Seat arrangement with glued brackets

Abstract

Seating arrangement (10), comprising: a seat (12) comprising: a seat shell (44) formed of carbon fiber and having a first lateral side wall (56) and a second lateral side wall (58) spaced from and opposite the first lateral side wall (56), a first side member (46) bonded to an inner side (80) of the first lateral side wall (56) facing the second lateral side wall (58) by means of an adhesive (90), and a second side member (48) bonded to an inner side (80) of the second lateral side wall (58) facing the first lateral side wall (56) by means of an adhesive (90), wherein the first side member (46) and the second side member (48) are formed of metal, and a seat back (14) pivotally mounted on the seat surface (12), the seat back (14) comprising: a seat back shell (164) formed from carbon fiber, a first clamp (166) which is glued to the seat back shell (164) by means of an adhesive (90), and a second bracket (168) spaced from the first bracket (166) and bonded to the seat back shell (164) by means of an adhesive (90), the first bracket (166) and the second bracket (168) being formed of metal.

Description

TECHNICAL FIELDThe present invention relates to a seat assembly that may include brackets adhered to a shell such as a carbon fiber shell.BACKGROUNDA vehicle seat with a fiber-reinforced plastic reinforcement section is disclosed in U.S. Pat. No. 8,985,696 B2. US 2016 / 0 221 485 A1 discloses a reinforcing system for vehicle seats.SUMMARYThe object of the present invention is to improve reinforcements of seat arrangements. This object is achieved by a seat arrangement according to claim 1 or a seat arrangement according to claim 10. The seat assembly may include a seat bottom and a seat back. The seat bottom may include a seat bottom shell, a first side member, and a second side member. The seat bottom shell may be formed of carbon fiber and may include a first lateral sidewall and a second lateral sidewall. The second lateral sidewall may be spaced apart from the first lateral sidewall and disposed opposite the first lateral sidewall. The first side member may be adhered to an inner side of the first lateral side wall by an adhesive. The second side member may be adhered to an inner side of the second lateral side wall by an adhesive. The first side member and the second side member may be formed of metal. The seat back may be pivotally disposed on the seat bottom. The seat back may include a seat back shell, a first bracket, and a second bracket. The seat back shell may be formed of carbon fiber. The first bracket may be adhered to the seat back shell by an adhesive. The second bracket may be spaced apart from the first bracket and may be adhered to the seat back shell by an adhesive. The first bracket and the second bracket may be formed of metal.In at least one embodiment, a seat assembly is provided. The seat assembly may include a seat bottom and a seat back. The seat bottom may include a seat bottom shell, a first side member, and a second side member. The seat surface shell can be formed from carbon fiber. The first side member and the second side member may be formed of metal and may be bonded to the seat bottom shell. The seat back may be pivotally disposed on the seat bottom. The seat back may include a seat back shell, a first bracket, and a second bracket. The seat back shell may be formed of carbon fiber and may include a back panel, a first side wall, and a second side wall. The first side wall and the second side wall may extend forward from the back panel. The first bracket may be adhered to the back panel and the first side wall by an adhesive. The second bracket may be spaced apart from the first bracket and may be adhered to the back panel and the second side wall by an adhesive. The first bracket and the second bracket may be formed of metal.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a perspective view of a seat assembly. FIG. 2 is a perspective view of the seat assembly without trim and cushion. FIG. 3 is a perspective view of a seat bottom structure of the seat assembly. FIG. 4 is a top view of the seat bottom structure of FIG. 3. FIG. 5 is an exploded view of the seat bottom assembly of FIG. 3. FIG. 6 is a front view of a seat back assembly of the seat assembly. FIG. 7 is an exploded view of the seat back assembly of FIG. 6. FIG. 8 is an enlarged perspective view of a portion of the seat back assembly of FIG. 6. FIG. 9 is a perspective view of a portion of the seat assembly of FIG. 2 without a seat bottom shell and a seat back shell.DETAILED DESCRIPTIONEmbodiments of the present invention will be described in detail below, but it should be noted that the embodiments described here are merely exemplary of the invention, which can also be realized by various alternative embodiments. The figures are not necessarily to scale, and some features may be exaggerated or minimized to illustrate details of particular components. The details of construction and function described and shown herein are not to be interpreted as limiting, but merely as a representative basis for one skilled in the art who seeks to practice the present invention.Referring now to FIG. 1, an example of a seat assembly 10 is shown. The seat assembly 10 may be configured for use in a vehicle such as a motor vehicle such as a car or truck, aircraft, or ship. The seat assembly 10 may include a seat bottom 12 and a seat back 14.As shown in FIGS. 1 and 2, the seat back 14 may be pivoted about an axis 20 with respect to the seat bottom 12. For example, a pair of tilting mechanisms 22 may pivotally connect the seat back 14 to the seat bottom 12, as best seen in FIG. 2. A synchronization bar 24 may extend along the axis 20 between the tilting mechanisms 22 to synchronize actuation of the tilting mechanisms 22 in a manner known to those skilled in the art. In at least one configuration, a lower tilt mechanism bracket 26 and an upper tilt mechanism bracket 28 may extend from the tilt mechanism 22. The lower tilt mechanism bracket 26 may connect a first plate of the tilt mechanism 22 to the seat bottom 12. The upper tilt mechanism bracket 28 may connect a second plate of the tilt mechanism 22 to the seat back 14.As shown in FIGS. 1-3, the seat bottom 12 may be configured to support a seat occupant. In a vehicle application, the seat bottom 12 may be mounted on a support surface, such as a vehicle floor. For example, the seat bottom 12 may be mounted to a seat track assembly 30, which in turn may be mounted to a support surface. The seat track assembly 30 may allow for longitudinal movement of the seat assembly 10 in a front / rear direction with respect to the support surface. In at least one configuration, the seat bottom 12 may include a seat bottom trim 40, a seat bottom cushion 42, a seat bottom shell 44, a first first side member 46, and a second side member 48.As shown in FIG. 1, the seat trim cover 40 may be disposed over or on the seat cushion 42 and may form or provide at least a portion of the visible outer surface of the seat bottom 12. Further, a seat occupant may be seated on the seat trim cover 40. The seat trim cover 40 may include a plurality of trim panels that may be joined together in any suitable manner, such as by sewing. Additionally, the seat bottom trim cover 40 may be formed from any suitable materials such as textile, leather, vinyl, carpet, or combinations thereof.The seat cushion 42 may be at least partially covered by the seat trim cover 40 and may be directly or indirectly retained by the seat pan 44. The seat cushion 42 may be formed of any suitable material, such as a foam.As shown in FIGS. 2-5, the seat bottom shell 44 may help provide structural support for the seat bottom 12. The seat bottom shell 44 may be formed of a fiber reinforced material, such as a polymer resin, which may include a reinforcing carbon fiber. In this way, the seat bottom shell 44 may provide the seat bottom 12 with high strength and low weight. In at least one configuration, the seat pan 44 may be configured as a pan that extends laterally across the seat pan 12 and may include a plurality of walls defining multiple sides of the perimeter of the seat pan 44. For example, the seat pan 44 may include a bottom wall 50, a back wall 52, a front wall 54, a first lateral side wall 56, and a second lateral side wall 58, and further include a seat pan cavity 60.As shown in FIGS. 3-5, the bottom wall 50 may at least partially define the bottom of the seat bottom 12. For example, the bottom wall 50 may extend in a longitudinal direction (i.e., in a direction between the front side and the rear side of the seat) from the rear wall 52 to the front wall 54 and in a lateral direction (i.e., in a direction perpendicular to the longitudinal direction between the left and right lateral sides of the seat assembly) from the first lateral side wall 56 to the second lateral side wall 58. The bottom wall 50 may have an upper surface that faces the seat cushion 42 and may directly or indirectly engage and support the seat cushion 42. In addition, the bottom wall 50 may include a plurality of seat track openings 62 through which the seat track assembly 30 may extend. In the configuration of FIG. 4, four seat track openings 62 are provided that are spaced apart from each other and are disposed adjacent to the first lateral sidewall 56 or the second lateral sidewall 58.The rear wall 52 may be disposed at the rear end of the seat bottom shell 44. The rear wall 52 may extend from an end of the bottom wall 50. Specifically, the rear wall 52 may extend in an upward direction toward the seat back 14 from a rear end of the bottom wall 50. The rear panel 52 may be disposed below the seat back 14.The front wall 54 may be disposed at a front end of the seat bottom shell 44. The front wall 54 may extend from a front end of the bottom wall 50, which may be disposed opposite the rear end. In this case, the front wall 54 can be arranged opposite the rear wall 52 and can be completely spaced apart from the rear wall 52.The first lateral side wall 56 may be disposed on a first lateral side of the seat bottom shell 44. For example, the first lateral side wall 56 may extend along a left side or a right side of the seat bottom shell 44. For convenience, the first lateral side wall 56 is shown as extending along the right side of the seat pan 44 when the seat pan 44 is viewed from above; however, the first lateral side wall 56 may also extend along the left side of the seat pan 44.The first lateral side wall 56 may extend upwardly from an end of the bottom wall 50. Additionally, the first lateral side wall 56 may extend from an end of the rear wall 52 to an end of the front wall 54. In at least one configuration, the first lateral side wall 56 may include an inner side 80, an outer side 82, and a tilt adjustment opening 84.The inner side 80 may face the center of the seat bottom 12. For example, the inner side 80 may face the second lateral sidewall 58.The outer side 82 may be disposed opposite the inner side 80. The outer side 82 may be directed to the exterior of the seat bottom shell 44.The tilt adjustment opening 84 may be a through hole that may extend from the inner side 80 to the outer side 82. As best seen in FIG. 2, the tilt adjustment aperture 84 may be configured to receive an actuator 86 such as a button or link that can effect adjustment of a tilt adjustment mechanism 88 (best seen in FIG. 9 ) that can change the angle of inclination or tilt angle of the seat bottom 12 in a manner known to those skilled in the art. For example, the tilt adjustment opening 84 may receive the actuator when the first lateral side wall 56 is disposed adjacent a vehicle door. In at least one configuration, the tilt adjustment opening 84 may be the only opening provided in the first lateral side wall 56.The second lateral sidewall 58 may be disposed opposite the first lateral sidewall 56. In this case, the second lateral side wall 58 can be arranged on a second lateral side of the seat surface shell 44. For example, the second lateral side wall 58 may extend along the left side or the right side of the seat bottom shell 44. For convenience, the second lateral sidewall 58 is shown as extending along the left side of the seat pan 44 when the seat pan 44 is viewed from above; however, the indications for the first lateral sidewall 56 and the second lateral sidewall 56 may be reversed.The second lateral side wall 58 may extend upwardly from an end of the bottom wall 50. Additionally, the second lateral side wall 58 may extend from an end of the rear wall 52 to an end of the front wall 54. In at least one configuration, the second lateral side wall 58 may include an inner side 80, an outer side 82, and a tilt adjustment opening 84, as described above. The inner side 80 of the second lateral sidewall 58 may face the center of the seat bottom 12 and the first lateral sidewall 56.As shown in FIGS. 4 and 5, the seat pan cavity 60 may be a depression defined and bounded by the seat pan 44. For example, the seat pan cavity 60 may be bounded by the bottom wall 50, the back wall 52, the front wall 54, the first lateral side wall 56, and the second lateral side wall 58.As shown in FIGS. 3-5, the first side member 46 may be received in the seat bottom shell cavity 60. In particular, the first side member 46 may be adhered to the inner side 80 of the first lateral side wall 56 by an adhesive 90. Additionally, the first side member 46 may be fully received in the seat pan cavity 60 in one or more configurations. For example, the first side member 46 may be disposed over the bottom wall 50 and may not extend vertically beyond the upper end of the first lateral side wall 56. Additionally, the first side member 46 may be longitudinally disposed between and spaced from the rear wall 52 and the front wall 54. The first lateral side member 46 may extend along the first lateral side wall 56 in a front / rear direction from a front end 100 of the first side member 46 to a rear end 102, which may be disposed opposite the front end 100. The first side member 46 may be provided as a separate component from the seat bottom shell 44 and may be formed of a different material than the seat bottom shell 44. For example, the first side member 46 may be formed of metal. In at least one configuration, first side member 46 may include a first pad 110, a second pad 112, a third pad 114, a tilt adjustment aperture 116, a first lower mounting hole 118, a second lower mounting hole 120, a rail mounting hole 122, a tilt adjustment link mounting hole 124, and one or more tilt adjustment actuator mounting holes 126.The first pad 110 may be disposed adjacent to the front end 100 of the first side member 46. For example, the first pad 110 may be disposed between the front end 100 and the third pad 114 in the longitudinal direction. In addition, the first pad 110 may be disposed between the front end 100 and the tilt adjustment link mounting hole 126 and / or the tilt adjustment link mounting hole 124 in the longitudinal direction. The first pad 110 may also be disposed between an upper side of the first side member 46 and a lower side of the first side member 46, which may be disposed opposite the upper side. The first pad 110 may laterally protrude from the first side member 46 to the first lateral sidewall 56. Herein, the first side member 46 may be spaced apart from the inner side 80 of the first lateral sidewall 56 between the first pad 110 and the third pad 114. The first pad 110 may have substantially the same contour as the portion of the inner side 80 on which the first pad 110 may be disposed or engaged. Optionally, the first pad 110 may be provided with a plurality of through holes 130 that may extend through the first pad 110.An adhesive 90 may glue the first pad 110 to the inner side 80. The adhesive 90 may be applied to the first pad 110 and / or the inner side 80. The adhesive 90 may also be received in one or more through holes 130. In this case, the through-holes 130 may provide an additional surface to which the adhesive 90 may be bonded and may allow residual adhesive 90 to flow into the through-holes 130 when the first pad 110 is pressed against the first lateral sidewall 56.The second pad 112 may be disposed adjacent to the rear end 102 of the first side member 46. For example, the second pad 112 may be disposed between the rear end 102 and the third pad 114 in the longitudinal direction. In addition, the second pad 112 may be disposed between the rear end 102 and the first lower mounting hole 118 and / or the second lower mounting hole 120 in the longitudinal direction. Herein, the second pad 112 may be disposed below the seat back 14. The second pad 112 may extend from the upper side of the first side member 46 to the lower side of the first side member 46. The second pad 112 may laterally protrude from the first side member 46 to the first lateral sidewall 56. Herein, the first side member 46 may be spaced apart from the inner side 80 of the first lateral sidewall 56 between the second pad 112 and the third pad 114. Additionally, the second pad 112 may be laterally disposed between the inner side 80 of the first lateral sidewall 56 and a lower tilt mechanism bracket 26 such that the second pad 112 is spaced apart from the lower tilt mechanism bracket 26, as best seen in FIG. 9. The second pad 112 may have substantially the same contour as the portion of the inner side 80 on which the second pad 112 may be disposed or engaged. Additionally, the second pad 112 may have a smaller area or contact area with the inner side 80 than the first pad 110. Optionally, the second pad 112 may be provided with a plurality of through holes 130 that may extend through the second pad 112. An adhesive 90 may glue the second pad 112 to the inner side 80. The adhesive 90 may be applied to the second pad 112 and / or the inner side 80. The adhesive 90 may also be received in one or more through holes 130, as discussed above.The third pad 114 may be disposed between the first pad 110 and the second pad 112 in the longitudinal direction. In addition, the third pad 114 may be spaced apart from the first pad 110 and the second pad 112. The second pad 112 may be disposed near the center of the first side member 46. Herein, the third pad 114 may not be disposed below the seat back 14 when the seat back 14 is in an upright position. The third pad 114 may be disposed between and spaced apart from the upper side of the first side member 46 and the lower side of the first side member 46. The third pad 114 may laterally protrude from the first side member 46 to the first lateral sidewall 56. The third pad 114 may have substantially the same contour as the portion of the inner side 80 on which the third pad 114 may be disposed or engaged. Additionally, the third pad 114 may have a larger area or contact area with the inner side 80 than the first pad 110 and the second pad 112. Optionally, the third pad 114 may be provided with a plurality of through holes 130 that may extend through the third pad 114. An adhesive 90 may glue the third pad 114 to the inner side 80. The adhesive 90 may be applied to the third pad 114 and / or the inner side 80. The adhesive 90 may also be received in one or more through holes 130, as discussed above.The tilt adjustment opening 116 may be disposed between the first pad 110 and the third pad 114 in the longitudinal direction. Here, the first pad 110 and the third pad 114 may be disposed on opposite sides of the tilt adjustment opening 116. The tilt adjustment opening 116 may be aligned with the tilt adjustment opening 84 in the seat bottom shell 44 and may receive a portion of the tilt adjustment mechanism 88, such as the actuator 86.The first lower mounting hole 118 and the second lower mounting hole 120 may facilitate mounting of a lower tilt mechanism bracket 26, best seen in FIG. 9. For example, the first lower mounting hole 118 and the second lower mounting hole 120 may each receive a fastener, such as a screw, that may facilitate mounting of the lower tilt mechanism bracket 26 to the first side member 46. The first lower mounting hole 118 and / or the second lower mounting hole 120 may be disposed between the second pad 112 and the third pad 114 in the longitudinal direction. Here, the second pad 112 and the third pad 114 may be disposed on opposite sides of the first lower mounting hole 118 and / or the second lower mounting hole 120. Another fastener 140, such as a sleeve or nut, may be aligned with the first lower mounting hole 118 and the second lower mounting hole 120. The attachment members 140 may be fixedly attached to the first side member 46 in any suitable manner, such as by welding. The attachment members 140 may be mounted in one or more configurations on an outer side of the first side member 46, which may face the first lateral side wall 56 of the seat bottom shell 44.The rail mounting hole 122 may facilitate mounting of the seat rail assembly 30 to the first side member 46. For example, the rail mounting hole 122 may receive a fastener, such as a screw, that may couple the seat rail assembly 30 to the first side member 46. The rail mounting hole 122 may be disposed between the second pad 112 and the third pad 114 in the longitudinal direction. A fastening member 140 may be aligned with the rail mounting hole 122 and may be fixedly fastened to the first side member 46. The fastening member 140 may be a fastening member such as a screw that may extend through the rail mounting hole 122.The tilt adjustment link mounting hole 124 may facilitate mounting a portion of the tilt adjustment mechanism 88 to the first side member 46. For example, the tilt adjustment link mounting hole 124 may receive a fastening member such as a pin or a bolt that may pivotally couple a link portion of the tilt adjustment mechanism 88 to the first side member 46. The tilt adjustment connection part mounting hole 124 may be disposed between the tilt adjustment opening 116 and the third pad 114 in the longitudinal direction. A fixing member 140 may be aligned with the tilt adjustment connection part mounting hole 124, and may be fixedly attached to the first side member 46. The fastening member 140 may receive the fastening member extending through the tilt adjustment connection part mounting hole 124.One or more tilt adjuster actuator mounting holes 126 may be disposed adjacent to the tilt adjuster opening 116. The tilt adjustment actuator mounting holes 126 may facilitate mounting a portion of the tilt adjustment mechanism 88, such as the actuator 86, to the first side member 46. A fastener 140 may be aligned with one or more of the tilt adjuster actuator mounting holes 126 and may be fixedly attached to the first side member 46. Each fastener 140 may receive the fastener, such as a screw, extending through a corresponding tilt adjuster actuator mounting hole 126.The second side member 48 may have a similar configuration to the first side member 46. for example, the second side member 48 may have mirror symmetry with the first side member 46, such as mirror symmetry with respect to a center plane 150 of the seat assembly 10, as best seen in FIG. 4. Accordingly, the second side member 48 may have the same parts as the first side member 46, but the second side member 48 may be adhered to the inner side 80 of the second lateral side wall 58 rather than the first lateral side wall 56. Like reference numerals are used to indicate corresponding portions of the first side member 46 and the second side member 48. The fastening members 140 may not be provided with the tilt adjusting actuator mounting holes 126 of the second side member 48, either, when the fastening members 140 are provided with the tilt adjusting actuator mounting holes 126 of the first side member 46, and vice versa. The second side member 48 may be a separate component from the seat bottom shell 44 and may be formed of a different material than the seat bottom shell 44. For example, the first side member 46 may be formed of a metal.As shown in FIGS. 1 and 2, the seat back 14 may be configured to support the back of a seat occupant. For convenience, the side of the seat back 14 or the side of the components of the seat back 14 that faces forward and toward a seat occupant, respectively, may be referred to as a front side. The side opposite to the front side may be referred to as a rear side. The side closest to the seat bottom 12 when the seat back 14 is not folded over the seat bottom 12 or is in the nominal seating position of FIG. 1 may be referred to as a lower side. The side opposite to the lower side may be referred to as an upper side. The left and right sides or lateral sides extending between the front side and the rear side and between the upper side and the lower side may be referred to as lateral sides. In at least one configuration, the seat back 14 may include a seat back trim 160, a seat back cushion 162, a seat back shell 164, a first bracket 166, and a second bracket 168.As shown in FIG. 1, the seat back trim cover 160 may be disposed over or on the seat back cushion 162 and may form or provide at least a portion of a visible exterior surface of the seat back 14. The seat back trim 160 may include a plurality of trim panels that may be joined together in any suitable manner, such as by sewing. Additionally, the seat back trim cover 160 may be formed from any suitable material such as textile, leather, vinyl, carpet, or combinations thereof.The seat back cushion 162 may be at least partially concealed by the seat back trim 160 and may be retained by the seat back shell 164. The seat back cushion 162 may be formed of any suitable material, such as a foam. The seat back cushion 162 may include or help define a pair of side cushions 170 and a central seating area 172, as best seen in FIG. 1.The side bolsters 170 may extend generally along opposite lateral sides of the seat back 14 and between the upper side and the lower side of the seat back bolster 162. Herein, the side bolsters 170 may be disposed along opposite sides of the central seating region 172, and may extend outward or forward from the central seating region 172 to a seat occupant.The central seating area 172 may be configured to support the back of a seat occupant. The middle seat portion 172 may be disposed between the side bolsters 170 and may extend between the upper side and the lower side of the seat back bolster 162.As shown in FIGS. 2 and 6-8, the seat back shell 164 may provide structural support for the seat back 14. The seat back shell 164 may be formed of a fiber reinforced material, such as a polymeric resin, which may include a reinforcing carbon fiber. In this way, the seat back shell 164 may provide the seat back 14 with high strength and low weight. In at least one configuration, the seat back shell 164 may define at least a portion of the exterior surface of the seat back 14. The seat back shell 164 may include a back panel 180, a first side wall 182, a second side wall 184, and a buckle 186.The back panel 180 may extend laterally across the back of the seat back 14. The back panel 180 may be integrally formed with the first side wall 182 and the second side wall 184 such that the back panel 180, the first side wall 182, and the second side wall 184 form an integral component. As best seen in FIG. 7, the back panel 180 may include a front side 190 and a rear side 192.The front side 190 may face a seat occupant or face a front side of the seat back 14.The rear side 192 may be disposed opposite the front side 190. The rear side 192 may be a rear side or an outer surface of the seat bottom shell 44.As shown in FIGS. 6-8, the first side wall 182 may extend from a lateral end of the back panel 180. For example, the first side wall 182 may extend in a forward direction from a left end or a right end of the back panel 180. Additionally, the first side wall may extend in a generally vertical direction between the upper and lower sides of the seat back 14. In at least one configuration, first sidewall 182 may include an inner side 200, an outer side 202, and a hole 204.The inner side 200 may face the center of the seat back 14. For example, the inner side 200 may face the second side wall 184.The outer side 202 may be disposed opposite the inner side 200. Herein, the outer side 202 may be an outer surface of the seat back shell 164.The hole 204 may be a through hole extending from the inner side 200 to the outer side 202. As best seen in FIG. 2, the hole 204 may receive a portion of a tilting mechanism 22 or a handle or connection portion that may extend from the tilting mechanism 22.The second side wall 184 may be disposed opposite the first side wall 182. Herein, the second side wall 184 may be disposed along a second lateral side of the seat back shell 164. For example, the second side wall 184 may extend along a left side or a right side of the seat back shell 164. For convenience, the second side wall 184 is shown to extend along the left side of the seat back shell 164 when the seat back shell 164 is viewed from the front, but the indications of the first side wall 182 and the second side wall 184 may be reversed. The second side wall 184 may have mirror symmetry like the first side wall 182. For example, the second sidewall 184 may have mirror symmetry with the first sidewall 182, such as a pure symmetry with respect to the center plane 150. Here, as described above, the second side wall 184 may include an inner side 200 that may face the mid-plane 150 and the first side wall 182, an outer side 202 that may be disposed opposite the inner side 200, and a hole 204.The buckle 186 may be fixedly mounted to the back panel 180. For example, the brace 186 may be mounted to the front side of the back panel 180 or to the first side wall 182 and the second side wall 184. The brace 186 may reinforce the seat back shell 164 near the shoulder or neck portion of a seat occupant and may be disposed below the seat back cushion 162.The seat back shell 164 and the seat bottom shell 44 may be provided in a common tool or in separate tools. For example, a carbon fiber textile may be placed on or tensioned over a tool or mold to have the contours of the desired shape of the seat back shell 164 and seat bottom shell 44. The fabric may then be formed in an autoclave at an elevated pressure and temperature with respect to ambient pressure and temperature and then cut into separate pieces as needed. The clip 186 may be formed in advance and may be placed in the tool or mold when the seat back shell 164 is formed such that the clip 186 is integral with the seat back shell 164. Then, various openings may be cut, drilled, or milled into the seat bottom shell 44 and the seat back shell 164, for example, before the first and second side members 46, 48 are adhered to the seat bottom shell 44 or the first and second brackets 166, 168 are adhered to the seat back shell 164.The first bracket 166 may be adhered to the back panel 180. In particular, the first clip 166 may be adhered to the front side 190 of the back panel 180 and to the inner side 200 of the first side wall 182 using an adhesive 90. Additionally, the first bracket 166 may not extend over a front edge of the first side wall 182, which may be disposed opposite the back panel 180. The first bracket 166 may be a separate component from the seat back shell 164 and may be formed of a different material than the seat back shell 164. For example, the first side member 46 may be formed of a metal. In at least one embodiment, first bracket 166 may include a first bracket pad 210, a second bracket pad 212, a third bracket pad 214, an intermediate portion 216, a first step 218, a second step 220, and a link arm 222.The first bracket pad 210 may be disposed on the front side 190 of the back panel 180. The first bracket pad 210 may be laterally disposed between the center plane 150 and the first side wall 182. For example, the first clip pad 210 may be spaced apart from the inner side 200 of the first side wall 182. In addition, the first bracket pad 210 may be disposed near the lower end of the back panel 180. The first clamping pad 210 may have substantially the same contour as the portion of the front side 190 on which the first clamping pad 210 may be disposed or engaged. Optionally, the first bracket pad 210 may be provided with a plurality of through holes 240 that may extend through the first bracket pad 210.An adhesive 90 may glue the first clip pad 210 to the front side 190. The adhesive 90 may be applied to the first clip pad 210 and / or the front side 190. The adhesive 90 may also be received in one or more through holes 240. In doing so, the through-holes 240 may provide an additional surface to which the adhesive 90 may bond, where excess adhesive 90 may flow into the through-holes 240 when the first clip pad 210 is pressed against the back panel 180.The second clip pad 212 may be disposed on the inner side 200 of the first side wall 182. Additionally, the second bracket pad 212 may be spaced apart from the first bracket pad 210. The second clip pad 212 may be spaced apart from the front side 190 of the back panel 180 in one or more configurations. The second clamping pad 212 may have substantially the same contour as the portion of the inner side 200 on which the second clamping pad 212 may be disposed or engaged. Additionally, the second bracket pad 212 may have a smaller area or contact area with the inner side 200 than the area or contact area that the first bracket pad 210 has with the front side 190 of the back panel 180. Optionally, the second bracket pad 212 may be provided with a plurality of through holes 240 that may extend through the second bracket pad 212. The adhesive 90 may glue the second clip pad 212 to the inner side 200. The adhesive 90 may be applied to the second clip pad 212 and / or the inner side 200. The adhesive 90 may also be received in one or more through holes 240, as discussed above.The third bracket pad 214 may also be disposed on the inner side 200 of the first side wall 182. Additionally, the third bracket pad 214 may be spaced apart from the first bracket pad 210 and the second bracket pad 212. The third bracket pad 214 may also be spaced apart from the front side 190 of the back panel 180 in one or more configurations. The third bracket pad 214 may be disposed below the second bracket pad 212 or closer to the lower end of the first side wall 182 than the second bracket pad 212. In particular, the third bracket pad 214 may be disposed further from the center plane 150 than the second bracket pad 212. For example, the third clip pad 214 may be disposed adjacent to the hole 204 in the first side wall 182 and extend partially around the perimeter of the hole 204. The third bracket pad 214 may have a smaller area or contact area with the inner side 200 than the second bracket pad 212. As best seen in FIGS. 6 and 8, the third bracket pad 214 may be laterally offset from the second bracket pad 212. In this case, the third clamping pad 214 can be arranged further from the central plane 150 than the second clamping pad 212. In addition, the third bracket pad 214 may be disposed closer to the seating surface 12 than the second bracket pad 212. Optionally, the second bracket pad 212 may be provided with a plurality of through holes 240 that may extend through the second bracket pad 212. The adhesive 90 may glue the second clip pad 212 to the inner side 200. The adhesive 90 may be adhered to the second clip pad 212 and / or the inner side 200. The adhesive 90 may also be received in one or more through holes 240, as discussed above.The first bracket pad 210, the second bracket pad 212, and the third bracket pad 214 may be arranged in different planes that may not be aligned parallel to each other. For example, the first bracket pad 210 and the second bracket pad 212 may be arranged in planes that are arranged in a range of 30 to 60° with respect to each other. For example, the first bracket pad 210 may be offset from the second bracket pad 212 by about 45°. Accordingly, the second bracket pad 212 and the third bracket pad 214 may be arranged in planes that are offset with respect to each other in a range of 30 to 60°. For example, the second bracket pad 212 may be offset from the third bracket pad 214 by about 45°. Positioning the first clip pad 210, the second clip pad 212, and the third clip pad 214 in offset planes may help prevent the first clip 166 from sliding along the seat back shell 164, which in turn may help prevent the first clip 166 from spreading the adhesive across the seat back shell 164 to positions where the adhesive is not desired between the first clip 166 and the seat bottom shell 164. Additionally, the offset planes may help prevent the first bracket 166 from scratching or otherwise damaging the seat back shell 164.The intermediate portion 216 may be disposed between the second bracket pad 212 and the third bracket pad 214. For example, the intermediate portion 216 may be disposed below the second bracket pad 212 and above the third bracket pad 214. Here, the second clamping pad 212 and the third clamping pad 214 may be disposed on opposite sides of the intermediate part 216. The intermediate portion 216 may be spaced apart from the first side wall 182. In at least one configuration, the intermediate portion 216 may include a first upper mounting hole 250 and a second upper mounting hole 252.The first upper mounting hole 250 and the second upper mounting hole 252 may facilitate mounting of the upper tilt mechanism bracket 28. For example, the first upper mounting hole 250 and the second upper mounting hole 252 may each receive a fastener, such as a screw, that may facilitate mounting of the upper tilt mechanism bracket 28 to the first bracket 166. Another fastener 140, such as a sleeve, may be aligned with the first upper mounting hole 250 and the second upper mounting hole 252. The fasteners 140 may be mounted in one or more configurations on an outer side of the intermediate portion 216, which may face the first side wall 182 of the seat back shell 164.The first step 218 may extend from the second bracket pad 212 to the intermediate portion 216. The first step 218 may extend laterally in a direction away from the center plane 150. For example, the first step 218 may extend from an end of the second clip pad 212 in a direction away from the mid-plane 150 to an upper end of the intermediate portion 216.The second stage 220 may be disposed opposite the first stage 218. Additionally, the second step 220 may extend from the third bracket pad 214 to the intermediate portion 216. The second step 220 may extend laterally in a direction away from the center plane 150. For example, the second step 220 may extend from a lower end of the intermediate portion 216 in a direction away from the mid-plane 150 to an upper side of the third clip pad 214. The second step 220 may also extend from the link arm 222.The link arm 222 may extend from the first bracket pad 210 to one or more portions of the first bracket 166. For example, the link arm 222 may extend from the first bracket pad 210 to the second bracket pad 212, the third bracket pad 214, the intermediate portion 216, the first step 218, the second step 220, or combinations thereof. In the configuration shown, the link arm 222 extends from the first bracket pad 210 to the third bracket pad 214, the intermediate portion 216, and the second stage 220. The link arm 222 may extend along and engage or contact the front side 190 of the back panel 180.The second bracket 168 may have a similar configuration to the first bracket 166. For example, like the first bracket 166, the second bracket 168 may have mirror symmetry, such as mirror symmetry, with respect to the mid-plane 150, as best seen in FIG. 6. Accordingly, the second clip 168 may have the same parts as the first clip 166, but the second clip 168 may be adhered to the inner side 200 of the second side wall 184 instead of the first side wall 182. Similar reference numerals are used to indicate corresponding portions of the first bracket 166 and the second bracket 168.A seat assembly combining large carbon fiber shells with metal brackets or side members may help reduce the overall weight of the seat assembly. And because the brackets or side members are bonded to the carbon fiber shells, welds, mechanical fasteners, additional brackets, or other connecting portions on the seat back frame or the seat bottom frame may be omitted, which may help reduce the overall dimensions or packaging space of the seat assembly. Additionally, the use of an adhesive for adhering components to carbon fiber shells may help reduce the total number of parts and further reduce or completely eliminate the number of parts protruding toward the seat occupant, thereby increasing seating comfort for the occupant.While exemplary embodiments have been described above, the present invention is not limited to the embodiments described herein. The description is to be understood as exemplary and not restrictive, and various changes may be made in the embodiments described herein without departing from the scope of the invention.

Claims

A seat assembly (10) comprising: a seat bottom (12) comprising: a seat bottom shell (44) formed of carbon fiber and having a first lateral side wall (56) and a second lateral side wall (58) spaced from and disposed opposite the first lateral side wall (56); a first side member (46) adhered to an inner side (80) of the first lateral side wall (56) facing the second lateral side wall (58) by an adhesive (90); and a second side member (48) adhered to an inner side (80) of the second lateral side wall (58) facing the first lateral side wall (56) by an adhesive (90), wherein the first side member (46) and the second side member (48) are formed of metal; and a seat back (14) pivotally disposed on the seat bottom (12), wherein the seat back (14) comprises: a seat back shell (164) formed from carbon fiber; a first bracket (166) bonded to the seat back shell (164) by an adhesive (90); and a second bracket (168) spaced from the first bracket (166) and bonded to the seat back shell (164) by an adhesive (90), wherein the first bracket (166) and the second bracket (168) are formed from metal.The seat assembly of claim 1, wherein the first side member (46) comprises a first pad (110) disposed proximate a front end of the first side member (46), a second pad (112) disposed proximate a rear end of the first side member (46) opposite the front end, and a third pad (114) disposed between the first pad (110) and the second pad (112) and spaced from the first pad (110) and the second pad (112), wherein the adhesive (90) is disposed on the first pad (110), the second pad (112), and the third pad (114) and adheres the first side member (46) to the seat bottom shell (44).The seat assembly of claim 2, wherein the third pad (114) has a larger area than the first pad (110), and the first pad (110) has a larger area than the second pad (112).The seat assembly of any of claims 2 or 3, wherein the second pad (112) is disposed below the seat back (14).The seat assembly of any one of claims 2 to 4, wherein the first pad (110), the second pad (112), and the third pad (114) each have a plurality of through holes (130) that receive the adhesive (90).The seat assembly of any of claims 2 to 5, wherein the first side member (46) includes a tilt adjustment opening (84) through which a tilt adjustment mechanism (88) extends, the first pad (110) and the third pad (114) being disposed on opposite sides of the tilt adjustment opening (84).The seat assembly of any of claims 2 to 6, wherein the first side member (46) includes a first lower mounting hole (118) and a second lower mounting hole (120) that facilitate mounting of a lower tilt mechanism bracket (26) extending from a tilt mechanism (22), the second pad (112) and the third pad (114) being disposed on opposing sides of the first lower mounting hole (118).The seat assembly of claim 7, wherein the second pad (112) is laterally disposed between the inner side (80) of the first lateral side wall (56) and the lower tilt mechanism bracket (26) such that the second pad (112) is spaced apart from the lower tilt mechanism bracket (26).The seat assembly of any of claims 2 to 8, wherein a seat track assembly (30) is mounted to the first side member (46) between the second pad (112) and the third pad (114).A seat assembly (10) comprising: a seat bottom (12) comprising: a seat bottom shell (44) formed of carbon fiber; a first side member (46) adhered to the seat bottom shell (44) by an adhesive (90); and a second side member (48) disposed opposite the first side member (46) and adhered to the seat bottom shell (44) by an adhesive (90), wherein the first side member (46) and the second side member (48) are formed of metal; and a seat back (14) pivotally disposed on the seat bottom (12), wherein the seat back (14) comprises: a seat back shell (164) formed of carbon fiber and a back panel (180); a first side wall (182) extending forward from the back panel (180); and a second side wall (184), The second clip comprising: a first clip (166) adhered to the back panel (180) and the first side wall (182) by an adhesive (90), and a second clip (168) spaced apart from the first clip (166) and the second side wall (184) by an adhesive (90), wherein the first clip (166) and the second clip (168) are formed of metal.The seat assembly of claim 10, wherein the first bracket (166) comprises a first bracket pad (210) spaced from the first side wall (182) and a second bracket pad (212) spaced from the first bracket pad (210), wherein the first bracket pad (210) and the second bracket pad (212) are adhered to the seat back shell (164).The seat assembly of claim 11, wherein the first bracket (166) comprises a third bracket pad (214) spaced apart from the first bracket pad (210) and the second bracket pad (212), wherein the adhesive (90) bonds the second bracket pad (212) and the third bracket pad (214) to the first sidewall (182), and the third bracket pad (214) is disposed closer to the seating surface (12) than the second bracket pad (212).The seat assembly of claim 12, wherein the second bracket pad (212) and the third bracket pad (214) are spaced apart from the back panel (180).The seat assembly of any of claims 12 or 13, wherein the first bracket pad (210) has a larger area than the second bracket pad (212) and the second bracket pad (212) has a larger area than the third bracket pad (214).The seat assembly of any of claims 12 to 14, wherein the first bracket pad (210), the second bracket pad (212), and the third bracket pad (214) each have a plurality of through holes (240) that receive the adhesive (90).The seat assembly of any of claims 12 to 15, wherein the first bracket (166) comprises an intermediate portion (216) having a first upper mounting hole (250) and a second upper mounting hole (252) that facilitate mounting of an upper tilt mechanism bracket (28) extending from a tilt mechanism (22), wherein the second bracket pad (212) and the third bracket pad (214) are disposed on opposite sides of the intermediate portion (216).The seat assembly of claim 16, wherein the first side wall (182) of the seat back shell (164) includes a hole (204) that receives the tilting mechanism (22), and wherein the third bracket pad (214) is disposed proximate the hole (204) and extends partially around the hole (204).The seat assembly of any of claims 16 to 17, wherein the second bracket pad (212) is disposed closer to a mid-plane (150) of the seat back (14) than the third bracket pad (214).The seat assembly of any of claims 16 to 18, wherein the first bracket (166) comprises a first step (218) extending from the second bracket pad (212) to the intermediate portion (216) and a second step (220) extending from the third bracket pad (214) to the intermediate portion (216), the intermediate portion (216) being laterally offset from the second bracket pad (212) and the third bracket pad (214).The seat assembly of any of claims 16 to 19, wherein a link arm (222) extends from the first bracket pad (210) to the intermediate portion (216) and the third bracket pad (214).

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