Modular hot stamped back frame

Abstract

A back frame for a seat assembly for use in an automotive vehicle is provided. The back frame includes a back panel, a stamped member, and a plurality of inserts. The stamped member is fixedly coupled to the back panel and includes a ridge, an inward wall, an outward wall, and a main channel. The inward wall and the outward wall extend away from the ridge. The main channel is defined between the inward wall, the ridge, and the outward wall. A plurality of outer holes are formed in the outward wall of the stamped member. The plurality of inserts are axially aligned with a respective one of the plurality of outer holes and fixedly coupled to the outward wall.

Description

MODULAR HOT STAMPED BACK FRAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63 / 779,405, filed on March 28, 2025, the disclosure of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates to a seat assembly for an automotive vehicle. More particularly, the invention relates to a back frame for use in an automotive seat assembly.DESCRIPTION OF RELATED ART

[0003] Automotive vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above a vehicle floor. In certain seating configurations, both the seat cushion and the seat back include a structural assembly having a rigid structure, a foam pad, and a fabric covering. Each structural assembly may also include various ancillary structures, such as a recliner mechanism and a headrest support, for example. The structural assemblies are configured to support the weight of the passenger during normal vehicle operation, and to manage loads transferred to the seat during an impact.

[0004] Certain seat structures are constructed from metal formed components. For example, one known seat back structure includes a left side member, a right side member, a top cross member, and a bottom cross member, each constructed via a metal forming process. The members may be coupled to one another, e g., via bolted or welded connections, to form the complete seat back structure. Further, the members may be coupled to a rigid panel, which extends between and supports the members. In addition, these commonly known seat back structures may include one or more brackets fastened to the members for attaching other components of the seat assembly. However, the number of components in these known seat back structures in combination with the manufacturing processes required to attach the components negatively impacts the part cost while also increasing the tooling and capital costs. Further, these known seat back structures are not easily scalable for use with other seat assemblies.

[0005] Other commonly known seat back structures may also be formed from a single piece of metal. For example, the single sheet of metal may be formed into the known seat back structurevia multiple drawing processes or via one or more stamping processes. A first known one-piece seat back structure for an automotive seat assembly is illustrated in U.S. Patent 9,707,878. The first known seat back structure is formed by bending a single piece of material via a plurality of stamping processes. The formed seat back structure includes a plurality of support tabs for attaching other components. However, the first known one-piece seat back structure is not easily scalable for use in other seat assemblies since the support tabs for attaching other components are formed during the stamping processes.

[0006] It is desirable to provide a back frame for use in an automotive seat assembly, which has a modular construction, and which is scalable for use in different seat assemblies while minimizing tooling changes, capital investment, and part cost impacts. It is also desirable to provide a back frame w hich is manufactured with a simplified manufacturing process. It is also desirable to provide a back frame w hich includes a reduced number of parts, a reduced number of weld locations, and a reduction in part mass.SUMMARY OF THE INVENTION

[0007] According to one embodiment, there is provided a back frame for a seat assembly for use in an automotive vehicle. The back frame includes a back panel, a stamped member, and a plurality of inserts. The stamped member is fixedly coupled to the back panel and includes a ridge, an inward wall, an outward wall, and a main channel. The inward wall and the outward wall extend aw ay from the ridge. The main channel is defined between the inward wall, the ridge, and the outward wall. A plurality of outer holes are formed in the outward wall of the stamped member. The plurality of inserts are axially aligned with a respective one of the plurality of outer holes and fixedly coupled to the outward wall.

[0008] According to another embodiment, there is provided a method of forming a back frame for a seat assembly. The method includes providing a back panel, providing a steel blank, heating the steel blank to an elevated temperature to form a heated steel blank, forming the heated steel blank into a stamped member having a desired shape using a single stamping process, quenching the stamped member to a reduced temperature lower than the elevated temperature, and welding the stamped member to the back panel. The stamped member includes a ridge, an inward wall, an outward wall, and a main channel. The inw ard wall and the outward wall extend away from the ridge. The main channel is defined betw een the inward wall, the ridge, and the outward wall.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0010] Figure l is a perspective view of a vehicle seat assembly having a back frame, according to one embodiment of the present invention;

[0011] Figure 2 is a front perspective view of the back frame of Figure 1;

[0012] Figure 3 is a rear perspective view of the back frame of Figure 2;

[0013] Figure 4 is an exploded view of the back frame of Figure 3;

[0014] Figure 5 is a rear view of a stamped member of Figure 4;

[0015] Figure 6 is a cross-sectional view of the back frame of Figure 2 taken along line 6-6 in Figure 2;

[0016] Figure 7 is a cross-sectional view of the back frame of Figure 2, taken along line 7-7 in Figure 2;

[0017] Figure 8 is an enlarged cross-sectional view of portion 8 of the seat assembly of Figure 1;

[0018] Figure 9 is an enlarged front view of a portion of the back frame of Figure 2;

[0019] Figure 10 is an enlarged front perspective view of aportion of the back frame of Figure 2;

[0020] Figure 11 is a flowchart showing a process to form the back frame of Figure 1, according to one embodiment of the present invention;

[0021] Figure 12 is a front view of a back frame, according to a second embodiment of the present invention;

[0022] Figure 13 is a rear perspective view of the back frame of Figure 12;

[0023] Figure 14 is an exploded view of the back frame of Figure 13;

[0024] Figure 15 is a rear view' of a stamped member of Figure 14;

[0025] Figure 16 is a cross-sectional view of the back frame of Figure 12, taken along line 16- 16 in Figure 12; and

[0026] Figure 17 is a cross-sectional view of the back frame of Figure 12 taken along line 17- 17 in Figure 12.DETAILED DESCRIPTION OF THE INVENTION

[0027] Figures 1-17 illustrate a back frame 10 for use in a vehicle seat assembly 12, according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0028] Figure 1 shows the back frame 10 integrated within the vehicle seat assembly 12, according to one embodiment of the present invention. The seat assembly 12 includes a seat back 14, a seat cushion 16, a left recliner 18, a right recliner 20, and a head restraint 22. The seat back 14 is pivotally coupled to the seat cushion 16 by the left and right recliners 18, 20. In addition, the head restraint 22 is slidably coupled to an upper portion of the seat back 14.

[0029] In more detail, the seat back 14 includes a back pad (not shown) supported by the back frame 10 and encased by a trim cover (not shown). Further, the seat back 14 also includes a left tube 32 and a right tube 34 for supporting the head restraint 22. The left and right tubes 32, 34 are laterally spaced apart and fixedly coupled to an upper portion of the back frame 10, as further described below. Depicted in Figure 4, the left and right tubes 32, 34 have a cylindrical shape with a respective bore 48, 50 extending axially therethrough. It will be appreciated that the size and shape of the left and right tubes 32, 34 might vary without altering the scope of the present invention. Depicted in Figure 1, the head restraint 22 includes a left rod 52 and a right rod 54, which are laterally spaced apart and extend downwardly therefrom. The left and right rods 52, 54 are slidably coupled to the bores 48, 50 in the left and right tubes 32, 34, respectively. The seat back 14 also includes a left A-bracket 56 and a right A-bracket 58, which are laterally spaced apart and fixedly coupled to the adjacent sides of the back frame 10. Depicted in Figure 8. each of the left and right A-brackets 56, 58 includes an upper opening 60spaced apart from a lower opening 62. The seat back 14 also includes a plurality of mechanical fasteners 63 fixedly coupling the left and right A-brackets 56, 58 to the back frame 10. The plurality of mechanical fasteners 63 are threaded fasteners and include a threaded shaft 67 projecting axially from a fastener head 68.

[0030] Depicted in Figure 1, the seat cushion 16 includes a foam pad (not shown) supported by a cushion frame 69 and encased by another trim cover (not shown). The seat cushion 16 also includes a left B-bracket 70 and a right B-bracket 71, which are laterally spaced apart and fixedly coupled to the adjacent sides of the cushion frame 69. The left and right A-brackets 56, 58 are pivotally coupled to the left and right B-brackets 70, 71 by the left and right recliners 18, 20, respectively.

[0031] Depicted in Figures 1-4, the back frame 10 provides a rigid structure for the seat back 14 and provides mounting locations for additional components (not shown) within the seat back 14. The back frame 10 is a modular assembly with a simplified structure that potentially reduces the part cost, reduces the part mass, simplifies the manufacturing process, and reduces the amount of required welds in comparison to a known back frame assembled with a plurality of tubular parts welded together. Further, the back frame 10 allows for a modular and scalable design, which may be adjusted for changes in the width, size, and location of the head restraint rods 52, 54. In addition, the back frame 10 may be adjusted to accommodate different widths of the seat cushion 16, different widths of the seat back 14, differences in the size, type, and location of the recliners 18, 20, and variation in the left and right A-brackets 56, 58, and the like, as non-limiting examples. The back frame 10 is illustrated as a component of a seat assembly 12 which is suitable for use in any vehicle row (i.e., a front row seat, a second row seat, a third row seat, and the like). It will be appreciated that the back frame 10 might be incorporated in various locations within the seat assembly 12 (such as forming a cushion frame 69 as a non-limiting example) and further might be incorporated into other types of seating assemblies, without altering the scope of the present invention.

[0032] Depicted in Figures 2-4, the back frame 10 includes a back panel 72, which is formed out of a metal and has a generally rectangular shape in profile. The back panel 72 includes a base 73, a left side 74, a right side 76, an upper end 78, a lower end 80, a front surface 82, and a rear surface 84. The base 73 extends laterally between the left and right sides 74, 76, extends vertically between the upper and lower ends 78, 80, and extends betw een the front and back surfaces 82, 84.

[0033] Depicted in Figures 3, 4, and 7, the back panel 72 includes a plurality of weld bosses 102, which are spaced apart and formed in the base 73. Each one of the plurality of weld bosses 102 has a truncated conical shape, which includes a tapered sidewall 104 and a top wall 106. The tapered sidewall 104 extends in a circumferential direction and extends axially between the base 73 and the top wall 106. It will be appreciated that the plurality of weld bosses 102 might vary in size, shape, quantity, relative position, and the like, as non-limiting examples without altering the scope of the present invention.

[0034] Depicted in Figures 2, 4 and 10, the back frame 10 also optionally includes a handle bracket 120 for supporting and / or mounting other components (not shown) within the seat back 14, such as a latch assembly (not shown), a release handle (not shown), and the like as nonlimiting examples. The handle bracket 120 is fixedly coupled to the back frame 10, as described below.

[0035] Depicted in Figures 2, 4. 7 and 8, the back frame 10 also includes a plurality of inserts 130 for attaching or otherwise fixedly coupling the left and right A-brackets 56, 58 to the back frame 10. It will be appreciated that the plurality of inserts 130 optionally includes one or more of a weld insert, a weld nut, a weld collar, and the like, as non-limiting examples and as is commonly known in the art. Each of the plurality of inserts 130 is formed out of a metal, is generally cylindrically shaped, and includes a shaft wall 138, a head end 140, a tail end 142, and an insert bore 146. The shaft wall 138 extends in a circumferential direction and extends axially between the head end 140 and the tail end 142. The insert bore 146 extends axially between the head and tail ends 140, 142. One or more of the plurality of inserts 130 might include an internal thread (not shown) extending in a circumferential direction along the insert bore 146, an external thread (not shown) extending in a circumferential direction along the shaft wall 138, a flange, one or more locating features, a stud projecting axially therefrom, or the like as non-limiting examples. It will be appreciated that the size, shape, quantity, and features of each of the plurality of inserts 130 might vary, without altering the scope of the present invention.

[0036] Depicted in Figures 4-10, the back frame 10 also includes a stamped member 148, which forms the main structure of the back frame 10. The stamped member 148 is fixedly coupled to the front surface 82 of the back panel 72. The stamped member 148 is formed as a single component out of a steel blank via a hot stamping process. An exemplary hot stamping process typically includes heating a low strength steel blank (not shown) to an elevatedtemperature in a furnace, such as 950 °C as a non-limiting example, forming the heated steel blank into a desired shape using a single stamping process (i.e.. a single hit) while the steel blank is at the elevated temperature, and quenching the stamped steel blank to a reduced temperature, such as 200 °C as a non-limiting example. Forming a shaped component out of low strength steel using the above described hot stamping process results in a shaped component comprising a high strength steel having a martensitic microstructure and may further have complex shapes. The stamped member 148 provides a simplified structure for the back frame 10 in place of commonly known welded assemblies formed out of multiple pieces.

[0037] In more detail, the stamped member 148 is generally ring-shaped and includes a front surface 150, a rear surface 152, a left-hand side 154. a right-hand side 156, a top end 158, a bottom end 160, and a central opening 162. The front and rear surfaces 150, 152 oppose each other, extend laterally between the left-hand and right-hand sides 154, 156, and extend vertically between the top end 158 and the bottom end 160. The central opening 162 extends axially through the stamped member 148. is spaced laterally between the left-hand and righthand sides 154, 156, and is spaced vertically between the top and bottom ends 158, 160. The stamped member 148 also includes an outward flange 164, an inward flange 166, a ridge 170, an outward wall 172, an inward wall 174, and a main channel 176. The outward flange 164 extends in a circumferential direction around an outer periphery of the stamped member 148 and extends generally outwardly in a radial direction. The inward flange 166 extends in a circumferential direction around a periphery of the central opening 162 and extends generally in a radial direction. The ridge 170 extends in a circumferential direction around the central opening 162, is spaced laterally between the outward and inward flanges 164, 166, and is offset in an axial direction therefrom. The outward wall 172 extends between an inner end of the outward flange 164 and an outer end of the ridge 170. The inward wall 174 extends between an inner end of the inward flange 166 and an inner end of the ridge 170. Said differently, the inward wall 174 and the outward wall 172 oppose each other and extend away from the ridge 170. Depicted in Figures 6-8, the main channel 176 is defined between the outward wall 172, the ridge 170, and the inward wall 174 on the rear surface 152 of the stamped member 148. It will be appreciated that the cross-sectional shape and size of the main channel 176 might vary without altering the scope of the present invention.

[0038] Depicted in Figures 4 and 5, the stamped member 148 also includes a mounting portion 178 formed in the ridge 170 near the top end 158 of the stamped member 148, which provides a mounting location for the left and right tubes 32, 34.

[0039] Depicted in Figures 4 and 5, the stamped member 148 also includes a left slot 184 and aright slot 186, which are laterally spaced apart along the mounting portion 178 for supporting the left and right tubes 32, 34, respectively. Each of the left and right slots 184, 186 include an outer segment 188, an inner segment 192, a first segment 196, and a second segment 200, respectively. The outer and inner segments 188, 192 are formed in the outward and inward walls 172, 174, respectively, adjacent to the mounting portion 178 and have arcuate-shaped cross-sections.

[0040] The first and second segments 196, 200 extend along the mounting portion 178 between adjacent ends of the outer and inner segment 188, 192, respectively. The left and right slots 184, 186 are sized and shaped to matingly engage with the left and right tubes 32, 34, respectively.

[0041] Depicted in Figure 10, the left and right slots 184, 186 are cut with a first laser (not shown) using a typical laser cutting process, as is commonly known in the art. Laser cutting the left and right slots 184, 186 after forming the stamped member 148 allows for adjustment in the relative placement, size, shape, diameter, and the like of the left and right slots 184, 186 to accommodate differences in configurations between various seat assemblies 12 without impacting tooling. For example, the relative position along the mounting portion 178 and / or the distance between the left and right slots 184, 186 might be increased and / or decreased, as illustrated by arrows 202 and 203, to accommodate variations between different seat assemblies 12.

[0042] Depicted in Figures 4 and 5, the stamped member 148 also includes a secondary portion 204 extending along the ridge 170 for supporting and attaching the handle bracket 120. Further, the stamped member 148 includes a first passage 205, a second passage 206, a third passage 208, and a fourth passage 210, and described as a plurality of passages 205, 206, 208, 210 for supporting and containing the plurality’ of inserts 130. respectively. The stamped member 148 also includes a plurality of inner holes 212, 214, 216, 218 and a plurality of outer holes 220, 222, 224, 226, also described as first through fourth inner holes 212, 214, 216, 218 and first through fourth outer holes 220, 222, 224, 226, respectively. In more detail, the first and secondpassages 205, 206 are spaced apart adjacent the left-hand side 154 of the stamped member 148 and extend laterally through the main channel 176 between the first and second inner holes 212, 214 in the inward wall 174 and the first and second outer holes 220, 222 in the outward wall 172, respectively. The third and fourth passages 208, 210 are spaced apart adjacent the right-hand side 156 of the stamped member 148 and extend laterally through the main channel 176 between the third and fourth inner holes 216, 218 in the inward wall 174 and the third and fourth outer holes 224. 226 in the outward wall 172, respectively.

[0043] The plurality of inner and outer holes 212, 214, 216, 218, 220, 222, 224, 226 are cut with a second laser (not shown) using a commonly known laser cutting process. Laser cutting the plurality of inner and outer holes 212, 214, 216. 218, 220, 222, 224, 226 after forming the stamped member 148 allows for adjustment in the relative placement, size, and shape, of the plurality of inner and outer holes 212, 214, 216, 218, 220, 222, 224, 226, as illustrated by arrow 228 in Figure 5, to accommodate differences in configurations between various seat assemblies 12 without impacting tooling.

[0044] Depicted in Figures 7 and 9, each one of the plurality of inserts 130 are inserted into the respective one of the plurality of passages 205, 206, 208, 210 and fixedly coupled to the stamped member 148 by a plurality of insert welds 229, 230. The plurality of insert welds 229, 230 include an inner weld 229 and an outer weld 230 formed between each one of the plurality of inserts 130 and the stamped member 148 along the adjacent inner hole 212, 214, 216, 218 and along the adjacent outer hole 220, 222, 224, 226, respectively.

[0045] Prior to forming the plurality of insert welds 229, 230, the plurality’ of inserts 130 might be slid laterally along the respective one of the plurality' of passages 205, 206, 208, 210 to accommodate different w idths and relative positions of the adjacent left and right A-brackets 56, 58, as represented by arrows 231, 232, 234, 236. The welding process to form the plurality of insert welds 229, 230 is unaffected by the lateral position of the plurality of inserts 130 along the respective one of the plurality of passages 205, 206, 208, 210 since the plurality of insert welds 229, 230 are formed in predetermined positions on the stamped member 148. As such, the back frame 10 of the present invention allows for changes in the seat assembly 12, including changes in the width of the seat back 14, the width of the seat cushion 16, changes in the left and right A-brackets 56, 58, and the like, with minimal impact on tooling since the lateral position of the plurality' of inserts 130 is adjustable within the respective one of the plurality of passages 205, 206, 208, 210 without affecting the welding process.

[0046] An exemplary' method or process of forming, assembling, and welding the back frame 10 is described below in reference to Figures 2-11. Depicted in Figure 11, the process is initiated in step 237, which includes providing a steel blank (not show n). Next, in step 238, the steel blank (not shown) is formed into the stamped member 148 using the hot stamping process described above. Next in step 239 and after the stamped member 148 is formed using the hot stamping process, one or more lasers forms the left and right slots 184, 186 and the plurality of inner and outer holes 212, 214. 216, 218. 220, 222, 224, 226 in the stamped member 148, using a commonly known laser cutting process.

[0047] Next, in step 240, the stamped member 148 is assembled with the remaining components of the back frame 10 to form a back frame assembly 10A (Figure 4). Specifically, the back panel 72, the left and right tubes 32, 34, the handle bracket 120, and the plurality of inserts 130 are provided and assembled with the stamped member 148, as further described below-. The stamped member 148 is assembled w ith the back panel 72 with the rear surface 152 of the stamped member 148 abutted against the front surface 82 of the back panel 72 with the outward and inward flanges 164, 166 abutted against and aligned with the top wall 106 of the associated weld bosses 102. Next, and as depicted in Figure 6, the left and right tubes 32, 34 are inserted into the left and right slots 184, 186, respectively, in the stamped member 148. Next, and as depicted in Figure 10, the handle bracket 120 is assembled with the secondary portion 204 of the stamped member 148. Next, and as depicted in Figures 7-9, the plurality of inserts 130 are assembled with the stamped member 148 by inserting the tail end 142 of each one of the plurality' of inserts 130 into and through the associated one of the plurality of inner holes 212, 214, 216, 218, into the respective one of the plurality of passages 205, 206, 208, 210, and through the respective one of the plurality of outer holes 220, 222, 224, 226.

[0048] Next, in step 241, components of the back frame assembly 10A are fixedly coupled to adjacent components using one or more commonly known welding processes to form the back frame 10. In more detail, the stamped member 148 is fixedly coupled to the back panel 72 by a plurality of flange welds 242 extending betw een the outward and inward flanges 164, 166 of the stamped member 148 and the adjacent weld bosses 102 on the back panel 72, as depicted in Figures 2, 3, and 7. The plurality of flange w elds 242 might be formed using resistance spot welding (RSW or spot welding), projection welding, or other commonly known welding processes. Next, and as depicted in Figures 2 and 6. the left and right tubes 32, 34 are fixedly coupled to the stamped member 148 by a plurality of tube welds 246 formed using a commonlyknown welding process, such as metal insert gas welding (MIG welding), gas metal arc welding (GMAW), or other suitable welding processes. Next, the handle bracket 120 is fixedly coupled to the stamped member 148 by one or more welds using an exemplary welding process such as MIG welding or another commonly known welding process. Next, and as depicted in Figures 7 and 9, the plurality of inserts 130 are fixedly coupled to the stamped member 148 by the plurality of insert welds 229, 230 using an exemplar}- welding process such as MIG welding or another commonly known welding process. Next, the exemplary process of forming the back frame 10 is terminated in step 251 after the welding process (step 241). It will be appreciated that the laser cutting process, the assembly process, and the welding processes used to form the back frame 10 might vary in sequential order, type, number and specific components, including omitting or adding certain components, and the like, without altering the scope of the present invention.

[0049] Next, the back frame 10 is fixedly coupled with the left and right A-brackets 56, 58, as depicted in Figure 8. In more detail, the threaded shaft 67 of each of the plurality- of mechanical fasteners 63 is inserted through a respective one of the plurality of openings 60, 62 in the left and right A-brackets 56, 58 and into the insert bore 146 in the adjacent one of the plurality of inserts 130 and mechanically fastened thereto.

[0050] A back frame 10' is shown in Figures 12-17, according to a second embodiment of the present invention. Elements in Figures 12-17 having like primed reference numerals represent similar elements as those described above. Only significant differences between the second embodiment and the prior embodiment are reflected in Figures 12-17 and the description below. The back frame 10' is modified to allow the back frame 10' to be assembled with welds formed by resistance spot welding (RSW), projection welding, or similar known welding processes. In contrast, the back frame 10 of the prior embodiment includes welds formed by resistance spot welding (RSW), projection welding, and the like in addition to certain welds formed by metal insert gas welding (MIG), gas metal arc welding (GMAW), and the like.

[0051] Depicted in Figures 12-15, the back frame 10' includes a back panel 72', a left tube 32', and a right tube 34'. The back panel 72' includes a base 73' and a plurality of weld bosses 102', which are spaced apart and project from the base 73'. The left and right tubes 32', 34' are laterally spaced apart and fixedly coupled to the back frame 10', as further described below. Further, each of the left and right tubes 32', 34' is formed out of a metal, has a generally rectangular-shaped cross-section, and includes a base wall 262' forming one side thereof. Itwill be appreciated that the shape, size, and features of the left and right tubes 32', 34' might vary without altering the scope of the present invention.

[0052] The back frame 10' also includes a stamped member 148' fixedly coupled to the back panel 72'. The lateral width of the back frame 10', the back panel 72', and / or the stamped member 148' is selected based on the requirements of the seat assembly 12' (Figure 1). The stamped member 148' includes a front surface 150', a rear surface 152', a left-hand side 154', a right-hand side 156', atop end 158', a central opening 162', an outward flange 164', an inward flange 166', a ridge 170', an outward wall 172', an inward wall 174', a main channel 176', and a secondary portion 204', which are generally constructed as described above in the first embodiment. It will be appreciated that the cross-sectional shape and size of the main channel 176' might vary without altering the scope of the present invention.

[0053] Depicted in Figures 14, 15 and 16, the stamped member 148' also includes a mounting portion 178' formed in the ridge 170' near the top end 158' of the stamped member 148', which provides a mounting location for the left and right tubes 32', 34'. The mounting portion 178' is shaped to matingly engage with the base wall 262' of the left and right tubes 32', 34'. In Figures 14 and 15, the mounting portion 178' is generally a planar surface. However, it will be appreciated that the shape, size, and location of the mounting portion 178' might vary without altering the scope of the present invention.

[0054] Depicted in Figures 14 and 15, the stamped member 148' also includes a plurality of inner holes 212', 214', 216', 218' and a plurality of outer holes 220'. 222', 224', 226' formed in stamped member 148' using a commonly known laser-cutting process. The laser-cutting process allows the specific locations and diameters of the plurality of inner and outer holes 212', 214', 216', 218', 220', 222', 224', 226' to be adjusted on the stamped member 148' to accommodate requirements for different seat assemblies 12' (Figure 1). The plurality of inner and outer holes 212', 214', 216', 218', 220', 222', 224', 226' includes first and second inner holes 212', 214' formed in the inward wall 174' along the left-hand side 154', third and fourth inner holes 216', 218' formed in the inward wall 174' along the right-hand size 156', first and second outer holes 220', 222' formed in the outward wall 172' along the left-hand side 154', and third and fourth outer holes 224'. 226' formed in the outward wall 172' along the righthand side 156'. The first through fourth outer holes 220', 222', 224', 226' are aligned axially with the first through fourth inner holes 212', 214', 216', 218', respectively. In the embodiment shown in Figures 14 and 15, each one of the plurality of inner holes 212', 214', 216', 218' hasa diameter larger than the diameter of the respective one of the plurality of outer holes 220', 222', 224', 226'.

[0055] Depicted in Figures 14, 15, and 17, the back frame 10' also includes a plurality of inserts 270' fixedly coupled to the stamped member 148' and corresponding in quantity to the plurality of outer holes 220', 222', 224', 226'. It will be appreciated that the plurality of inserts 270' might include one or more of a weld insert, a weld nut, a weld collar, and the like, as non-hmiting examples and as is commonly known in the art. Each of the plurality of inserts 270' is depicted in Figures 14, 15, and 17 as a weld nut having agenerally cylindrical shape and includes a rim wall 278' extending in a circumferential direction, a bottom surface 280', a top surface 282', a threaded aperture 284' extending axially therethrough, and a plurality of projections 286' extending from the bottom surface 280'. It will be appreciated that the plurality of inserts 270' might vary in size, shape, features, and the like, as is commonly known in the art.

[0056] An exemplary process of assembling the back frame 10' is described below in reference to Figures 13-17. Initially, the stamped member 148' is assembled with the back panel 72' with the outward and inward flanges 164', 166' abutted against and aligned with the associated weld bosses 102', as depicted in Figures 12 and 13. Next, a plurality of flange w elds 242' are formed extending between the outward and inward flanges 164', 166' and the adjacent weld bosses 102'. The plurality of flange welds 242' might be formed using resistance spot welding (RSW or spot welding), projection welding, or other commonly known welding processes.

[0057] Next, and as depicted in Figures 12 and 16, the left and right tubes 32', 34' are assembled with the stamped member 148' with the base wall 262' abutted against the mounting portion 178'. The location of the left and right tubes 32', 34' is adjustable along the mounting portion 178' in the lateral direction (arrow' 287') to accommodate the mounting requirements for the head restraint 22' for different seat assemblies 12' (Figure 1). Next, the left and right tubes 32', 34' are fixedly coupled to the stamped member 148' by’ a plurality of tube welds 246'. Next, the handle bracket 120' is abutted against the secondary' portion 204' of the stamped member 148' and fixedly coupled thereto by a plurality of secondary welds 290'. The plurality of tube welds 246' and the plurality of secondary w elds 290' are formed using resistance spot welding (RSW or spot welding), projection welding, or other commonly known welding processes.

[0058] Next, and as depicted in Figure 17, the plurality of inserts 270' are inserted through the respective one of the plurality of inner holes 212', 214', 216', 218' and the projections 286'abuted against the outward wall 172' with the threaded aperture 284' axially aligned with the respective one of the plurality of outer holes 220'. 222', 224', 226'. Next, the projections 286' on each one of the plurality of inserts 270' are fixedly coupled to the outward wall 172' by a plurality of nut welds 292' formed using resistance spot welding (RSW or spot welding), projection welding, or other commonly known welding processes.

[0059] As discussed above, the back frame 10, 10' of the present invention provides a simplified structure which reduces the cost, mass, number of components, and complexity of the manufacturing process. The back frame 10, 10' reduces the complexity of the manufacturing process by reducing the amount of welds required to assemble the back frame 10, 10' and further reduces the amount of MIG welding required during assembly. Further, the back frame 10, 10' has a modular construction which is scalable to accommodate changes in the size and relative position of the left and right rods 52, 54 of the head restraint 22, 22'. In addition, the modular construction of the back frame 10, 10' allows for accommodating changes in the width, size, shape, and location of the left and right recliners 18, 20, the left and right A-brackets 56, 58, the seat cushion 16, and the seat back 14 for different seat assemblies 12, 12'.

[0060] The invention has been described in an illustrative manner, and it is to be understood that the terminology’, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:

1. A back frame for a seat assembly for use in an automotive vehicle, the back frame comprising:a back panel;a stamped member fixedly coupled to the back panel and comprising a ridge, an inward wall, an outward wall, and a main channel, wherein the inward wall and the outward wall extend away from the ridge and the main channel is defined between the inward wall, the ridge, and the outward wall;a plurality of outer holes formed in the outward wall of the stamped member; and a plurality of inserts axially aligned with a respective one of the plurality of outer holes and fixedly coupled to the outward wall.

2. The back frame as set forth in claim 1, wherein:the stamped member further comprises an outward flange extending therefrom; and the outward flange is fixedly coupled to the back panel.

3. The back frame as set forth in claim 1 or claim 2, wherein:the plurality of inserts further comprises one or more of a weld nut, a weld insert, and a weld collar.

4. The back frame as set forth in any one of claims 1 to 3, further comprising:a left tube and a right tube; andthe stamped member further comprises a mounting portion extending along a portion of the ridge;wherein the left tube and the right tube are fixedly coupled to the mounting portion.

5. The back frame as set forth in claim 4, wherein:the stamped member further includes a left slot and a right slot formed in the mounting portion and spaced laterally apart; andthe left tube and the right tube are fixedly coupled to the left slot and the right slot, respectively.

6. The back frame as set forth in any one of claims 1 to 5, the stamped member further comprising:a central opening extending through the stamped member;wherein the ridge, the inward wall, and the outward wall extend in a circumferential direction at least partially around the central opening.

7. The back frame as set forth in claim 6, wherein:the stamped member further comprises an inward flange extending in the circumferential direction at least partially along the central opening; andthe inward flange is fixedly coupled to the back panel.

8. The back frame as set forth in any one of claims 1 to 7, wherein:the stamped member further comprises a plurality of inner holes formed in the inward wall and axially aligned with the respective one of the plurality of outer holes.

9. The back frame as set forth in claim 8, wherein:the plurali ly of inserts are fixedly coupled to the inward wall and axially aligned with a respective one of the plurality of inner holes.

10. A method of forming a back frame for a seat assembly, the method comprising:providing a back panel;providing a steel blank;heating the steel blank to an elevated temperature to form a heated steel blank; forming the heated steel blank into a stamped member having a desired shape using a single stamping process, wherein the stamped member comprises a ridge, an inward wall, an outward wall, and a main channel, wherein the inward wall and the outward wall extend away from the ridge, and wherein the main channel is defined between the inward wall, the ridge, and the outward wall;quenching the stamped member to a reduced temperature lower than the elevated temperature; andwelding the stamped member to the back panel.

11. The method as set forth in claim 10, further comprising:cutting a plurality of outer holes in the outward wall using a laser.

12. The method as set forth in claim 11, further comprising:providing a plurality of inserts;axially aligning the plurality of inserts with a respective one of the plurality of outer holes; andwelding the plurality of inserts to the outward wall.

13. The method as set forth in claim 12, further comprising:cutting a plurality of inner holes in the inward wall using a second laser;axially aligning the plurality of inserts with a respective one of the plurality of inner holes; andwelding the plurality of inserts to the inward wall.

14. The method as set forth any one of claims 10 to 13, further comprising:providing a left tube and a right tube;abutting the left tube and the right tube against the stamped member; and welding the left tube and the right tube to the stamped member.

15. The method as set forth in claims 10 to 13, further comprising:cutting a left slot and a right slot in the stamped member using a first laser; providing a left tube and a right tube; andat least partially inserting the left tube and the right tube into the left slot and the right slot, respectively, prior to welding the left tube and the right tube to the stamped member.

Images