Small continuous recliner

Abstract

In a small continuous recliner, the neck ring (2.1) has a center point (O). The tooth surfaces of the external gear teeth of the gear rack (2) and the internal gear ring of the ring gear rack (3) have a contact point (D). The center point (O) and the contact point (D) are connected to form a first connection line (OD). Each tooth of the external gear teeth of the gear rack (2) has a first working arc segment (a~b). The first working arc segment (a~b) of the contact teeth of the gear rack (2) has a first arc segment center (01). Each tooth of the internal gear ring of the ring gear rack (3) has a second working arc segment (c~d). The second working arc segment (c~d) of the contact teeth of the ring gear rack (3) has a second arc segment center (02). The first arc segment center (01) and the second arc segment center (02) are connected to form a second connection line (0102). The contact point (D) is located on the second connection line (0102). The angle formed by the first connection line (OD) and the second connection line (0102) is between 85° and 95°. When actually used, the radial component force on the tooth surface is made as small as possible, and undesirable phenomena such as tooth slippage and reverse drive are less likely to occur. Thereby, the compression strength, bending strength, and fatigue strength of the tooth part are improved by the tooth profile design, the strength of the recliner is improved, while maintaining the strength, the diameter of the recliner is reduced, the weight is lightened, and thereby weight reduction is achieved.

Description

Technical Field

[0001] The present invention relates to an automobile seat, and more specifically, to a small continuous recliner.

Background Art

[0002] With the development of new energy vehicles and the strengthening of the implementation of the carbon neutral policy, weight reduction at the component level is urgent. Regarding recliners (angle adjusters), it has become the market requirement for such products to be as small and lightweight as possible while maintaining strength. It is required to maintain and further improve the strength of the recliner of the automobile seat and reduce its size. How to achieve miniaturization and weight reduction while ensuring strength through structural innovation has become a major issue for manufacturers of automobile seat recliners.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The present invention provides a small continuous recliner that can achieve miniaturization and weight reduction of the recliner while ensuring strength.

Means for Solving the Problems

[0004] The small continuous recliner according to the present invention includes a gear rack and a ring gear rack that are rotatable relative to each other. The gear rack has an external gear, and the ring gear rack has an internal gear ring. The gear rack and the ring gear rack are connected to each other through the external gear and the internal gear ring that mesh with each other. The gear rack has a neck ring that is concentric with the external gear of the gear rack, and the gear rack and the ring gear rack, an eccentric member that is driven by a drive cam and rotates in the circumferential direction to drive the gear rack and the ring gear rack to perform a relative rolling motion. The neck ring has a center point, and the tooth surfaces of the external gear of the gear rack and the internal gear ring of the ring gear rack have a contact point. The center point and the contact point are connected to form a first connection line. Each tooth of the external gear of the gear rack has a first working arc segment, and the first working arc segment of the contacting tooth of the gear rack has a first arc segment center. Each tooth of the internal tooth ring of the ring gear rack has a second working arc segment, and the second working arc segment of the contacting tooth of the ring gear rack has a second arc segment center. The first arc segment center and the second arc segment center are connected to form a second connection line. The contact point is located on the second connection line, and the angle formed by the first connection line and the second connection line is between 85° and 95°.

[0005] Preferably, the first working arc segment of the contacting tooth of the gear rack has a first arc radius, the second working arc segment of the contacting tooth of the ring gear rack has a second arc radius, and the ratio of the first arc radius to the second arc radius is between 1.05 and 1.15.

[0006] Preferably, each tooth of the external gear of the gear rack has a first tooth profile width, each tooth of the internal tooth ring of the ring gear rack has a second tooth profile width, and the tooth width ratio of the first tooth profile width to the second tooth profile width is between 1.1 and 1.6.

[0007] Preferably, the drive cam includes a cylindrical segment that is axially inserted into the neck ring and extends.

[0008] Preferably, the gap between the cylindrical segment and the neck ring is between 0.05 mm and 0.15 mm.

[0009] Preferably, the drive cam is an integrally formed member.

[0010] Preferably, the eccentric member is restricted by the fitting of a wedge and a spring so that the external gear of the gear rack is press-fitted into the internal tooth ring of the ring gear rack at the meshing position.

[0011] Preferably, the gear rack has a first stepped surface for supporting the wedge, the ring gear rack has a burring boss, and the first stepped surface is provided close to the top surface of the burring boss.

[0012] Preferably, the gear rack includes a boss for connecting the small continuous recliner to the external connection plate, a third stepped surface for supporting the external connection plate, and a second stepped surface formed by press molding together with the third stepped surface, and the first stepped surface and the second stepped surface are on the same plane.

[0013] Preferably, the distance between the second stepped surface and the third stepped surface is equal to the material thickness of the gear rack.

[0014] Preferably, the small continuous recliner further includes a hoop for integrally holding the gear rack and the ring gear rack.

[0015] Preferably, the third stepped surface has a protruding height so that the external connection plate can be arranged on the third stepped surface avoiding the hoop.

[0016] Preferably, the wedge is supported by the neck ring with its curved inner surface and supports the ring gear rack with its curved outer surface.

[0017] Preferably, the drive cam has a drive segment, the wedge is composed of two wedge sections, the drive segment is inserted into the clearance between the narrow sides of the two wedge sections, and both ends of the spring are connected to the opposing wide sides of the two wedge sections respectively so that the spring acts on the wedge sections in the circumferential direction to force the two wedge sections to separate.

[0018] Preferably, the small continuous recliner further includes a friction bearing provided between the curved outer surface of the wedge and the central hole of the ring gear rack.

[0019] Preferably, the small continuous recliner further includes a cover that is covered on the drive cam and fixedly connected to the ring gear rack.

Advantages of the Invention

[0020] In the small continuous recliner according to the present invention, the contact point is provided on the second connection line, and the angle formed by the first connection line and the second connection line is between 85° and 95°, thereby minimizing the radial component force on the tooth surface and making it difficult to generate undesirable phenomena such as tooth slippage and reverse drive. As a result, the compression strength, bending strength, and fatigue strength of the tooth part are improved by the tooth profile design, the strength of the recliner is improved, while maintaining the strength, the diameter of the recliner is reduced, the weight is lightened, and thus weight reduction is achieved. As described above, the small continuous recliner according to the present invention is structurally innovative, thereby further simplifying the manufacturing and processing of parts, achieving weight reduction and miniaturization while ensuring a high strength level, and meeting the market demand.

Brief Description of the Drawings

[0021]

Figure 1

[0022]

Figure 2

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Figure 3

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Figure 4

[0025]

Figure 5

[0026]

Figure 6

[0027]

Figure 7

[0028]

Figure 8

[0029]

Figure 9

Mode for Carrying Out the Invention

[0030] Hereinafter, with reference to the drawings, preferred embodiments of the present invention will be shown and these embodiments will be described in detail.

[0031] As shown in FIGS. 1 and 2, a small continuous recliner according to a preferred embodiment of the present invention includes a hoop 1, a gear rack 2, and a ring gear rack 3. Among them, the gear rack 2 and the ring gear rack 3 are provided so as to be rotatable relative to each other, and the hoop 1 holds the gear rack 2 and the ring gear rack 3 integrally. In this embodiment, the hoop 1 for absorbing the axial acting force is fixedly connected to the ring gear rack 3. It should be understood that the hoop 1 does not interfere with the relative rotation between the gear rack 2 and the ring gear rack 3.

[0032] Regarding the installation of the small continuous recliner, the gear rack 2 is attached to the seat, and the ring gear rack 3 is attached to the back portion, whereby the inclination angle of the back portion with respect to the seat is adjusted. Of course, the attachment positions of the gear rack 2 and the ring gear rack 3 may be exchanged, that is, the gear rack 2 may be attached to the back portion and the ring gear rack 3 may be attached to the seat.

[0033] The gear rack 2 and the ring gear rack 3 are connected to each other by gears so as to facilitate adjustment and fixation. In order to enable connection by gears, an external gear is formed on the gear rack 2, an internal gear ring is formed on the ring gear rack 3, and the external gear and the internal gear ring mesh with each other. The diameter of the tooth tip circle of the external teeth of the external gear is smaller than the diameter of the tooth base circle of the internal teeth of the internal gear ring by at least the height of one tooth. Between the external gear and the internal gear ring, there is at least a difference of one tooth in the number of teeth, and this difference enables the rolling movement of the internal gear ring on the external gear.

[0034] The gear rack 2 has a neck ring 2.1 that is concentric with the external gear. The small continuous recliner according to the present embodiment further includes a wedge 5 that is supported by the neck ring 2.1 with its curved inner surface and supports the ring gear rack 3 with its curved outer surface. In that case, the small continuous recliner according to the present embodiment further includes a friction bearing 4 provided between the curved outer surface of the wedge 5 and the central hole 3.1 of the ring gear rack 3. Further, the small continuous recliner according to the present embodiment further includes a drive cam 6. The drive cam 6 has a columnar segment 6.1 extending in the axial direction inserted into the neck ring 2.1, and a boring hole for matching and accommodating the drive shaft is provided in the central portion, whereby the drive cam 6 can be braked by the drive shaft. In the present embodiment, the drive cam 6 is a metal member. Further, the drive cam 6 has a drive segment 6.2. The wedge 5 is composed of two wedge sections, and the drive segment 6.2 of the drive cam 6 is inserted into the clearance between the narrow sides of the two wedge sections. And the small continuous recliner according to the present embodiment further includes a spring 7, and both ends of the spring 7 are respectively connected to the opposing wide sides of the two wedge sections, whereby the spring 7 acts on the wedge sections in the circumferential direction to forcibly separate the two wedge sections. In this way, the eccentric member is restricted by the fitting of the wedge 5 and the spring 7, whereby the external gear of the gear rack 2 is press-fitted into the internal gear ring of the ring gear rack 3 at the meshing position. Further, the small continuous recliner according to the present embodiment further includes a cover 8 that is covered on the drive cam 6 and fixedly connected to the ring gear rack 3.

[0035] The process of assembling the small continuous recliner according to this embodiment is specifically as follows. When the friction bearing 4 is press-fitted into the central hole 3.1 of the ring gear rack 3 so as to be a shrink fit, the external gear of the gear rack 2 and the internal gear ring of the ring gear rack 3 are engaged, the cylindrical segment 6.1 of the drive cam 6 is inserted into the neck ring 2.1 of the gear rack 2, and both ends of the spring 7 are respectively inserted into the holes on the wide side of the two wedge sections of the wedge 5. The wedge 5 is disposed in close contact with the space formed by the friction bearing 4 and the neck ring 2.1. The hoop 1 and the ring gear rack 3 are connected by welding, and the cover 8 and the ring gear rack 3 are connected by welding.

[0036] The operating mechanism of the small continuous recliner according to this embodiment specifically includes the following. During driving by the rotary drive shaft, first, all the torque is transmitted to the drive cam 6, and then, it is transmitted to the eccentric member (formed by the wedge 5 and the spring 7) by the drive segment 6.2. The eccentric member slides along the friction bearing 4 to deflect the eccentric direction, whereby the position of the external gear of the gear rack 2 on the internal gear ring of the ring gear rack 3 is displaced. In this way, continuous and adjustable adjustment of the inclination of the back portion becomes possible.

[0037] In particular, in the small continuous recliner of the present invention, by designing the tooth profiles of the gear rack 2 and the ring gear rack 3, the tooth compressive strength, bending strength, and fatigue strength are improved, and also the strength of the gear rack 2 and the ring gear rack 3 with the same diameter is increased. By designing the tooth profiles of the gear rack 2 and the ring gear rack 3 while maintaining the strength, the diameters of the gear rack 2, the ring gear rack 3, and its hoop 1 can be reduced, the weight can be decreased, and thus weight reduction can be achieved.

[0038] As shown in FIG. 3, the tooth profile width of the gear rack 2 is A, and the tooth profile width of the ring gear rack 3 is B. In the present invention, the tooth width ratio A / B is between 1.1 and 1.6. In this way, while ensuring the dynamic strength, the strength in the case of fatigue operation is ensured.

[0039] As shown in Fig. 4, each tooth of the external gear of the gear rack 2 has a working arc segment a - b, and each tooth of the internal gear ring of the ring gear rack 3 has a working arc segment c - d, and both of them are fitted to each other.

[0040] Taking the contacting teeth as an example, as shown in Fig. 5, the working arc segment a - b (see Fig. 4) of the contacting teeth of the gear rack 2 has 1 an arc segment center O 1 and an arc radius R 2 ; the working arc segment c - d (see Fig. 4) of the contacting teeth of the ring gear rack 3 has 2 an arc segment center O 1 and an arc radius R 2 . O is the center of the neck ring 2.1 of the gear rack 2. The contact point D between the tooth surfaces of the gear rack 2 and the ring gear rack 3 is on the connecting line between the arc segment center O 1 and the arc segment center O 1 ; and the angle formed by the OD connecting line and the O 2 D connecting line (i.e., the O 1 O 2 connecting line) is between 85° and 95°. In this way, the radial component force on the tooth surface can be made as small as possible, and it is possible to make it difficult to generate undesirable phenomena such as tooth slippage and reverse drive. Also, the ratio R 1 / R 2 between the arc radius R 1 and the arc radius R 2 is between 1.05 and 1.15 (slightly larger than 1). With such a design, when a force is applied between the two teeth, the contact surface can be enlarged, the compressive strength of the tooth surface can be improved, and both the fatigue strength and the dynamic strength are favorably affected.

[0041] In particular, for the drive cam 6 of the small continuous recliner of the present invention, the cylindrical segment 6.1 is inserted into the neck ring 2.1 to improve the strength of the recliner. While maintaining the strength, the diameters of the gear rack 2, the ring gear rack 3, and its hoop 1 can be reduced, and their weights can be lightened, thereby achieving weight reduction. And the drive cam 6 of the small continuous recliner of the present invention is a single integrally formed part, that is, the cylindrical segment 6.1 and the drive segment 6.2 are integrally formed with the main body. Compared with a separate drive system composed of multiple parts (for example, three parts), both the manufacturing process and the assembly process of the drive cam 6 of the present invention are simplified.

[0042] Regarding the transmission of the force applied to the small continuous recliner of the present invention, as shown in FIG. 6, the external force F1 finally acts on the neck ring 2.1 of the gear rack 2 through the friction bearing 4 and the wedge 5 by the ring gear rack 3. At this time, the neck ring 2.1 generates a resistance force through its own deformation. If the deformation amount of the neck ring 2.1 is too large, slippage of the teeth of the recliner may occur, that is, the strength may be lost. Therefore, the strength of the neck ring 2.1 itself directly affects the strength of the recliner. Due to the limitations of the manufacturing process such as fine blanking, the thickness and strength of the neck ring 2.1 cannot be improved infinitely. Therefore, in many cases, this part becomes the part that limits the strength improvement of the recliner. In the present invention, the cylindrical segment 6.1 of the drive cam 6 inserted into the neck ring 2.1 effectively resists the deformation of the neck ring 2.1 and improves the strength. It should be understood that in a low-strength working situation, the deformation amount of the neck ring 2.1 is extremely small, and the material of the drive cam 6 may be, for example, plastic.

[0043] A clearance is required for the fitting between the cylindrical segment 6.1 of the drive cam 6 and the neck ring 2.1 of the gear rack 2. This is because the drive cam 6 rotates within the neck ring 2.1 to drive the recliner. If there is no clearance or the clearance is too small, there will be drawbacks such as difficult assembly or increased operating torque. Considering strength, even if minor deformation occurs in the neck ring 2.1, the cylindrical segment 6.1 of the drive cam 6 can resist the deformation of the neck ring 2.1. Therefore, the smaller the clearance between the cylindrical segment 6.1 and the neck ring 2.1, the more preferable it is. In the present invention, through tolerance analysis and analysis using finite element strength calculation software, a compatible effect is obtained. Specifically, in the present invention, the clearance between the cylindrical segment 6.1 and the neck ring 2.1 is set between 0.05 mm and 0.15 mm. Thereby, while ensuring the smooth installation and operation of the drive cam 6, the drive cam 6 is brought into close contact with the inner surface of the neck ring 2.1 as much as possible. When the neck ring 2.1 receives force and deforms slightly, it contacts the cylindrical segment 6.1 of the drive cam 6. At this time, the cylindrical segment 6.1 begins to provide a reaction force F2 to assist the neck ring 2.1 in resisting its own deformation, thereby improving the strength of the recliner. That is, in the case of sufficient strength, the neck ring 2.1 is strongly supported in a timely manner to ensure the strength of the recliner.

[0044] In particular, in the small continuous recliner of the present invention, by providing a flush step surface, the bias force in the force-receiving path of the recliner is reduced, the strength is improved, and the manufacturing of parts becomes easier.

[0045] As shown in Fig. 7, the force transmission path inside the recliner is as follows. The external force F0 is transmitted to the wedge 5 through the friction bearing 4 by the action of the ring gear rack 3, and finally, the wedge 5 applies the acting force F1 to the neck ring 2.1. The line indicating the action of the external force F0 is represented by the tooth force receiving center plane P1, and the line where the acting force F1 acts is represented by the neck ring force receiving center plane P2. When these two planes P1 and P2 are not at the same height, a bias arm L is generated, and further a bias moment is generated. The greater the bias moment, the more disadvantageous it is to the strength of the recliner. Therefore, the bias arm L should be made as small as possible.

[0046] As shown in Fig. 8, in the recliner of the prior art, the gear rack has a first step surface 2.2', a second step surface 2.3', a boss 2.4', and a third step surface 2.5'. Among them, the boss 2.4' is used for welding the recliner and the external connection plate, and the third step surface 2.5' supports the external connection plate. The third step surface 2.5' has a protruding height d so that the external connection plate can be arranged on the third step surface 2.5' avoiding the hoop. Due to the characteristics of the fine blanking process, the second step surface 2.3' is a press surface formed simultaneously with the forming of the third step surface 2.5'. The distance between the second step surface 2.3' and the third step surface 2.5' is the material thickness of the rack, that is, the position of the second step surface 2.3' depends on the protruding height d. Also, the ring gear rack has a burring boss, and the burring boss is limited by the material thickness and strength. Since the burring height is small, it is necessary to raise the first step surface 2.2' for arranging the wedge to approach the top surface of the burring boss. Therefore, there is a height difference t between the first step surface 2.2' and the second step surface 2.3', and as a result, it is known that the bias arm L (see Fig. 7) becomes large. Furthermore, since the first step surface 2.2' and the second step surface 2.3' are not on the same surface, in the press forming process, it is necessary to repeat the press a plurality of times to manufacture the first step surface 2.2' and the second step surface 2.3' individually, making the process complicated.

[0047] As shown in Fig. 9, the gear tooth plate 2 of the present invention also has a first stepped surface 2.2 and a second stepped surface 2.3. Among them, the first stepped surface 2.2 is a plane that supports the wedge 5. In order to stably maintain the posture when the wedge 5 receives force, it is necessary to be as close as possible to the top surface P3 of the burring boss 3.1 of the ring gear tooth plate 3. In the present invention, by increasing the material thickness of the ring gear tooth plate 3, the height h of the burring boss 3.1 is increased, and it is no longer necessary to increase the first stepped surface 2.2 to match the height h of the burring boss 3.1. Also, the position of the second stepped surface 2.3 is kept constant. Therefore, the first stepped surface 2.2 and the second stepped surface 2.3 may be configured to be on the same plane. By eliminating the height difference, the bias arm L (see Fig. 7) is reduced, and the purpose of optimizing the strength is achieved. Furthermore, from the perspective of the manufacturing process, the first stepped surface 2.2 and the second stepped surface 2.3 can be formed by only one-step pressing, simplifying the manufacturing process.

[0048] The above is only a preferred embodiment of the present invention and does not limit the scope of the present invention. Various modifications are possible to the above embodiments of the present invention. That is, all simple and equivalent changes and modifications made based on the claims and the content of the specification of the present invention application shall be included in the protection scope of the claims of the present invention patent. What is not described in detail in the present invention is the content of the prior art.

Claims

1. A small continuous recliner, a gear rack (2) and a ring gear rack (3) that are rotatable relative to each other, wherein the gear rack (2) has an external gear, the ring gear rack (3) has an internal gear ring, and the gear rack (2) and the ring gear rack (3) are connected to each other via the external gear and the internal gear ring that mesh with each other, and the gear rack (2) has a neck ring (2.1) that is concentric with the external gear, the gear rack (2) and the ring gear rack (3); an eccentric member (5, 7) that is driven by a drive cam (6) and rotates in the circumferential direction to drive the gear rack (2) and the ring gear rack (3) to perform a relative rolling motion; the neck ring (2.1) has a center point (O), the tooth surfaces of the external gear of the gear rack (2) and the internal gear ring of the ring gear rack (3) have a contact point (D), the center point (O) and the contact point (D) are connected to form a first connection line (OD); Each tooth of the external gear of the gear rack (2) has a first working arc segment (a to b), and the first working arc segment (a to b) of the contact teeth of the gear rack (2) has a first arc segment center (O １ ), each tooth of the internal gear ring of the ring gear rack (3) has a second working arc segment (c to d), and the second working arc segment (c to d) of the contact teeth of the ring gear rack (3) has a second arc segment center (O ２ ), the first arc segment center (O １ ) and the second arc segment center (O ２ ) are connected to form a second connection line (O １ O ２ ). The contact point (D) is located on the second connection line (O １ O ２ ), and the angle formed by the first connection line (OD) and the second connection line (O １ O ２ ) is between 85° and 95°, which is characterized by A small continuous recliner.

2. The first working arc segment (a - b) of the contact teeth of the gear rack (2) has a first arc radius (R １ ), and the second working arc segment (c - d) of the contact teeth of the ring gear rack (3) has a second arc radius (R ２ ). The ratio (R １ / R ２ ) between the first arc radius (R １ ) and the second arc radius (R ２ ) is between 1.05 and 1.15, characterized in that The small continuous recliner according to Claim 1.

3. Each tooth of the external gear of the gear rack (2) has a first tooth profile width (A), each tooth of the internal gear ring of the ring gear rack (3) has a second tooth profile width (B), and the tooth width ratio (A / B) between the first tooth profile width (A) and the second tooth profile width (B) is between 1.1 and 1.6, which is characterized in that; The small continuous recliner according to Claim 1.

4. The drive cam (6) includes a cylindrical segment (6.1) that is axially inserted into and extends in the neck ring (2.1), which is characterized in that; The small continuous recliner according to Claim 1.

5. The gap between the cylindrical segment (6.1) and the neck ring (2.1) is between 0.05 mm and 0.15 mm, which is characterized in that; The small continuous recliner according to Claim 4.

6. The drive cam (6) is an integrally formed member, which is characterized in that; The small continuous recliner according to Claim 1.

7. The eccentric member (5, 7) is restricted by the fitting of a wedge (5) and a spring (7) so as to be press-fitted into the internal gear ring of the ring gear rack (3) at the position where the external gear of the gear rack (2) meshes, which is characterized in that; The small continuous recliner according to Claim 1.

8. The gear rack (2) has a first stepped surface (2.2) for supporting the wedge (5), the ring gear rack (3) has a burring boss (3.1), and the first stepped surface (2.2) is provided close to the top surface (P3) of the burring boss (3.1). The small continuous recliner according to claim 7.

9. The gear rack (2) includes a boss for connecting the small continuous recliner to an external connection plate, a third stepped surface for supporting the external connection plate, and a second stepped surface (2.3) formed by press molding together with the third stepped surface, and the first stepped surface (2.2) and the second stepped surface (2.3) are on the same surface. The small continuous recliner according to claim 8.

10. The distance between the second stepped surface (2.3) and the third stepped surface is equal to the material thickness of the gear rack (2). The small continuous recliner according to claim 9.

11. Further comprising a hoop (1) for integrally holding the gear rack (2) and the ring gear rack (3). The small continuous recliner according to claim 9.

12. The third stepped surface has a protruding height (d) so that the external connection plate can be arranged on the third stepped surface avoiding the hoop (1). The small continuous recliner according to claim 11.

13. The wedge (5) is supported by the neck ring (2.1) with its curved inner surface and supports the ring gear rack (3) with its curved outer surface. The small continuous recliner according to claim 7.

14. The drive cam (6) has a drive segment (6.2), the wedge (5) is composed of two wedge sections, the drive segment (6.2) is inserted into the clearance between the narrow sides of the two wedge sections, and both ends of the spring (7) are respectively connected to the opposing wide sides of the two wedge sections so that the spring (7) acts on the wedge sections in the circumferential direction to forcibly separate the two wedge sections. The small continuous recliner according to claim 13.

15. Further comprising a friction bearing (4) provided between the curved outer surface of the wedge (5) and the central hole (3.1) of the ring gear rack (3). The small continuous recliner according to claim 13.

16. Further comprising a cover (8) which is covered on the drive cam (6) and fixedly connected to the ring gear toothed plate (3). The small continuous recliner according to claim 13.

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