Integral blow-molded, steel reinforced automotive seating structure

Information

  • Patent Grant
  • 6679558
  • Patent Number
    6,679,558
  • Date Filed
    Thursday, July 26, 2001
    23 years ago
  • Date Issued
    Tuesday, January 20, 2004
    20 years ago
Abstract
A method of manufacturing a seat back includes placing a steel support structure within a mold and blow-molding a hollow plastic body onto the steel support structure to form a seat back with the steel support structure integrally supported within the body. The steel support structure may be a hollow, U-shaped steel tube having first and second attachment features at distal ends thereof for attachment to a lower seat structure.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates to a seating structure and a method of manufacturing a seating structure in which a steel support structure is placed within a mold and a plastic body is blow-molded against the steel support structure to form a seat back in which the steel structure is integrally supported in the body.




2. Background Art




In vehicle interior design, there exists a continuing need to reduce costs, part count and weight associated with vehicle seat assemblies while the vehicle seat assemblies are required to satisfy various design requirements, such as flexibility for improved cargo storage, comfort, safety, etc. In vans, minivans and sport utility vehicles, bench seats or split bench seats are often provided in the second and third row of the vehicle. These seats must be lightweight if they are collapsible or removable. Also, it is generally desirable to provide lightweight seats even if they are not removable. Due to increasing cargo transporting usage of such vehicles, it is important that these seats be designed to withstand significant impact from the rear as a result of forward movement of cargo stored in the rear of the vehicle.




It is desirable to provide a reinforced, lightweight and low cost seat assembly to satisfy impact requirements and provide the needed functionality while minimizing costs associated with the manufacture and assembly of the seat.




SUMMARY OF THE INVENTION




The present invention provides a seating apparatus in which a plastic body is blow-molded over the steel support structure to form a seat back wherein the steel support structure is integrally supported in the body.




The steel support structure is preferably a hollow, U-shaped steel tube having first and second attachment features at distal ends thereof. Alternatively, if the rear impact requirements were minimal, the steel support structure may comprise first and second independent partial frame supports configured for pivotal attachment to a lower seat. Of course, these designs may be tuned to provide the appropriate rear impact support.




In the preferred embodiment, the hollow, U-shaped steel tube would be swaged into a flat configuration at its distal ends, and the first and second attachment features would comprise boles drilled through the swaged ends. Preferably, the blow-molded plastic body would be a hollow structure with front and rear walls and would include C-shaped portions positioned around the steel support structure to rigidly attach the plastic body to the steel support structure.




Accordingly, an object of the invention is to provide an improved vehicle seat assembly with reduced manufacturing and assembly costs.




Another object of the invention is to provide an improved vehicle seat assembly in which a steel support structure is secured to a plastic base.




The above objects and other objects, features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

shows a perspective view of a seat back assembly in accordance with the present invention;





FIG. 2

shows a cross-sectional view taken at line


2





2


of

FIG. 1

;





FIG. 3

shows a schematic exploded perspective view of an apparatus for blow-molding a seat back in accordance with the embodiment of

FIG. 1

; and





FIG. 4

shows a schematic exploded perspective view of an apparatus for blow-molding a seat back in accordance with an alternative embodiment of the invention.











DETAILED DESCRIPTION OF THE BEST MODES FOR CARRYING OUT THE INVENTION




Referring to

FIGS. 1 and 2

, a seat back assembly


10


is shown in accordance with the present invention. The seat back assembly shown is provided, for example, for use in a second row split-bench seat in a van. The seat back assembly includes a “60% portion”


12


and a “40% portion”


14


. As shown, the 60% portion


12


and 40% portion


14


each include a hollow. U-shaped steel tube


16


,


18


, respectively. The steel tubes


16


,


18


include swaged ends


20


,


22


,


24


,


26


each having an attachment feature, such as a hole


28


,


30


,


32


,


34


, respectively. The attachment holes


28


,


30


,


32


,


34


are configured to enable pivotal attachment to a lower seat.




The U-shaped steel tubes


16


,


18


provide considerable impact strength for the seat back portions


12


,


14


.




As shown in cross-sectional view in

FIG. 2

, the plastic body


35


of the 40% portion


14


of the seat back


10


is a hollow, blow-molded structure including rear and front walls


36


,


38


, respectively. As shown, the plastic body


35


forms a C-shaped portion


40


which is molded over the hollow tube


18


and shrinks onto the tube


18


when cooled to form a secure attachment between the plastic body


35


and the tube


18


.




Returning to

FIG. 1

, the plastic bodies


33


,


35


of the 60% portion


12


and 40% portion


14


of the seat back assembly


10


each include cutout portions


44


,


46


,


48


,


50


through which the distal ends of the U-shaped tubes


16


,


18


protrude.




After molding, foam and fabric would be applied to the resulting seat back structures


12


,


14


.




Rather than using a hollow steel tube as described herein, a square tube, or other shaped structural steel members could be used. The steel structures are effective in transporting impact energy to the lower seating structure, especially those energies those generated by the headrest and rear intrusion impacts. This invention also addresses the need to reduce part numbers in these assemblies, reduce weight, reduce system costs, and reduce the potential for rattles in comparison with bolted structures.




While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.



Claims
  • 1. A seat back comprising:a hollow plastic body blow-molded into a generally rectangular shape, the plastic body having front and rear walls; and a steel support structure insert-molded within the plastic body to form the seat back, said steel support structure comprising a hollow U-shaped steel tube having first and second attachment features at distal ends thereof; wherein said rear wall of the plastic body forms C-shaped portions around the steel support structure to rigidly attach the plastic body to the steel support structure.
  • 2. The seat back of claim 1, wherein the distal ends of the steel support structure are each swaged into a flat configuration.
  • 3. A seat back comprising:a hollow plastic body blow-molded into a generally rectangular shape, the plastic body having front and rear walls; and a steel support structure insert-molded within the plastic body to form the seat back, wherein said steel support structure comprises first and second partial frame tubular supports having first and second attachment features at distal ends thereof for pivotal attachment to a lower seat; wherein the rear wall of the plastic body forms C-shaped portions around the tubular supports of the steel support structure to rigidly attach the plastic body the steel support structure.
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5499859 Angell Mar 1996 A
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6286902 Yoshimura Sep 2001 B1
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Number Date Country
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