Method for manufacturing a vehicle seat and vehicle back frame

Abstract

To provide a vehicle seat which can integrally mold a back board of a back frame with two side frames.SOLUTION: A vehicle seat includes a seat cushion, a seat back, and a back frame supporting the seat back. The back frame has a back board, a first side frame extending in a forward direction of a seat from a first end in a seat width direction of the back board, and a second side frame extending in a forward direction of the seat from a second end in the seat width direction of the back board. The back board has a main region, and at least one pass region which is adjacent to the main region, is thicker than the main region and extends in the seat width direction.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a vehicle seat and a vehicle back frame.

Background Art

[0002] In the back frame of a vehicle seat, one in which two side frames and an upper panel are integrally formed is known (see Patent Document 1 and Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the back frame as described above, if a portion with a small wall thickness is provided, there is a risk that the metal may not flow sufficiently during casting. Therefore, it is not easy to integrally form a backboard having an arbitrary thickness together with the side frames.

[0005] One aspect of the present disclosure aims to provide a vehicle seat in which a backboard of a back frame can be integrally formed with two side frames.

Means for Solving the Problems

[0006] One aspect of the present disclosure is a vehicle seat (1) comprising a seat cushion (2), a seat back (3), and a back frame (4) supporting the seat back (3). The back frame (4) includes a backboard (41), a first side frame (42) extending forward from a first end of the backboard (41) in the seat width direction, and a second side frame (43) extending forward from a second end of the backboard (41) in the seat width direction. The backboard (41) includes a main region (411A) and at least one path region (412A) adjacent to the main region (411A), having a greater thickness than the main region (411A), and extending in the seat width direction.

[0007] With this configuration, molten metal can be supplied in the sheet width direction by the pass region (412A) during the molding of the back frame (4). Therefore, the back board (41) can be integrally molded with the first side frame (42) and the second side frame (43) while controlling the thickness of the back board (41) to reduce its weight.

[0008] In one aspect of this disclosure, the backboard (41) may have a plurality of path regions (412A, 412B, 412C) arranged vertically, with at least one path region (412A). With such a configuration, the thickness of the backboard (41) can be controlled during the molding of the back frame (4) while providing an opening in the backboard (41).

[0009] In one aspect of the present disclosure, the thickness of the upper (4122) and lower (4123) portions of at least one pass region (412A) may be greater than the thickness of the central portion (4121) of at least one pass region (412A). Such a configuration facilitates the supply of molten metal from the pass region (412A) to the main region (411A) during the molding of the back frame (4).

[0010] In one aspect of this disclosure, the backboard (41) may have a rectangular opening (414A) adjacent to the path region (412A) and in which the thickness of the corner is greater than the thickness of the path region (412A). With such a configuration, the thickness of the main region (411A) around the opening (414A) can be easily controlled when molding the back frame (4).

[0011] Another aspect of the present disclosure is a method for manufacturing a vehicle back frame (4), which includes a backboard (41), a first side frame (42) extending forward from a first end of the backboard (41) in the seat width direction toward the seat, and a second side frame (43) extending forward from a second end of the backboard (41) in the seat width direction toward the seat. The method for manufacturing a vehicle back frame comprises the step of pouring molten metal into a mold (100).

[0012] The mold (100) includes a main portion (101A) that forms the main region (411A) of the backboard (41), at least one pass portion (102A) that is adjacent to the main region (411A), has a greater thickness than the main region (411A), and forms at least one pass region (412A) that extends in the width direction of the back frame (4), a first side portion (105) that forms the first side frame (42), and a second side portion (106) that forms the second side frame (43). In the pouring process, molten metal is supplied from at least one pass portion (102A) to the main portion (101A).

[0013] With this configuration, the pass region (412A) can supply molten metal in the sheet width direction. Therefore, the thickness of the backboard (41) can be controlled to reduce weight, and the backboard (41) can be integrally molded with the first side frame (42) and the second side frame (43).

[0014] In one aspect of this disclosure, the mold (100) may have at least one pass section (102A) and a plurality of pass sections (102A, 102B, 102C) arranged vertically in the back frame (4). With such a configuration, it is possible to control the thickness of the back board (41) while providing an opening in the back board (41).

[0015] In one aspect of the present disclosure, at least one pass portion (102A) may form at least one pass region (412A) in which the thickness of the upper end (4122) and lower end (4123) is greater than the thickness of the central portion (4121). Such a configuration can facilitate the supply of molten metal from the pass region (412A) to the main region (411A).

[0016] In one aspect of this disclosure, the mold (100) may have an opening-forming portion (104A) adjacent to the path region (412A) that forms a rectangular opening (414A) whose corner thickness is greater than the thickness of the path region (412A). With such a configuration, the thickness of the main region (411A) around the opening (414A) becomes easier to control.

[0017] The symbols in the parentheses above are merely examples indicating the correspondence with the specific configurations described in the embodiments described later, and this disclosure is not limited to the specific configurations indicated by the symbols in the parentheses above. [Brief explanation of the drawing]

[0018] [Figure 1] Figure 1 is a schematic perspective view of a vehicle seat in an embodiment. [Figure 2] Figure 2 is a schematic front view of the back frame of the vehicle seat shown in Figure 1. [Figure 3] Figure 3A is a schematic cross-sectional view along the line IIIA-IIIA in Figure 2, while Figures 3B and 3C are schematic cross-sectional views in a different embodiment from Figure 3A. [Figure 4] Figure 4 is a flowchart showing a method for manufacturing a vehicle back frame in an embodiment. [Figure 5] FIG. 5 is a schematic view of a mold used in the method for manufacturing a vehicle back frame of FIG. 4.

Embodiments for Carrying out the Invention

[0019] Hereinafter, embodiments to which the present disclosure is applied will be described with reference to the drawings. [1. First Embodiment] [1-1. Configuration] The vehicle seat 1 shown in FIG. 1 includes a seat cushion 2, a seat back 3, and a back frame 4.

[0020] The vehicle seat 1 of the present embodiment is used as a seat for a passenger car. In the following description and in each drawing, the directions refer to the directions in a state where the vehicle seat 1 is assembled to a vehicle (i.e., a passenger car). Also, in the present embodiment, the seat width direction coincides with the left-right direction of the vehicle, and the front of the seat coincides with the front of the vehicle.

[0021] The seat cushion 2 is a part for supporting the buttocks etc. of the seated person. The seat back 3 is a part for supporting the back of the seated person. The back frame 4 supports the seat back 3.

[0022] <Back Frame> The back frame 4 has a back board 41, a first side frame 42, and a second side frame 43.

[0023] The back board 41, the first side frame 42, and the second side frame 43 are integrally formed by casting a metal such as aluminum, for example. That is, the back board 41, the first side frame 42, and the second side frame 43 are integrated.

[0024] <Back Board> The backboard 41 is a panel that constitutes the rear wall of the back frame 4. As shown in Figure 2, the backboard 41 has a plurality of main areas 411A, 411B, 411C, 411D, 411E, 411F, a plurality of path areas 412A, 412B, 412C, 412D, and a plurality of openings 414A, 414B, 414C, 414D, 414E.

[0025] The first main region 411A, the second main region 411B, the third main region 411C, the fourth main region 411D, the fifth main region 411E, and the sixth main region 411F are each plate-shaped portions, demarcated by path regions 412A-412D and openings 414A-414E. The thickness of each main region 411A-411F is approximately the same, for example, 2 mm.

[0026] The first main region 411A constitutes the right shoulder portion of the back frame 4. The first main region 411A is provided with a first base 415A to which functional components (e.g., switches, levers, etc.) are attached. The first base 415A is a portion of the first main region 411A that protrudes forward of the seat. The lower end of the first main region 411A is in contact with the first path region 412A.

[0027] The second main region 411B constitutes the left shoulder portion of the back frame 4. The second main region 411B is located to the left of the first main region 411A, with the first opening 414A in between. The lower end of the second main region 411B is in contact with the fourth path region 412D.

[0028] The third main region 411C is located below the second main region 411B, with the fourth path region 412D in between. The third main region 411C is provided with a second base 415C to which functional components are attached. The second base 415C is a portion of the third main region 411C that protrudes forward from the seat. The upper end of the third main region 411C is in contact with the fourth path region 412D. The lower end of the third main region 411C is in contact with the first path region 412A.

[0029] The fourth main region 411D is located below the first main region 411A, with the first path region 412A in between. The fourth main region 411D is provided with a belt path 416 through which a seat belt (not shown) is inserted. The belt path 416 consists of an opening provided in the fourth main region 411D and a portion of the fourth main region 411D that has been deformed into an arch shape. The upper end of the fourth main region 411D is in contact with the first path region 412A. The lower end of the fourth main region 411D is in contact with the second path region 412B.

[0030] The fifth main region 411E is located below the fourth main region 411D, with the second path region 412B in between. The fifth main region 411E is provided with a boss 417 for fixing functional components. The boss 417 is a bottomed cylindrical portion that protrudes forward from a part of the fifth main region 411E. The upper end of the fifth main region 411E is in contact with the second path region 412B. The lower end of the fifth main region 411E is in contact with the third path region 412C.

[0031] The sixth main region 411F is located to the left of the fifth main region 411E, with the fifth opening 414E in between. The sixth main region 411F is provided with a bracketed opening 418 to which functional components are attached. The bracketed opening 418 consists of an opening provided in the sixth main region 411F and a portion of the sixth main region 411F that has been deformed into a bracket shape. The upper end of the sixth main region 411F is in contact with the second path region 412B. The lower end of the sixth main region 411F is in contact with the third path region 412C.

[0032] The first pass region 412A, the second pass region 412B, the third pass region 412C, and the fourth pass region 412D are each strip-shaped areas extending in the sheet width direction. Furthermore, the first pass region 412A, the second pass region 412B, and the third pass region 412C are arranged side-by-side in the vertical direction. In Figure 2, the first pass region 412A, the second pass region 412B, the third pass region 412C, and the fourth pass region 412D are given a rough hatch pattern.

[0033] The first path region 412A extends from the left end (i.e., the first side frame 42) to the right end (i.e., the second side frame 43) of the backboard 41. The first path region 412A is adjacent to the first main region 411A, the third main region 411C, and the fourth main region 411D. The first path region 412A is thicker than the first main region 411A, the third main region 411C, and the fourth main region 411D.

[0034] As shown in Figure 3A, the first pass region 412A has a central portion 4121, an upper end portion 4122, and a lower end portion 4123. The central portion 4121 is the region between the upper end portion 4122 and the lower end portion 4123 in the vertical direction. The thickness of the central portion 4121 is, for example, 3 mm.

[0035] The upper end portion 4122 is adjacent to the first main region 411A or the third main region 411C. The lower end portion 4123 is adjacent to the fourth main region 411D. The thickness of the upper end portion 4122 and the lower end portion 4123 is even greater than the thickness of the central portion 4121.

[0036] In other words, the upper end portion 4122 and the lower end portion 4123 protrude forward of the sheet compared to the central portion 4121. This facilitates the supply of molten metal from the first pass region 412A to the first main region 411A, the third main region 411C, and the fourth main region 411D during the molding of the back frame 4.

[0037] Furthermore, as shown in Figure 3B, the thickness of the upper end portion 4122 and the lower end portion 4123 may decrease toward the outward direction in the vertical direction (i.e., toward the adjacent main region). In the case of Figure 3B, the front surfaces of the upper end portion 4122 and the lower end portion 4123 are inclined to connect the front surface of the central portion 4121 with the front surfaces of the main regions 411A, 411C, and 411D.

[0038] Furthermore, as shown in Figure 3C, the thicknesses of the upper end portion 4122 and the lower end portion 4123 may be the same as the thickness of the central portion 4121. In the case of Figure 3C, the first pass region 412A has a constant thickness in the vertical direction.

[0039] As shown in Figure 2, the upper and lower edges of the first path region 412A (excluding the connection portion with the belt path 416) are parallel to the sheet width direction. The upper edge of the first path region 412A is adjacent to the first main region 411A, the first opening 414A, and the third main region 411C. The lower edge of the first path region 412A is adjacent to the fourth main region 411D and the third opening 414C.

[0040] The second path region 412B extends from the left end to the right end of the backboard 41, below the first path region 412A. The second path region 412B is adjacent to the fourth main region 411D, the fifth main region 411E, and the sixth main region 411F. The second path region 412B is thicker than the fourth main region 411D, the fifth main region 411E, and the sixth main region 411F. The cross-sectional shape of the second path region 412B is the same as that of the first path region 412A.

[0041] The upper and lower edges of the second path region 412B are parallel to the sheet width direction. The upper edge of the second path region 412B is adjacent to the fourth main region 411D and the third opening 414C. The lower edge of the second path region 412B is adjacent to the fifth main region 411E, the fourth opening 414D, the fifth opening 414E, and the sixth main region 411F.

[0042] The third path region 412C extends from the left end to the right end of the backboard 41, below the second path region 412B. The third path region 412C is adjacent to the fifth main region 411E and the sixth main region 411F. The third path region 412C is thicker than the fifth main region 411E and the sixth main region 411F. The cross-sectional shape of the third path region 412C is the same as that of the first path region 412A.

[0043] The upper and lower edges of the third path region 412C are parallel to the sheet width direction. The upper edge of the third path region 412C is adjacent to the fifth main region 411E, the fifth opening 414E, and the sixth main region 411F. The lower edge of the third path region 412C is adjacent to the lower end of the backboard 41.

[0044] The fourth path region 412D extends above the first path region 412A, from the left end of the backboard 41 toward the first path region 412A. In other words, the right end of the fourth path region 412D merges with the first path region 412A.

[0045] The fourth path region 412D is adjacent to the second main region 411B and the third main region 411C. The fourth path region 412D is thicker than the second main region 411B and the third main region 411C. The cross-sectional shape of the fourth path region 412D is the same as that of the first path region 412A.

[0046] The upper and lower edges of the fourth path region 412D each have a portion parallel to the sheet width direction and a portion inclined with respect to the sheet width direction. The upper edge of the fourth path region 412D is adjacent to the second main region 411B and the second opening 414B. The lower edge of the fourth path region 412D is adjacent to the third main region 411C.

[0047] The first opening 414A, the second opening 414B, the third opening 414C, the fourth opening 414D, and the fifth opening 414E are rectangular portions adjacent to at least one of the first path region 412A, the second path region 412B, the third path region 412C, and the fourth path region 412D. The openings 414A-414E have openings in their internal regions. The four corners of the openings 414A-414E are each chamfered.

[0048] Furthermore, the thickness of the edges of openings 414A-414E, including the four corners, is greater than the thickness of the adjacent path regions 412A-412D. The thickness of the edges of openings 414A-414E is, for example, 3.5 mm or more. Note that in Figure 2, fine hatching is applied to the edges of openings 414A-414E.

[0049] The first opening 414A is adjacent to the first main region 411A, the second main region 411B, and the first path region 412A. The thickness of the edge of the first opening 414A is greater than the thickness of the first path region 412A. The second opening 414B is adjacent to the second main region 411B and the fourth path region 412D. The thickness of the edge of the second opening 414B is greater than the thickness of the fourth path region 412D.

[0050] The third opening 414C is adjacent to the fourth main region 411D, the first path region 412A, and the second path region 412B. The thickness of the edge of the third opening 414C is greater than the thickness of the first path region 412A and the second path region 412B. The fourth opening 414D is adjacent to the fifth main region 411E and the second path region 412B. The thickness of the edge of the fourth opening 414D is greater than the thickness of the second path region 412B.

[0051] The fifth opening 414E is adjacent to the fifth main region 411E, the sixth main region 411F, the first path region 412A, and the second path region 412B. The thickness of the edge of the fifth opening 414E is greater than the thickness of the first path region 412A and the second path region 412B.

[0052] <Side frame> The first side frame 42 and the second side frame 43 are panel-shaped members that extend in the vertical direction of the sheet and are arranged apart from each other in the width direction of the sheet.

[0053] The first side frame 42 extends forward from the first end (i.e., the left end) of the backboard 41 in the seat width direction. The second side frame 43 extends forward from the second end (i.e., the right end) of the backboard 41 in the seat width direction. The length of the first side frame 42 and the second side frame 43 in the seat front-rear direction is greater than the length in the seat width direction.

[0054] <Manufacturing method for vehicle back frames> The method for manufacturing a vehicle back frame in this embodiment is a method for obtaining the back frame 4 shown in Figure 2. As shown in Figure 4, the method for manufacturing a vehicle back frame includes a pouring step S10 and an extraction step S20.

[0055] <Pouring process> In this process, molten metal such as aluminum is poured into a mold 100 shown in Figure 5. The mold 100 has a plurality of main parts 101A, 101B, 101C, 101D, 101E, 101F, a plurality of pass parts 102A, 102B, 102C, 102D, a plurality of opening forming parts 104A, 104B, 104C, 104D, 104E, a first side part 105, a second side part 106, and an injection port 110.

[0056] The first main section 101A is the space that forms the first main region 411A. The second main section 101B is the space that forms the second main region 411B. The third main section 101C is the space that forms the third main region 411C. The fourth main section 101D is the space that forms the fourth main region 411D. The fifth main section 101E is the space that forms the fifth main region 411E. The sixth main section 101F is the space that forms the sixth main region 411F.

[0057] The first path section 102A is the space that forms the first path region 412A. The second path section 102B is the space that forms the second path region 412B. The third path section 102C is the space that forms the third path region 412C. The fourth path section 102D is the space that forms the fourth path region 412D.

[0058] The first path section 102A, the second path section 102B, and the third path section 102C are arranged vertically in the back frame 4. The path sections 102A-102D are configured such that, for example, the thickness of the upper end 4122 and the lower end 4123 shown in Figure 3A is greater than the thickness of the central part 4121, forming a path region.

[0059] The first opening-forming portion 104A is the space that forms the first opening 414A. The second opening-forming portion 104B is the space that forms the second opening 414B. The third opening-forming portion 104C is the space that forms the third opening 414C. The fourth opening-forming portion 104D is the space that forms the fourth opening 414D. The fifth opening-forming portion 104E is the space that forms the fifth opening 414E.

[0060] The first side portion 105 is the space that forms the first side frame 42. The first side portion 105 is in communication with the first path portion 102A, the second path portion 102B, the third path portion 102C, and the fourth path portion 102D.

[0061] The second side portion 106 is a space that forms the second side frame 43. The second side portion 106 is in communication with the first path portion 102A, the second path portion 102B, and the third path portion 102C.

[0062] The injection port 110 is a flow channel for supplying molten metal into the mold 100. The injection port 110 communicates with at least the first pass section 102A, the second pass section 102B, the third pass section 102C, and the fourth pass section 102D via the first side section 105. The injection port 110 is located on the left side of the back frame 4 of the mold 100.

[0063] In this process, the mold 100 is set up with the right side of the back frame 4 facing downwards, and molten metal is supplied to the injection port 110. In this state, the longitudinal directions of the first pass section 102A, the second pass section 102B, and the third pass section 102C are parallel to the vertical direction.

[0064] The molten metal supplied to the injection port 110 flows vertically downward through the first pass section 102A, the second pass section 102B, the third pass section 102C, and the fourth pass section 102D. As a result, the molten metal is supplied from these pass sections 102A-102D to the main section 101A-101F and the opening forming section 104A-104E.

[0065] <Removal process> In this process, the molded product formed from molten metal poured into the mold 100 is removed from the mold 100. The back frame 4 is obtained by performing the necessary processing on the removed molded product.

[0066] [1-2. Effects] According to the embodiments described in detail above, the following effects can be obtained. (1a) During the molding of the back frame 4, molten metal can be supplied in the sheet width direction by the pass regions 412A-412D (i.e., pass sections 102A-102D). Therefore, the back board 41 can be integrally molded with the first side frame 42 and the second side frame 43 while controlling the thickness of the back board 41 to reduce its weight.

[0067] (1b) By arranging multiple path regions 412A-412C (i.e., path sections 102A-102C) in a vertical direction, it is possible to create an opening in the backboard 41 while controlling the thickness of the backboard 41 during the molding of the back frame 4.

[0068] (1c) The thickness of the corners of the openings 414A-414E is greater than the thickness of the path region 412A-412D, which makes it easier to control the thickness of the main region 411A-411F around the openings 414A-414E when molding the back frame 4.

[0069] [2. Other Embodiments] While embodiments of this disclosure have been described above, it goes without saying that this disclosure is not limited to the embodiments described above and can take various forms.

[0070] (2a) In the vehicle seat of the above embodiment, the back frame does not necessarily have to have multiple path regions. For example, the back frame may have only one path region.

[0071] (2b) In the vehicle seat of the above embodiment, the thickness of the corner of the opening does not necessarily have to be greater than the thickness of the adjacent path area. Also, the back frame does not necessarily have to have an opening.

[0072] (2c) The vehicle seat of the above embodiment can also be applied to seats used in automobiles other than passenger cars, and seats used in vehicles other than automobiles, such as railway cars, ships, and aircraft.

[0073] (2d) The functions of one component in the above embodiment may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Also, some parts of the configuration of the above embodiment may be omitted. Also, at least some parts of the configuration of the above embodiment may be added to, substituted for, or otherwise used in the configuration of other above embodiments. Any aspect of the technical concept specified by the wording of the claims is an embodiment of the present disclosure. [Explanation of symbols]

[0074] 1...Vehicle seat, 2...Seat cushion, 3...Seat back, 4...Back frame, 41...Backboard, 42...First side frame, 43...Second side frame, 100...Mold, 101A-101F...Main section, 102A-102D...Path section 104A-104E...Opening forming section, 105...First side section, 106...Second side section, 110...Inlet, 411A-411F...Main area, 412A-412D...Path area 414A-414E…Opening, 415A, 415C…Base, 416…Belt path, 417...Boss, 418...Opening with bracket, 4121...Center section, 4122...Upper end section, 4123...Lower end.

Claims

1. Seat cushion and, The seatback and, A back frame that supports the aforementioned seat back, Equipped with, The aforementioned back frame is Backboard and A first side frame extending forward from the first end of the backboard in the seat width direction, A second side frame extending forward from the second end of the backboard in the seat width direction, It has, The aforementioned backboard is Main domain and, At least one path region adjacent to the main region, having a greater thickness than the main region, and extending in the sheet width direction, It has, A vehicle seat in which the thickness of the upper and lower ends of the at least one path region is greater than the thickness of the central part of the at least one path region.

2. Seat cushion and, The seatback and, A back frame that supports the aforementioned seat back, Equipped with, The aforementioned back frame is Backboard and A first side frame extending forward from the first end of the backboard in the seat width direction, A second side frame extending forward from the second end of the backboard in the seat width direction, It has, The aforementioned backboard is Main domain and, At least one path region adjacent to the main region, having a greater thickness than the main region, and extending in the sheet width direction, It has, The backboard is adjacent to the path area and has a rectangular opening at its corners where the thickness is greater than the thickness of the path area, making it a seat for a vehicle.

3. A vehicle seat according to claim 1 or claim 2, The backboard is a vehicle seat having a plurality of path areas arranged vertically, with each path area comprising at least one path area.

4. A method for manufacturing a vehicle back frame, comprising a backboard, a first side frame extending forward from a first end of the backboard in the seat width direction toward the seat, and a second side frame extending forward from a second end of the backboard in the seat width direction toward the seat, It includes a process of pouring molten metal into a mold, The aforementioned mold is The main part forming the main area of ​​the backboard, At least one path portion adjacent to the main region and having a greater thickness than the main region, and forming at least one path region extending in the width direction of the back frame, The first side portion forming the first side frame, The second side portion forming the second side frame, It has, A method for manufacturing a vehicle back frame, comprising the pouring step of supplying molten metal to the main part from at least one pass section.

5. A method for manufacturing a vehicle back frame according to claim 4, A method for manufacturing a vehicle back frame, wherein the mold has a plurality of path sections arranged vertically in the back frame, with the at least one path section being a plurality of path sections arranged vertically in the back frame.

6. A method for manufacturing a vehicle back frame according to claim 4 or claim 5, A method for manufacturing a vehicle back frame, wherein the at least one path portion forms the at least one path region in which the thickness of the upper end and lower end portion is greater than the thickness of the central portion.

7. A method for manufacturing a vehicle back frame according to claim 4 or claim 5, A method for manufacturing a vehicle back frame, wherein the mold has an opening-forming portion adjacent to the path region and forming a rectangular opening in which the thickness of the corner portion is greater than the thickness of the path region.

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