Manufacturing method for automobile seat parts with excellent shape fixability

Abstract

To provide an automobile seat component with excellent shape freezing property that can reduce the amount of deformation during mold release in press molding.SOLUTION: An aspect of the present disclosure is a metallic automobile seat component with excellent shape freezing property which is used for a frame of an automobile seat. The automobile seat component comprises: a band plate-shaped body which is curved in a direction in which a first end of the first end and a second end in a width direction bulges; a first flange which projects in a direction crossing a plate surface of the body from the first end; and a second flange which projects in a direction crossing the plate surface of the body from the second end and faces the first flange. The first flange has an uneven part provided along a longer direction of the body.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to an automobile seat part having excellent shape freezing property and a method for manufacturing the same. [Background technology]

[0002] In the frame of an automobile seat, a panel-shaped seat part having flanges on both sides in the width direction is used (see Patent Document 1). This part is curved in an arch shape to match the shape of the seat. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-3599 A Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned seat parts are formed by pressing metal sheets using a die. This press compresses the outer curved flange and expands the inner curved flange. Therefore, when the die is removed after pressing is completed, the outer curved flange tries to expand due to stress, and the inner curved flange tries to contract due to stress. These stresses cause the seat parts to twist, causing them to deviate from the die shape.

[0005] In order to keep such shape deviation within the tolerance, it is necessary to prepare a mold with a shape that takes into account the deformation of the seat parts when they are released. Therefore, if the deformation of the seat parts is large (i.e., the shape fixability is poor), the amount of work required to obtain a mold with the appropriate expected shape increases.

[0006] An object of one aspect of the present disclosure is to provide an automobile seat part having excellent shape freezing properties that can reduce the amount of deformation at the time of demolding in press molding. [Means for solving the problem]

[0007] One aspect of the present disclosure is a metallic automobile seat part (1) with excellent shape fixability for use in a frame (104) of an automobile seat (100). The automobile seat part (1) includes a strip-shaped main body (2) having a first end (21) and a second end (22) in the width direction, the first end (21) of which is curved in a bulging direction, a first flange (3) protruding from the first end (21) in a direction intersecting with the plate surface of the main body (2), and a second flange (4) protruding from the second end (22) in a direction intersecting with the plate surface of the main body (2) and facing the first flange (3). The first flange (3) has an uneven portion (31) provided along the longitudinal direction of the main body (2).

[0008] According to this configuration, the length of the first flange (3) along the longitudinal direction of the main body (2) is increased by the uneven portion (31). Therefore, the compressive stress of the first flange (3) generated during press molding can be reduced. As a result, the amount of deformation of the automobile seat part (1) during demolding in press molding is reduced. In other words, the automobile seat part (1) having excellent shape freezing property can be obtained.

[0009] In one embodiment of the present disclosure, the uneven portion (31) may include at least one recess (31B) or at least one protrusion (31C). The at least one recess (31B) or the at least one protrusion (31C) may reach the end face (32) of the first flange (3) opposite the main body (2). With this configuration, the portion of the press die for forming the uneven portion (31) can be easily released from the first flange (3). This improves the manufacturing efficiency of the automobile seat component (1).

[0010] In one embodiment of the present disclosure, the uneven portion (31) may include a reference wall (31A) and at least one recessed portion (31B) recessed inward in the width direction of the main body (2) from the reference wall (31A). This configuration makes it easy to adjust the outer dimensions of the first flange (3).

[0011] In one embodiment of the present disclosure, the width of at least one recess (31B) along the longitudinal direction of the main body (2) may decrease toward the first end (21). With this configuration, the amount of deformation during pressing can be reduced in the region of the recess (31B) close to the main body (2). As a result, the occurrence of defects during molding can be suppressed.

[0012] Another aspect of the present disclosure is a method for manufacturing a metal automobile seat part (1) used in a frame (104) of an automobile seat (100). The method for manufacturing the automobile seat part includes a step of bending a metal plate material at a first end (21) and a second end (22) by pressing using a die so as to form a strip-shaped main body (2), a step of forming a first flange (3) by pressing using a die on the bent portion at the first end (21), and a step of forming a second flange (4) by pressing using a die on the bent portion at the second end (22).

[0013] The main body (2) has a first end (21) and a second end (22) in the width direction, and the first end (21) is curved in a bulging direction. The first flange (3) protrudes from the first end (21) in a direction intersecting with the plate surface of the main body (2). The second flange (4) protrudes from the second end (22) in a direction intersecting with the plate surface of the main body (2) and faces the first flange (3).

[0014] In the bending step, a concave-convex portion (31) is formed along the longitudinal direction of the main body (2) at the portion to be bent in the first end portion (21).

[0015] According to this configuration, before the first flange (3) is molded, the length of the portion of the main body (2) that will be processed into the first flange (3) along the longitudinal direction is increased by the uneven portion (31). This reduces the compressive stress of the first flange (3) that occurs during press molding. As a result, the amount of deformation of the automobile seat part (1) during release from the mold in press molding is reduced. In other words, the automobile seat part (1) with excellent shape freezing property is obtained.

[0016] Another aspect of the present disclosure is a method for manufacturing a metal automobile seat part (1) used in a frame (104) of an automobile seat (100). The method for manufacturing the automobile seat part includes a step of bending a metal plate material at a first end (21) and a second end (22) by pressing using a die so as to form a strip-shaped main body (2), a step of forming a first flange (3) by pressing using a die on the bent portion at the first end (21), and a step of forming a second flange (4) by pressing using a die on the bent portion at the second end (22).

[0017] The main body (2) has a first end (21) and a second end (22) in the width direction, and the first end (21) is curved in a bulging direction. The first flange (3) protrudes from the first end (21) in a direction intersecting with the plate surface of the main body (2). The second flange (4) protrudes from the second end (22) in a direction intersecting with the plate surface of the main body (2) and faces the first flange (3).

[0018] In the step of forming the first flange (3), the first flange (3) is formed while forming the uneven portion (31) along the longitudinal direction of the main body (2).

[0019] According to this configuration, when the first flange (3) is molded, the length of the first flange (3) along the longitudinal direction of the main body (2) is increased by the uneven portion (31). Therefore, the compressive stress of the first flange (3) generated during press molding can be reduced. As a result, the amount of deformation of the automobile seat part (1) when it is released from the mold in press molding is reduced. In other words, the automobile seat part (1) having excellent shape freezing property can be obtained.

[0020] Note that the symbols in the above parentheses are examples showing the correspondence with the specific configurations etc. described in the embodiments described below, and the present disclosure is not limited to the specific configurations etc. shown by the symbols in the above parentheses. [Brief description of the drawings]

[0021] [Figure 1]FIG. 1 is a schematic perspective view showing an automobile seat according to an embodiment. [Diagram 2] 2A and 2B are schematic perspective views showing an automobile seat component according to an embodiment. [Diagram 3] FIG. 3 is a schematic cross-sectional view taken along line III-III in FIG. 2A. [Figure 4] 4A is a schematic plan view of the concave-convex portion of FIG. 2A, and FIG. 4B is a schematic front view of the concave-convex portion of FIG. 4A. [Diagram 5] FIG. 5 is a flow diagram of a method for manufacturing an automobile seat part according to an embodiment. [Figure 6] FIG. 6A is a schematic diagram showing a main body molding step, FIG. 6B is a schematic diagram showing a bending step, FIG. 6C is a schematic diagram showing a first flange molding step, and FIGS. 6D and 6E are schematic diagrams showing a second flange molding step. [Figure 7] FIG. 7A is a schematic plan view of a concave-convex portion in an embodiment different from that in FIG. 4A, and FIG. 7B is a schematic front view of the concave-convex portion of FIG. 7A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, embodiments to which the present disclosure is applied will be described with reference to the drawings. [1. First embodiment] [1-1. Configuration] The automobile seat 100 shown in FIG. 1 includes a seat cushion 101, a seat back 102, a cushion frame 103, a back frame 104, and a recliner 105.

[0023] The automobile seat 100 is used as a seat for a passenger vehicle. Note that the directions in the following description and in each drawing refer to the directions when the automobile seat 100 is installed in the automobile. In this embodiment, the seat width direction coincides with the left-right direction of the automobile, and the front of the seat coincides with the front of the automobile.

[0024] The seat cushion 101 is a portion for supporting the buttocks of a seated person. The seat back 102 is a portion for supporting the back of the seated person. The cushion frame 103 supports the seat cushion 101. The back frame 104 supports the seat back 102.

[0025] The recliner 105 connects the back frame 104 to the seat cushion 101. The recliner 105 allows the back frame 104 to rock relative to the seat cushion 101 in the front-rear direction of the seat.

[0026] The back frame 104 has a first side frame 104A, a second side frame 104B, and an upper frame 104C. The first side frame 104A and the second side frame 104B extend in the up-down direction and are spaced apart from each other in the seat width direction. The upper frame 104C connects the first side frame 104A and the second side frame 104B in the seat width direction.

[0027] The first side frame 104A has a metal automobile seat component 1 shown in FIGS. 2A and 2B.

[0028] <Automobile seat parts> The automobile seat component 1 is a band-shaped panel that constitutes the main body of the first side frame 104A.

[0029] A recliner 105 is attached to a first end 1A in the longitudinal direction of the automobile seat part 1. A second end 1B in the longitudinal direction of the automobile seat part 1 is fixed to an upper frame 104C. The automobile seat part 1 includes a main body 2, a first flange 3, and a second flange 4.

[0030] <Main body> The main body 2 is a band-shaped part curved like an arch when viewed in the thickness direction. The main body 2 has a first end 21 and a second end 22 in the width direction (that is, the direction perpendicular to the longitudinal direction).

[0031] The main body 2 is curved in a direction in which the first end 21 bulges out. In other words, the first end 21 of the main body 2 is disposed on the outside of the curve, and the second end 22 is disposed on the inside of the curve. Therefore, the first end 21 is curved so as to be convex in a direction away from the second end 22.

[0032] <First flange and second flange> The first flange 3 is a plate-like portion that protrudes from the first end 21 of the main body 2 in a direction intersecting the plate surface of the main body 2 (i.e., in the thickness direction of the main body 2). The first flange 3 is formed by bending the metal plate that constitutes the main body 2 at the first end 21 by press molding.

[0033] The second flange 4 is a plate-like portion that protrudes from the second end 22 of the main body 2 in a direction intersecting the plate surface of the main body 2 and faces the first flange 3 in the width direction of the main body 2. The second flange 4 is formed by bending the metal plate that constitutes the main body 2 at the second end 22 by press molding.

[0034] 3, a cross section perpendicular to the longitudinal direction of the automobile seat part 1 is a C-shaped open cross section. A tip 3A of the first flange 3 (i.e., the end opposite to the main body 2) and a tip 4A of the second flange 4 are each curved toward the inside in the width direction of the automobile seat part 1.

[0035] 2A and 2B, the first flange 3 has an uneven portion 31 provided along the longitudinal direction of the main body 2. The uneven portion 31 increases the length and surface area of ​​the first flange 3 along the longitudinal direction of the main body 2.

[0036] 4A and 4B, in this embodiment, the uneven portion 31 is composed of a plurality of recesses 31B arranged side by side along the longitudinal direction of the main body 2. Specifically, the uneven portion 31 includes a reference wall 31A that determines the outer shape of the first flange 3, and a bead-shaped recess 31B that is recessed inward in the width direction of the main body 2 from the reference wall 31A.

[0037] Note that Figure 4A is a schematic diagram of the first flange 3 viewed from the outside in the width direction of the main body 2 (i.e., the opposite side to the second flange 4), and Figure 4B is a schematic diagram of the first flange 3 viewed from the tip 3A side.

[0038] The recess 31B reaches an end face 32 of the first flange 3 opposite the main body 2 (i.e., the end face of the tip portion 3A). In other words, the end face 32 is partially bent toward the inside of the main body 2 in the width direction.

[0039] Furthermore, the width W of the recess 31B along the longitudinal direction of the main body 2 becomes smaller toward the first end 21 of the main body 2. That is, the width of the recess 31B at the end face 32 is greater than the width of the portion of the recess 31B closest to the main body 2. Note that, although the width of the recess 31B changes continuously in this embodiment, the width of the recess 31B may change intermittently.

[0040] In this embodiment, the multiple recesses 31B having the same shape are arranged at equal intervals. However, the shapes of the multiple recesses 31B do not necessarily have to be the same. Furthermore, the intervals between the multiple recesses 31B do not all have to be equal.

[0041] In this embodiment, the length L1 of the recess 31B in the protruding direction of the first flange 3 (i.e., the direction perpendicular to the longitudinal direction of the main body 2) is equal to or greater than ½ of the protruding length L2 of the first flange 3. However, the length L of the recess 31B may be less than ½ of the protruding length L2 of the first flange 3.

[0042] In this embodiment, the maximum depth D of the recess 31B is equal to or greater than ½ of the thickness of the end surface 32 of the first flange 3. However, the maximum depth D of the recess 31B may be less than ½ of the thickness of the end surface 32 of the first flange 3.

[0043] [1-2. Effects] According to the embodiment described above in detail, the following effects can be obtained. (1a) The length of the first flange 3 along the longitudinal direction of the main body 2 is increased by the uneven portion 31. This reduces the compressive stress of the first flange 3 that occurs during press molding. As a result, the amount of deformation of the automobile seat part 1 during release from the mold in press molding is reduced. In other words, the automobile seat part 1 has excellent shape freezing properties.

[0044] (1b) Since the recess 31B reaches the end face 32 of the first flange 3, the portion of the press die for forming the recessed and projected portions 31 can be easily released from the first flange 3. This improves the manufacturing efficiency of the automobile seat component 1.

[0045] (1c) By configuring the uneven portion 31 with the recess 31B recessed inward from the reference wall 31A, the outer dimension of the first flange 3 can be easily adjusted.

[0046] (1d) The width of the recess 31B becomes smaller toward the first end 21 of the main body 2, which reduces the amount of deformation during pressing in the region of the recess 31B close to the main body 2. As a result, defects during molding can be suppressed.

[0047] [2. Second embodiment] [2-1. Configuration] The method for manufacturing an automobile seat component shown in Fig. 5 includes a main body molding step S10, a bending step S20, a first flange molding step S30, and a second flange molding step S40. By this manufacturing method, the automobile seat component 1 shown in Fig. 2A is obtained.

[0048] <Body molding process> In this process, as shown in Fig. 6A, a metal plate material M is pressed in the thickness direction using a first die D1 and a first punch P1, thereby forming a concave-convex shape in a portion corresponding to the main body 2 of the automobile seat part 1.

[0049] <Bending process> 6B, in this step, the plate material M after the body forming step S10 is bent by pressing using a second die D2 and a second punch P2 at the portions corresponding to the first end 21 and the second end 22 of the main body 2. This forms a strip-shaped main body 2 curved in a direction such that the first end 21 bulges out.

[0050] In this process, the uneven portion 31 is formed along the longitudinal direction of the main body 2 in the first portion M1 to be bent in the first end portion 21 (i.e., the portion to be machined into the first flange 3). The uneven portion 31 can be formed simultaneously with bending the plate material M by providing the second die D2 and the second punch P2 with unevenness corresponding to the shape of the uneven portion 31.

[0051] <First flange forming process> In this step, as shown in FIG. 6C, the first portion M1 bent at the first end portion 21 of the plate material M is pressed using a third die D3 and a third punch P3.

[0052] As a result, the tip of the first region M1 where the uneven portion 31 is formed is bent inward by pressing, forming the tip 3A of the first flange 3, which is a depressed angle portion (i.e., an undercut portion). As a result, the first flange 3 is formed, protruding from the first end 21 in a direction intersecting with the plate surface of the main body 2.

[0053] <Second flange forming process> In this process, as shown in Fig. 6D, a fourth die D4 and a fourth punch P4 are used to press the second portion M2 bent at the second end portion 22 of the plate material M. This adjusts the bending angle of the second portion M2 with respect to the main body 2.

[0054] In this process, as shown in Fig. 6E, the second portion M2 after the bend angle adjustment is pressed using a fifth die D5 and a fifth punch P5. As a result, the tip of the second portion M2 is bent inward by the press, and the tip portion 4A of the second flange 4, which is a depressed angle portion, is formed. As a result, the second flange 4 is formed, which protrudes from the second end 22 in a direction intersecting with the plate surface of the main body 2.

[0055] The second flange-forming step S40 may be performed before the first flange-forming step S30.

[0056] [2-2. Effects] According to the embodiment described above in detail, the following effects can be obtained. (2a) Before the first flange 3 is molded, the length of the first portion M1 to be processed into the first flange 3 along the longitudinal direction of the main body 2 is increased by the uneven portion 31. This reduces the compressive stress of the first flange 3 generated during press molding. As a result, the amount of deformation of the automobile seat part 1 during release from the mold in press molding is reduced. In other words, the automobile seat part 1 has excellent shape freezing property.

[0057] [3. Third embodiment] [3-1. Configuration] The method for manufacturing an automobile seat part of this embodiment includes a main body molding step S10, a bending step S20, a first flange molding step S30, and a second flange molding step S40, as shown in FIG. 5, similarly to the method for manufacturing an automobile seat part of the second embodiment.

[0058] The manufacturing method of this embodiment is similar to the manufacturing method of the second embodiment, except that instead of forming the concave-convex portion 31 in the bending step S20, the concave-convex portion 31 is formed in the first flange forming step S30.

[0059] In this embodiment, in the first flange molding process S30, the first flange 3 is molded while forming the uneven portion 31 along the longitudinal direction of the main body 2. The uneven portion 31 can be formed simultaneously with bending the first region M1 by providing the third die D3 and the third punch P3 in Fig. 6C with unevenness corresponding to the shape of the uneven portion 31.

[0060] [3-2. Effects] According to the embodiment described above in detail, the following effects can be obtained. (3a) During molding of the first flange 3, the length of the first flange 3 along the longitudinal direction of the main body 2 is increased by the uneven portion 31. This reduces the compressive stress of the first flange 3 that occurs during press molding. As a result, the amount of deformation of the automobile seat part 1 during demolding in press molding is reduced. In other words, the automobile seat part 1 has excellent shape freezing ability.

[0061] [4. Other embodiments] Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take various forms.

[0062] (4a) In the automobile seat part of the above embodiment, the width of the recess constituting the uneven portion of the first flange does not necessarily have to become smaller toward the first end. For example, the width of the recess may be constant.

[0063] (4b) In the automobile seat component of the above embodiment, as shown in Figures 7A and 7B, the uneven portion 31 of the first flange 3 may include a reference wall 31A and a bead-shaped protrusion 31C that bulges outward in the width direction of the main body 2 beyond the reference wall 31A.

[0064] (4c) In the automobile seat part of the above embodiment, the recesses or protrusions constituting the uneven portion do not necessarily have to reach the end face of the first flange. In other words, the recesses or protrusions may be provided at a position away from the end face of the first flange.

[0065] (4d) The automobile seat parts of the above embodiments can be used as parts of the back frame other than the side frame. Also, the automobile seat parts of the above embodiments can be used as frames of automobile seats other than the back frame (for example, cushion frames).

[0066] (4e) The function of one component in the above embodiments may be distributed among multiple components, or the functions of multiple components may be integrated into one component. In addition, a part of the configuration of the above embodiments may be omitted. In addition, at least a part of the configuration of the above embodiments may be added to or substituted for the configuration of another of the above embodiments. Note that all aspects included in the technical idea identified from the wording of the claims are embodiments of the present disclosure. [Explanation of symbols]

[0067] 1 ... automobile seat part, 1A ... first end, 1B ... second end, 2 ... main body, 3...first flange, 3A...tip portion, 4...second flange, 4A...tip portion, 21...first end portion, 22...second end portion, 31...uneven portion, 31A...reference wall, 31B...recess portion, 31C: protrusion; 32: end surface; 100: automobile seat; 101: seat cushion; 102...seat back, 103...cushion frame, 104...back frame, 104A: first side frame; 104B: second side frame; 104C...upper frame, 105...recliner.

Claims

1. A method for manufacturing a metal automobile seat part used in a frame of an automobile seat, comprising the steps of: a step of bending a metal plate material at a first end and a second end by pressing using a die so as to form a strip-shaped main body in which the first end is curved in a bulging direction out of a first end and a second end in a width direction; forming a first flange protruding from the first end in a direction intersecting with a plate surface of the main body by pressing the bent portion of the first end using a die; a step of pressing the bent portion of the second end portion using a die to form a second flange that protrudes from the second end portion in a direction intersecting with a plate surface of the main body and faces the first flange; Equipped with In the bending step, a concave-convex portion is formed along a longitudinal direction of the main body at a portion of the first end that is to be bent.

2. A method for manufacturing a metal automobile seat part used in a frame of an automobile seat, comprising the steps of: a step of bending a metal plate material at a first end and a second end by pressing using a die so as to form a strip-shaped main body in which the first end is curved in a bulging direction out of a first end and a second end in a width direction; forming a first flange protruding from the first end in a direction intersecting with a plate surface of the main body by pressing the bent portion of the first end using a die; a step of pressing the bent portion of the second end portion using a die to form a second flange that protrudes from the second end portion in a direction intersecting with a plate surface of the main body and faces the first flange; Equipped with In the step of molding the first flange, the first flange is molded while forming a concave-convex portion along a longitudinal direction of the main body.

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