecting piece and a sixth connecting piece disposed on the wire frame, the fifth connecting piece being located on the side of the wire frame away from the side wing mounting bracket and connected to the backrest frame, and the sixth connecting piece being located on the side of the wire frame away from the side wing mounting bracket and connected to the backrest frame.

[0012] The integrated rear seat of the car provided by the present invention may also have the following features: the airbag bracket is an integral stamped sheet metal part; the wire frame is made of high carbon cold-drawn steel wire bent into shape, and the wire frame is used separately as a special mounting reference part for the airbag, and is separately assembled to the inner side of the main load-bearing frame of the seat back.

[0013] The integrated rear seat of a car provided by the present invention may also have the following feature: the side wing foam is provided with a wiring groove adapted to the wire frame, and the wire frame is embedded in the wiring groove.

[0014] The present invention also provides an assembly method for the above-mentioned integrated automotive rear seat, characterized by the following steps: Step S1, prefabrication and forming process of prefabricated parts; Step S2, pre-assembly process of side wing airbag unit; Step S3, side wing foaming and wire frame fitting process; Step S4, side wing shell assembly process; Step S5, backrest main frame assembly process; Step S6, seat cushion and backrest assembly process; Step S7, off-line inspection process.

[0015] The technical effects of this invention are as follows: The integrated rear seat of the automobile provided by this invention includes a rear seat cushion and a rear seat back connected to the rear seat cushion. The rear seat back is provided with rear seat side wings on both sides, and the rear seat side wings are provided with side wing airbag units. This can provide a more accurate installation reference for the airbag bracket, ensure the accurate positioning of the airbag module, effectively disperse and withstand the huge impact force when the airbag deploys, avoid local stress concentration, ensure that the frame does not undergo permanent plastic deformation at the moment of airbag deployment, effectively avoid secondary damage caused by deformation of vehicle body accessories, meet the requirements for lightweighting and weight reduction of the seat side wings, greatly shorten the development cycle and reduce costs. Attached Figure Description

[0016] This manual includes the following figures, which illustrate the following: Figure 1 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 2 ; Figure 3 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 3 ; Figure 4 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 1 ; Figure 5 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 2 ; Figure 6 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 3 ; Figure 7 This is a schematic diagram of the side airbag unit in an embodiment of the present invention. Figure 1 ; Figure 8 This is a schematic diagram of the side airbag unit in an embodiment of the present invention. Figure 2 .

[0017] The following are labeled in the diagram: Rear seat cushion-10, Rear seat backrest-20, Backrest frame-21, Rear seat cushion-22, Seat back panel-23, Rear seat side wing-30, Side wing shell-31, Side wing foam-32, Side wing skin-33, Side wing mounting bracket-34, Side wing airbag unit-40, Airbag bracket-41, Airbag module-42, Fixing component-43, Steel wire frame-431, First connecting piece-432, Second connecting piece-433, Third connecting piece-434, Fourth connecting piece-435, Fifth connecting piece-436, Sixth connecting piece-437. Detailed Implementation

[0018] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention, and to facilitate its implementation.

[0019] Figure 1 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 2 ; Figure 3 This is a schematic diagram of the structure of the integrated rear seat of a car in an embodiment of the present invention. Figure 3 .

[0020] like Figure 1 , Figure 2 as well as Figure 3As shown, the integrated rear seat of the automobile provided by the present invention includes a rear seat cushion 10 and a rear seat backrest 20 connected to the rear seat cushion 10. The rear seat backrest 20 has rear seat side wings 30 on both sides, and the rear seat side wings 30 have side wing airbag units 40 inside. This can provide a more accurate installation reference for the airbag bracket, ensure the accurate positioning of the airbag module, effectively disperse and withstand the huge impact force when the airbag deploys, avoid local stress concentration, ensure that the frame does not undergo permanent plastic deformation at the moment of airbag deployment, effectively avoid secondary damage caused by deformation of vehicle body accessories, meet the requirements of lightweight seat side wings, greatly shorten the development cycle and reduce costs.

[0021] The two sets of rear seat side wings 30 have completely identical structures and are symmetrically arranged, which can simultaneously achieve all-round side collision protection for occupants on both sides of the rear seats. The rear seat side wings 30 integrate side wing airbag units 40. As a core passive safety protection component, the side wing airbag units 40 can be inflated in a very short time of 15ms to 30ms when the vehicle is involved in dangerous situations such as side collision, side pole collision, and oblique side collision at intersection. They quickly form a flexible buffer barrier in the chest, abdomen, and hip areas of the rear occupants, effectively absorbing 30% to 50% of the lateral impact kinetic energy and reducing the risk of rib fractures, trunk contusions, and pelvic injuries. Among them, it can increase the side collision injury reduction rate of elderly passengers to more than 38% and reduce the probability of chest and abdominal injuries of children by 52%, which greatly improves the passive safety protection level of the rear seats of the vehicle.

[0022] The rear seat backrest 20 includes a backrest frame 21 and a rear seat cushion 22 set on the backrest frame 21. The rear seat side wings 30 are connected to the backrest frame 22. The backrest frame 21 is made of high-strength steel pipe bent and welded or high-strength steel sheet metal stamping. It provides static support and the main load bearing capacity of the vehicle collision for the entire rear seat backrest. It is the core main load-bearing frame structure of the seat. It mainly bears the static load of the occupants leaning against it, the main impact load of the frontal and side collisions of the vehicle, and does not participate in or directly bear the instantaneous impact load of the airbag deployment. It protects the mechanical performance of the main frame from the airbag system from the structural level.

[0023] A seat back panel 23 is fixedly mounted on the side of the backrest frame 21 away from the rear seat cushion 22. The seat back panel 23 is made of high-strength engineering plastic and is integrally injection molded. The surface is smooth and flat, which can achieve the effects of dustproof, sound insulation and beautiful covering of the seat back. At the same time, it can protect the back structure of the backrest frame 21 and avoid frame corrosion and abnormal noise caused by driving bumps and interior friction.

[0024] The rear seat side wings 30 are rigidly connected and fixed to the left and right sides of the backrest frame 21, forming an integrated backrest structure with the backrest frame 21, ensuring the overall rigidity and shape integrity of the rear seat, while also achieving stable integrated installation of the side wing airbag unit 40.

[0025] Figure 4 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 1 ; Figure 5 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 2 ; Figure 6 This is a schematic diagram of the structure of the rear seat side wing and side wing airbag unit in an embodiment of the present invention. Figure 3 .

[0026] like Figure 4 , Figure 5 as well as Figure 6 As shown, the rear seat side wing 30 includes a side wing shell 31 and a side wing foam component 32 disposed within the side wing shell 31. The side wing shell 31 is also provided with a side wing skin 33. As the core component for side protection of the rear seat, the rear seat side wing 30 adopts a three-layer composite structure of side wing shell 31, side wing foam component 32 and side wing skin 33. The side wing shell 31 provides rigid protection, the side wing foam component 32 provides support and cushioning, and the side wing skin 33 provides surface decoration and protection.

[0027] The side wing shell 31 is made of high-strength ABS and PC composite engineering plastic through one-piece injection molding. It has high strength, high toughness, anti-aging and high and low temperature resistance. It can withstand the interior squeezing, friction and minor bumps during vehicle operation. At the same time, it provides a stable cavity for the side wing foam 32 and the side wing airbag unit 40, ensuring the overall shape of the side wing is regular. The side wing foam component 32 is integrally molded with high-density polyurethane foam material and fills the internal cavity of the side wing shell 31. The foam density is precisely controlled between 32kg / m³ and 35kg / m³. It has the functions of flexible buffering, support and shaping, sound insulation and shock absorption, and wrapping and protection. On the one hand, it can improve the comfort of the rear seat side wing. On the other hand, it can achieve initial buffering and energy absorption in the early stage of side collision. At the same time, it forms a flexible wrapping and protection for the internal airbag unit, steel wire frame and connecting piece assembly, avoiding abnormal noise and corrosion of metal structure. At the same time, it reserves a precise airbag deployment channel to ensure that the airbag can smoothly break through the foam layer and the outer skin layer when it is deployed, without jamming or tearing. The side wing skin 33 is made of wear-resistant PVC leather or knitted fabric and is tightly attached to the outer surface of the side wing shell 31. It has the characteristics of wear resistance, wrinkle resistance, easy cleaning and strong weather resistance, which can improve the aesthetics of the interior and the driving experience. At the same time, as the outermost protective structure for airbag deployment, its tensile strength and tear strength have been specially matched and designed to crack in an orderly manner at the moment of airbag deployment, which not only ensures the smooth deployment of airbag, but also avoids the safety hazards caused by large-area skin splash.

[0028] The side wing shell 31 is equipped with a side wing mounting bracket 34, which is integrally stamped from cold-rolled steel plate, resulting in high structural rigidity and dimensional accuracy. This bracket provides a transitional support reference for the docking and assembly of the rear seat side wing 30 and the backrest frame 21. One side of the side wing mounting bracket 34 is rigidly fixed to the inner wall of the side wing shell 31 via bolts and snap-fit ​​locking, ensuring a secure and stable connection and effectively transferring the overall assembly load of the side wing. The other side of the side wing mounting bracket 34 extends outward to dock with the backrest frame 21, achieving precise positioning and assembly between the side wing shell 31 and the main frame. This ensures a smooth transition between the overall shape of the side wing and the main backrest body, without any steps, offset, loosening, or abnormal noise.

[0029] Figure 7 This is a schematic diagram of the side airbag unit in an embodiment of the present invention. Figure 1 ; Figure 8 This is a schematic diagram of the side airbag unit in an embodiment of the present invention. Figure 2 .

[0030] like Figure 7 and Figure 8 As shown, the side airbag unit 40 includes an airbag bracket 41 and an airbag module 42 mounted on the airbag bracket 41. The airbag bracket 41 is an integrally stamped sheet metal part, serving as the dedicated load-bearing and positioning structure for the airbag module 42. It undertakes the functions of all-round limiting, fixing, and load transfer of the airbag module 42, and is the core carrier to ensure the accurate deployment posture of the airbag. The airbag module 42 is a standardized mass-produced rear side airbag assembly, integrating core components such as a gas generator, sodium azide gas-generating agent, folding airbag, sealing protective cloth, and mounting base. In the event of a collision, it effectively protects the occupant's chest, ribs, abdomen, and pelvis, significantly reducing the risk of serious injury.

[0031] The airbag support 41 is connected to a fixing component 43, which is connected to the backrest frame 21 and the side wing foam component 32. The fixing component 43 includes a wire frame 431 and a first connecting piece 432 and a second connecting piece 433 disposed on the wire frame 431. The first connecting piece 432 is connected to the airbag support 41 and is rigidly locked to the airbag support 41 by bolts, providing a stable installation reference for the airbag support 41 and the airbag module 42, and preventing airbag assembly misalignment, loosening during use, and vibration drift. The second connecting piece 433 is arranged on the side of the wire frame 431 near the side wing mounting bracket 34 and is locked to the side wing mounting bracket 34 by bolts, realizing the rigid connection between the wire frame 431 and the side wing shell 31 and the side wing mounting bracket 34, ensuring that the internal airbag bearing structure and the external side wing shell structure are integrally formed, and improving the overall structural rigidity and shape stability of the side wing.

[0032] The fixing component 43 also includes a third connecting piece 434 and a fourth connecting piece 435 disposed on the wire frame 431. The third connecting piece 434 is connected to the side wing foam component 32, and the fourth connecting piece 435 is connected to the side wing foam component 32. The third connecting piece 434 and the fourth connecting piece 435 are foam-embedded fixing connecting pieces. The third connecting piece 434 and the fourth connecting piece 435 are symmetrically arranged on both sides of the middle part of the wire frame 431, and are simultaneously fixedly connected with the side wing foam component 32 through the built-in pre-embedded buckles and adhesive structure, so as to realize the integrated embedding and binding of the wire frame 431 and the side wing foam component 32. This effectively restricts the movement, displacement and vibration of the wire frame 431 inside the foam cavity, and completely eliminates the abnormal noise problem caused by the friction between the metal wire and the foam under the long-term bumpy and vibrating conditions of the vehicle. At the same time, the flexible wrapping characteristics of the foam component are used to form all-round anti-corrosion, anti-collision and anti-fatigue protection for the wire frame 431, welding points and connecting piece structure, which greatly improves the durability and service life of the structure. The parallel arrangement of the third connecting piece 434 and the fourth connecting piece 435 enables uniform force distribution on both sides, ensuring that the connection between the wire frame 431 and the side foam component 32 is free from unilateral pulling and local detachment, thus greatly improving structural stability.

[0033] The fixing component 43 also includes a fifth connecting piece 436 and a sixth connecting piece 437 disposed on the wire frame 431. The fifth connecting piece 436 and the sixth connecting piece 437 are the main frame docking connecting pieces. The fifth connecting piece 436 and the sixth connecting piece 437 are symmetrically arranged side by side on the wire frame 431 away from the side wing mounting bracket 34, belonging to the outer fixing point of the wire frame 431. They are specifically bolted to the preset mounting point on the inner side of the backrest frame 21 to achieve rigid docking and fixing of the entire fixing component 43, airbag unit 40, side wing assembly and main load-bearing frame. The parallel fixing structure of the fifth connecting piece 436 and the sixth connecting piece 437 can realize the double-point symmetrical force on the outer side of the wire frame 431, ensuring that the overall assembly of the wire frame 431 is flat, without skewing or warping, further improving the flatness and positioning accuracy of the airbag mounting reference, and at the same time, further dispersing the lateral collision load and improving the overall structural impact resistance.

[0034] By welding the first connecting piece 432, the second connecting piece 433, the third connecting piece 434, the fourth connecting piece 435, the fifth connecting piece 436, and the sixth connecting piece 437 onto the wire frame 431, a distributed, highly rigid connection point array is formed. This array can evenly distribute the enormous impact load and side collision intrusion load at the moment of airbag detonation to the entire area of ​​the wire frame 431 through six independent force transmission paths. Furthermore, the flexible buffering and full-area force transmission of the wire frame 431 completely eliminates local stress concentration, significantly improving the structure's impact resistance, fatigue resistance, and deformation resistance. During the development phase, the design and position of the airbag support 41 can be independently optimized by simply adjusting the shape of the wire frame 431 and the position of the connecting pieces, without altering the main frame. This greatly shortens the development cycle and reduces costs.

[0035] The 431 steel wire frame is formed by bending high-carbon cold-drawn steel wire. The steel wire material is selected from national standard high-quality 65# high-carbon cold-drawn carbon steel wire, with a preferred wire diameter of 4.5mm. The tensile strength is ≥1600MPa and the yield strength is ≥1400MPa. It has the characteristics of high strength, high toughness, low springback, and excellent dimensional stability, completely breaking the traditional technical prejudice in the industry that "small-diameter steel wire cannot bear the impact load of airbag deployment". The 431 steel wire frame is an independent and dedicated airbag installation reference component. It is completely assembled separately to the inside of the main load-bearing frame of the seat back, without rigid coupling with the main frame and without transmitting impact load. It truly achieves independent reference and mechanical decoupling, eliminating the problems of tolerance transmission and weakening of the main frame from the root.

[0036] The side wing foam component 32 is equipped with a wiring groove that is compatible with the wire frame. The wiring groove is perfectly matched with the outer contour of the wire frame 431. The wire frame 431 is embedded in the wiring groove. The wiring groove is integrally formed by foaming mold. The contour, depth and width of the groove are precisely matched with the wire frame 431. The wire frame 431 is embedded in the wiring groove, realizing a gapless fit between the wire frame 431 and the side wing foam component 32. The wiring groove can limit the wire frame 431, completely eliminating the displacement, shaking and rotation of the wire frame 431 inside the side wing foam component 32, ensuring the long-term stability of the airbag reference. The wiring groove can form a full-round protection for the wire frame 431, avoiding the exposure of the metal structure, corrosion, abnormal noise and wear. The wiring groove also helps to constrain the airbag deployment channel, ensuring that the airbag deploys in an orderly manner along the preset trajectory when it is deployed, further avoiding the risk of interference and jamming of the interior.

[0037] The present invention also provides an assembly method for the above-described integral rear seat of an automobile, characterized by the following steps: Step S1 involves the prefabrication and forming of components, including the backrest frame 21, seat back panel 23, side wing shell 31, side wing foam 32, side wing skin 33, and side wing mounting bracket 34. Simultaneously, high-carbon cold-drawn steel wire is CNC bent into a wire frame 431. At preset points on the wire frame 431, resistance welding is used to weld the first connecting piece 432, the second connecting piece 433, the third connecting piece 434, the fourth connecting piece 435, the fifth connecting piece 436, and the sixth connecting piece 437. After welding, the components undergo three-coordinate dimensional inspection and electrophoretic corrosion protection to obtain a semi-finished integrated fixing component 43. A separate stamping process is used to prepare the integrated sheet metal airbag bracket 41, followed by deburring and electrophoretic corrosion protection.

[0038] Step S2, the pre-assembly process of the side airbag unit, involves snapping and limiting the airbag module 42 into the internal limiting structure of the airbag bracket 41 to form the airbag pre-assembly sub-assembly; and locking the airbag bracket 41 to the first connecting piece 432 on the wire frame 431 with standard bolts to complete the pre-assembly assembly of the side airbag unit and the fixing component 43.

[0039] Step S3, the process of fitting the side wing foam and the wire frame 431: A wiring groove matching the contour of the wire frame 431 is opened on the side wing foam 32, and the wire frame 431 with the airbag unit assembled is embedded into the wiring groove; the third connecting piece 434 and the fourth connecting piece 435 are used to bond and fix the wire frame 431 and the side wing foam 32 with the built-in pre-embedded buckles, so as to realize the integrated binding of the wire frame 431 and the side wing foam 32.

[0040] Step S4, side wing housing 31 assembly process: The side wing mounting bracket 34 is fixedly assembled to the inner wall of the side wing housing 31; the side wing foam component 32, which is used to bind the steel wire frame 431 and the airbag unit, is placed into the side wing housing 31 as a whole, and is bolted to the side wing mounting bracket 34 through the second connecting piece 433, so that the fixing component 43, the airbag unit, the side wing foam component 32, and the side wing housing 31 form a complete side wing assembly; finally, the side wing skin 33 is covered and attached to the outer surface of the side wing housing 31 to complete the overall prefabrication of the rear side wing of one side seat.

[0041] Step S5, backrest main frame assembly process: The rear seat cushion 22 is assembled and fixed to the front of the backrest frame 21, and the seat back panel 23 is assembled on the back of the backrest frame 21; the prefabricated rear seat side wings on both sides are connected to the left and right sides of the backrest frame 21, and the fifth connecting piece 436 and the sixth connecting piece 437 on the outer side of the wire frame 431 are bolted to the backrest frame 21 to achieve rigid connection between the side wing assembly and the backrest frame 21.

[0042] Step S6, seat cushion and backrest assembly process: The bottom hinge and buckle structure of the fully assembled rear seat backrest 20 is connected and assembled with the rear seat cushion 10. After adjusting the backrest rotation gap and locking stroke, the fastening is completed to obtain the finished one-piece car rear seat. Step S7, the offline inspection process, involves conducting dimensional accuracy testing, airbag installation coordinate verification, vibration durability simulation testing, and appearance covering integrity testing on the finished seats. After passing the inspection, the seats are put into storage.

[0043] This invention addresses a series of industry pain points commonly found in existing integrated automotive rear seat side wing airbag installation structures, including large installation benchmark deviations, insufficient frame rigidity, significant stress concentration, easy deformation upon collision, high modification and development costs, poor mass production consistency, insufficient lightweighting, and weak durability and reliability. It innovatively proposes a multi-connector distributed steel wire welding benchmark structure. Through a completely new overall seat structure layout, airbag load-bearing decoupling design, multi-point three-dimensional connection system, and modular pre-assembly process, this invention systematically solves the inherent technical defects of traditional rear seat side wing airbag seats from six dimensions: structural mechanics, manufacturing precision, platform development, mass production process, durability and safety, and lightweighting and energy saving.

[0044] This invention differs from the outdated structural form of traditional seat main frame bearing airbag impact, single / two-point centralized connection, and sheet metal stacking transition. It adopts an independent high-precision steel wire frame as the exclusive installation benchmark for airbags, and is equipped with six sets of differentiated functional connecting pieces to construct a three-dimensional distributed bearing point matrix. This achieves layered mechanical decoupling and precise positioning coordination of airbag unit, side wing assembly, backrest frame, and foam interior, which greatly improves the passive safety performance of rear seat side collisions, product iteration efficiency, and industrial mass production quality.

[0045] The integrated rear seat of an automobile provided by the present invention includes a rear seat cushion 10 and a rear seat backrest 20 connected to the rear seat cushion 10. The rear seat backrest 20 has rear seat side wings 30 on both sides, and the rear seat side wings 30 have side wing airbag units 40. This can provide a more accurate installation reference for the airbag bracket, ensure the accurate positioning of the airbag module, effectively disperse and withstand the huge impact force when the airbag deploys, avoid local stress concentration, ensure that the frame does not undergo permanent plastic deformation at the moment of airbag deployment, effectively avoid secondary damage caused by deformation of vehicle body accessories, meet the requirements of lightweight seat side wings, greatly shorten the development cycle and reduce costs.

[0046] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A one-piece rear seat for automobiles, characterized in that, It includes a rear seat cushion (10) and a rear seat backrest (20) connected to the rear seat cushion (10). The rear seat backrest (20) has rear seat side wings (30) on both sides, and the rear seat side wings (30) have side wing airbag units (40) inside.

2. The integrated rear seat for automobiles according to claim 1, characterized in that, The rear seat backrest (20) includes a backrest frame (21) and a rear seat cushion (22) disposed on the backrest frame (21). A seat back panel (23) is provided on the side of the backrest frame (21) away from the rear seat cushion (22). The rear seat side wing (30) is connected to the backrest frame (21).

3. The integrated rear seat for automobiles according to claim 2, characterized in that, The rear seat side wing (30) includes a side wing housing (31) and a side wing foam (32) disposed in the side wing housing (31), and the side wing housing (31) is also provided with a side wing skin (33).

4. The integrated rear seat for automobiles according to claim 3, characterized in that, The side wing housing (31) is provided with a side wing mounting bracket (34), one side of the side wing mounting bracket (34) is connected to the side wing housing (31), and the other side of the side wing mounting bracket (34) is connected to the backrest frame (21).

5. The integrated rear seat for automobiles according to claim 4, characterized in that, The side airbag unit (40) includes an airbag bracket (41) and an airbag module (42) disposed on the airbag bracket (41). The airbag bracket (41) is connected to a fixing component (43), which is connected to the backrest frame (21) and the side airbag foam (32).

6. The integrated rear seat for automobiles according to claim 5, characterized in that, The fixing component (43) includes a wire frame (431) and a first connecting piece (432) and a second connecting piece (433) disposed on the wire frame (431). The first connecting piece (432) is connected to the airbag bracket (41), and the second connecting piece (433) is connected to the side wing mounting bracket (34).

7. The integrated rear seat for automobiles according to claim 6, characterized in that, The fixing component (43) further includes a third connecting piece (434) and a fourth connecting piece (435) disposed on the wire frame (431). The third connecting piece (434) is connected to the side wing foam (32), and the fourth connecting piece (435) is connected to the side wing foam (32). The fixing component (43) further includes a fifth connecting piece (436) and a sixth connecting piece (437) disposed on the wire frame (431). The fifth connecting piece (436) is located on the side of the wire frame (431) away from the side wing mounting bracket (34) and is connected to the backrest frame (21). The sixth connecting piece (437) is located on the side of the wire frame (431) away from the side wing mounting bracket (34) and is connected to the backrest frame (21).

8. The integrated rear seat of a car according to claim 7, characterized in that, The airbag bracket (41) is an integral stamped sheet metal part; the wire frame (431) is formed by bending high carbon cold-drawn steel wire, and the wire frame (431) is used as a special installation reference part for airbags and is separately assembled to the inner side of the main load-bearing frame of the seat back.

9. The integrated rear seat of a car according to claim 8, characterized in that, The side wing foam component (32) is provided with a wiring groove that is compatible with the wire frame (431), and the wire frame (431) is embedded in the wiring groove.

10. A method for assembling an integral rear seat for an automobile according to any one of claims 1 to 9, characterized in that, Includes the following steps: Step S1, prefabrication and forming process of prefabricated parts; Step S2, pre-assembly process of side airbag unit; Step S3, side airbag foaming and wire frame fitting process; Step S4, side airbag assembly process; Step S5, backrest main frame assembly process; Step S6, seat cushion and backrest assembly process; Step S7, off-line inspection process.

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