WO2010068745A1

WO2010068745A1 - Dissimilar material connector

Info

Publication number: WO2010068745A1
Application number: PCT/US2009/067484
Authority: WO
Inventors: Ornela Zekavica; Nicholas L. Petouhoff; Daniel J. Sakkinen
Original assignee: Johnson Control Technology Company
Priority date: 2008-12-10
Filing date: 2009-12-10
Publication date: 2010-06-17

Abstract

A connector for use in a vehicle seat, the connector comprising a flexible wire member having a first end and a second end; a first nodule located on the first end of the flexible wire member and a second nodule located on the second end of the wire member; and wherein the first end of the wire member is coupled to a first structure and the second end is coupled to a second structure to thereby secure the first structure to the second structure.

Description

DISSIMILAR MATERIAL CONNECTOR

CROSS-REFERENCE TO RELATED APPLICATIONS

[Oθθl] This application claims the benefit of and priority to U.S. Provisional

Patent Application No. 61/121,410, filed December 10, 2008, titled: DISSIMILAR MATERIAL CONNECTOR, in the name of Zekavica et al. which is incorporated by reference herein.

BACKGROUND

[0002] The present disclosure relates generally to the field of vehicle seating.

More specifically, this disclosure relates to a connector for coupling components formed from similar or dissimilar materials.

[0003] Vehicle seat components may be formed from a variety of materials through a variety of processes. For example, laser tailor welding involves forming a component from two or more dissimilar materials with different properties (e.g., thickness, grades, surface finishes, platings, coatings, etc.) to form a tailor welded blank (TWB), and then performing additional operations on the blank (e.g., forming, cutting, rolling, stamping, punching, etc.) to form the finished component. This technique may also be used to form a tailor weided coil (TWC) or a tailored welded tube (TWT). Unlike traditional components formed from a single material and having a single thickness, components formed from TWBs, TWCs, and TWTs may be engineered to provide a portion of the component having a greater thickness, different grade materials and/or a different geometry where needed, and provide portions with lesser thickness, lower grade materials and/or different structures to allow for reductions in mass, size, number of components, and/or cost over traditionally formed seat components and structures. The vehicle seat components may then be coupled together and/or to other vehicle structures using conventional methods (e.g., welding, bolts, etc.). These conventional coupling methods have significant drawbacks/limitations that make them unusable because, among other things, of the material type and/or thickness used.

[0004] There remains a significant and continuing need to provide an improved and/or alternative means for coupling two or more components formed from similar or dissimilar materials, adding rigidity to the joint between components, and enhancing coupling versatility.

SUMMARY

[0005] A connector for use in a vehicle seat, the connector comprising a flexible wire member having a first end and a second end; a first nodule located on the first end of the flexible wire member and a second nodule located on the second end of the wire member; and wherein the first end of the wire member is coupled to a first structure and the second end is coupled to a second structure to thereby secure the first structure to the second structure.

[0006] A vehicle seat comprising a seat frame structure having a first member and a second member; a flexible wire member having a first end and a second end, a first nodule located on the first end of the flexible wire member, and a second nodule located on the second end of the wire member; and wherein the first end of the wire member is coupled to the first seat frame member and the second end is coupled to a second seat frame member to thereby secure the first seat frame member to the second seat frame member.

[0007] A method of connecting seat frame members together for use in a vehicle seat, the method comprising the steps of providing a first seat frame member having an aperture and a second seat frame member having an aperture; providing a connector having a wire member having a first end and a second end; inserting the first end of the wire member into the aperture of the first seat frame member and inserting the second end of the wire member into the aperture of the second seat frame member; and modifying the first end and the second end of the wire member thereby securing the first seat frame member to the second seat frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a vehicle having a seat assembly according to an exemplary embodiment.

[0009] FIG. 2 is a perspective view of a seat assembly according to an exemplary embodiment.

[0010] FIG. 3 is a diagram of a connector according to an exemplary embodiment.

[0011] FIG. 4 is an alternate diagram of a connector according to an exemplary embodiment.

[0012] FIG. 5 is a diagram of two components formed from dissimilar material and coupled together perpendicularly via a connector according to an exemplary embodiment.

[0013] FIG. 6 is diagram of two components formed from dissimilar material and coupled together in the same plane via a connector according to an exemplary embodiment.

[0014] FIG. 7 is a perspective view of a vehicle seat frame assembly including components coupled together via connectors according to an exemplary embodiment.

[0015] FIG. 8 is a perspective view of the seat back frame of FIG. 7 according to an exemplary embodiment.

[0016] FIG. 9 is an exploded perspective view of the seat back frame of FIG.

8 according to an exemplary embodiment. [0017] FIG. 10 is a perspective view of the seat back frame of FIG. 7 and enlarged diagrams of the coupling area between the first side member and the upper cross member and the first side member and the lower cross member according to an exemplary embodiment.

[0018] FIGS. 1 IA through 1 IE are a series of diagrams depicting a process for coupling the seat base cross member of FIG. 7 to the lift link and seat base cross member connector using connectors according to an exemplary embodiment.

[0019] FIG. 12 is a rear perspective view of a rear bench seat having different components coupled together according to an exemplary embodiment.

DETAILED DESCRIPTION

[0020] Referring generally to the figures and in particular to FIG. 1, a vehicle

10 is shown according an exemplary embodiment. The vehicle includes one or more vehicle seats 12 provided for occupants of the vehicle 10. While the vehicle 10 shown is a 4-door sedan, it should be understood that the vehicle seat 12 may be used in a mini-van, sport utility, cross-over or any other type of vehicle or any other means in or by which someone travels or something is carried or conveyed for any market or application including everything from office seating and transportation to planes and space travel and everything in between.

[0021] Referring now to FIG. 2, there is shown a vehicle seat assembly 12 in an upright or design position according to an exemplary embodiment. The seat assembly 12 shown includes a seat back 14 pivotably coupled to a seat base (cushion) 16 via a recliner mechanism 18 which enables the seat back 14 to be selectively pivoted in the fore and aft directions. The seat assembly 12 also includes a head restraint 20 and a seat base portion 22. The head restraint 20 extends upward from the seat back 14 and is configured to restrain the head of an occupant during an impact. The seat base portion 22 may be configured to allow the seat 12 to be selectively positioned (manually or motor driven) relative to the vehicle interior via a track assembly 24. The vehicle seat assembly 12 further includes a trim cover 26 for covering the seat frame 28, foam/cushions 30 and other internal components of the vehicle seat 12 to enhance occupant comfort and aesthetic appearance.

[0022] Referring now to FIGS. 3 and 4, a connector 32 according to one exemplary embodiment is shown. The connector 32 includes a wire 34, a first end or nodule, 36 and a second end or nodule 38. The wire 34 may be formed from any suitable material (e.g., steel, plastic, rubber, cord, cable, strand, fiber, fabric, etc.) and be formed to have any suitable level of flexibility. The wire 34 may also have any suitable length, size, dimension, shape, diameter, strength, gauge, color, and the like. The first and second nodules 36, 38 are coupled to the first end and second end of the wire 40, 42, respectively. The nodules 36, 38 may be formed from any suitable material (e.g., steel, plastic, rubber, cord, cable, strand, fiber, etc.) and be formed to have any suitable level of flexibility. The nodules 36, 38 may also have any suitable length, size, dimension, shape, diameter, strength, gauge, color, and the like. Alternatively, the wire 34 and nodules 36, 38 may be formed as one integral unit or formed by crimping the connector 32 (e.g., wire 34, etc.), as best shown in FIG. 1 IE.

[0023] Referring now to FIGS. 5 and 6, two components 44, 46 formed from dissimilar material and coupled together via connectors 32 are shown. In FIG. 5, a connector 32 couples a first vertical component 44 made of a first material to a second horizontal component 46 made from a second material. The first vertical component 44 is coupled together to the second horizontal component 46 in an interlocking perpendicular arrangement. The first nodule 36 of the connector 32 is lockably inserted into an aperture 48 (slot, slit, opening, receiver, etc.) of the first vertical component 44 and the second nodule 38 of the connector 32 is lockably inserted into an aperture 50 (slot, slit, opening, receiver, etc.) of the second horizontal component 46 thereby forming a rigid wire joint between the two components made of dissimilar material 44, 46. Alternatively, the nodules 36, 38 may be coupled to the components 44, 46 in other suitable manners (e.g., snapped into, clipped onto, etc.). In FIG. 6, a connector 32 couples a first component 44 and a second component 46 formed from dissimilar materials in the same plane. The connector 32 may also be used with any joint shapes, number of components, number of material layers (e.g., thicknesses, etc.), and with the same, similar, and/or dissimilar materials. The connector 32 provides various benefits including, among other things, the ability to connect components formed from similar/dissimilar materials, added rigidity to joints formed be coupling two or more components, providing an area (e.g., wire 34) that may be used for additional attachments.

[0024] Referring now to FIGS. 7 through 10, a vehicle seat frame assembly

28, a seat back frame 52, and seat base frame 54 components are shown. The vehicle seat frame assembly 28 includes, among other components, a seat back frame 52 and seat base frame 54. The seat back frame 52 includes, among other components, a first side member 56, a second side member 58, an upper cross member 60, and a lower cross member 62. The first end (top) 64, 66 of the side members 56, 58 are coupled to the upper cross member 60 and the second end (bottom) 68, 70 of the side members 56, 58 are coupled to the lower cross member 62, thereby forming a seat back frame 52 that is generally rectangular in shape. The components of the seat back (e.g., side members 56, 58, cross members 60, 62, etc.) may be formed from tailored welded blanks (TWBs), tailored welded coils (TWCs), and/or tailored welded tubes (TWTs). The components may be engineered to provide a portion having a greater thickness (e.g., THKl, THK2, THK3, etc.), different grade materials (e.g., Material 1, Material 2, Material 3, etc.) and/or a different geometry where needed, and provide portions with lesser thickness, lower grade materials and/or different structures to allow for reductions in mass, size, number of components, and/or cost over traditionally formed seat components and structures, as shown in FIG. 10. Each portion may be coupled to the other via a connector 32 at various connection/coupling areas 72. For example, the first end portions 64, 66 and the second end portions 68, 70 of the side members 56, 58 may be coupled to the middle portion 74, 75 of the side members 56, 58 using connectors 32, thereby forming a rigid interlocking connection between dissimilar materials in the same plane, as best shown in FIG. 6. Similarly, the upper and/or lower cross member 60, 62 of the seat back frame may be coupled to the first and second side members 56, 58 using connectors 32, thereby forming a rigid interlocking and perpendicular connection 76, 78 between dissimilar materials, as best shown in FlG. 5. These same techniques applied to the seat back frame 52 may be applied to other seat structures such as the seat base frame 54 which includes, among other components, a first side member 78, a second side member 80, a front cross member (tube) 82, and a rear cross member (tube) 84.

[0025] Referring now to FIGS. 11 A through 1 1 E, a series of diagrams depicting a process of coupling the seat base cross member 84 of FIG. 7 to a lift link 86 using a connector 32 is shown. More particularly, FIG. 1 IA shows a cross section of the seat base cross member (torsion tube) 84. A number of apertures 88 (punch holes) are formed in the seat base cross member 84, as shown in FIG. 1 IB. Next, connectors 32 (wires) are inserted into the apertures 88 such that each end of the connectors 32 extends beyond the seat base cross member 84, as best shown in FIG. l lC. Each end of the connectors 32 is then bent and inserted into the seat structure sub-assembly 54 (e.g., seat base frame, lift link, seat base cross member, torsion connector, etc.), as shown in FIG. 1 IE. Each end of the connectors 32 is then modified (e.g., crimped, capped, clamped, clipped, welded, glued/adhered, etc.) to secure the connector 32 in place, as shown in FIG. 1 IF.

[0026] Referring now to FIG. 12, a rear bench seat frame 90 having components (e.g., rear bench seat beam 92, etc.) formed from TWBs, TWCs and/or TWTs with variable thicknesses and/or strengths according to an exemplary embodiment is shown. The bench seat beam 92 may include, among other features, a first end portion 94, a second end portion 96, and a middle portion 98. The bench seat beam 92 may be engineered to provide a portion 94, 96, 98 having a greater thickness, different grade materials and/or a different geometry where needed, and provide portions 94, 96, 98 with lesser thickness, lower grade materials and/or different structures to allow for reductions in mass, size, number of components, and/or cost over traditionally formed seat components and structures. Each portion 94, 96, 98 may be coupled to the other via a connectors 32 at various connection/coupling areas 100. For example, the first and second end portions 94, 96 of the bench seat beam 92 may be coupled to the middle portion 98 of the bench seat beam 92 using connectors 32, thereby forming a rigid interlocking connection between dissimilar materials in the same plane, as best shown in FIG. 6.

[0027] For purposes of this disclosure, the term "coupled" means the joining of two components (mechanical and/or electrical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

[0028] It is also important to note that the construction and arrangement of the elements of the vehicle seat as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present innovations.

Claims

WHAT IS CLAIMED IS:

1. A connector for use in a vehicle seat, the connector comprising: a wire member having a first end and a second end; a first nodute located on a first end of the flexible wire member and a second nodule located on a second end of the wire member; and wherein the first end of the wire member is coupled to a first structure and the second end is coupled to a second structure to thereby secure the first structure to the second structure.

2. The connector of Claim 1, wherein the first nodule and second nodule are integral with the wire member.

3. The connector of Claim 2, wherein the first nodule and second nodule are formed from a forming of the first end and the second end of the wire member.

4. The connector of Claim 3, wherein the connector is made from a material selected from at least one of steel, plastic, rubber, cord, cable, strand, fiber, and fabric.

5. A vehicle seat comprising: a seat frame structure having a first member and a second member; a flexible wire member having a first end and a second end, a first nodule located on the first end of the flexible wire member, and a second nodule located on the second end of the wire member; and wherein the first end of the wire member is coupled to the first seat frame member and the second end is coupled to a second seat frame member to thereby secure the first seat frame member to the second seat frame member.

6. The vehicle seat of Claim 5, wherein the first nodule and second nodule are integral with the flexible wire member.

7. The vehicle seat of Claim 6, wherein the first nodule and second nodule are formed from a crimping of the first end and second end of the flexible wire member.

8. The vehicle seat of Claim 7, wherein the connector is made from at least one of steel, plastic, rubber, cord, cable, strand, fiber, and fabric.

9. The vehicle seat of Claim 5, wherein the seat frame structure is one of a seat back frame member and a seat base frame member.

10. The vehicle seat of Claim 9, wherein the first member and second member of the seat frame structure is one of a seat back frame side member, a seat back frame upper cross member, a seat back frame lower cross member, a seat base frame side member, a seat base frame rear cross member, a seat base frame front cross member, and a seat lift link member.

11. The vehicle seat of Claim 10, wherein the first member and second member have at least a first portion and a second portion; wherein the first portion and the second portion differ from one another in at least one of mass, size, material type, shape, thickness, length, and width.

12 The vehicle seat of Claim 11, wherein a portion of the first seat frame member protrudes into a portion of the second seat frame member thereby interlocking the first seat frame member to the second seat frame member.

13. A method of connecting first and second seat frame members together for use in a vehicle seat frame, the method comprising the steps of: providing a first seat frame member having an aperture and a second seat frame member having an aperture; providing a connector having a wire member having a first end and a second end; inserting the first end of the wire member into the aperture of the first seat frame member and inserting the second end of the wire member into the aperture of the second seat frame member; and modifying the first end and the second end of the wire member thereby securing the first seat frame member to the second seat frame member.

14. The method of Claim 13, wherein the first end and the second end of the wire member are modified by at least one of crimping, capping, welding, clamped, clipped, and glued.

15. The method of Claim 14, further comprising the steps of: inserting a portion of the first seat frame member into a portion of the second seat frame member thereby interlocking the first seat frame member to the second seat frame member.