Hydroformed seatback frame

Abstract

An automotive seat assembly comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.

1 . An automotive seat frame assembly comprising: 
 an automotive seatbottom frame; and    an automotive seatback frame connected to the seatbottom frame, the seatback frame comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.    
   
   
       2 . The automotive seat frame assembly of  claim 1  wherein the hydroformed hollow metal tube comprises a wall having substantially uniform thickness along its entire length.  
   
   
       3 . The automotive seat frame assembly of  claim 2  wherein the cross-sectional shape of the hydroformed hollow metal tube is formed using a low pressure hydroforming process.  
   
   
       4 . The automotive seat frame assembly of  claim 1  wherein the bottom ends of the vertical support sections have a cross-sectional shape that facilitates connection of the seatback frame to the seatbottom frame.  
   
   
       5 . The automotive seat frame assembly of  claim 4  wherein the cross-sections of the respective bottom ends of the first and second vertical support sections have a shape that corresponds with the shape of the seatbottom frame at the location where the seatback frame is connected to the seatbottom frame.  
   
   
       6 . The automotive seat frame assembly of  claim 5  wherein the cross-sections of the respective bottom ends of the first and second vertical support sections are shaped to be received by, or be received within, the seatbottom frame connecting the seatback frame to the seatbottom frame.  
   
   
       7 . The automotive seat frame assembly of  claim 1  wherein a portion of at least one of the vertical support sections has a generally triangular cross-section.  
   
   
       8 . The automotive seat frame assembly of  claim 7  wherein the triangular cross-section is at a location of the at least one vertical support section where the at least one of the vertical support sections will bear the highest load during a rear impact.  
   
   
       9 . The automotive seat frame assembly of  claim 1  wherein the transverse section has a front side and wherein at least a portion of the front side is depressed to form a recess large enough to receive a person's neck.  
   
   
       10 . The automotive seat frame assembly of  claim 1  wherein the transverse section is adapted to receive a headrest.  
   
   
       11 . The automotive seat frame assembly of  claim 10  wherein the transverse section has a top side and a bottom side, wherein the top side has a pair of holes and the bottom side has a pair of holes, and wherein the pair of holes in the top side are axially aligned with the pair holes in the bottom side to enable the transverse section to receive posts from a headrest.  
   
   
       12 . The automotive seat frame assembly of  claim 10  wherein the holes are extruded.  
   
   
       13 . The automotive seat frame assembly of  claim 1  wherein the respective bottom ends of the first and second support sections have a cross-sectional shape that allows the seatback frame to be connected to the seatbottom frame, wherein a portion of at least one of the vertical support sections has a generally triangular cross-section, wherein the transverse section has a front side having a recess large enough to receive a person's neck, and wherein the transverse section is adapted to receive a headrest.  
   
   
       14 . An automotive seatback frame for use with an automotive seat having a seatbottom having a seatbottom frame, and a seatback having a seatback frame, the automotive seatback frame comprising: 
 a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the top ends of the first and second support sections.    
   
   
       15 . The automotive seatback frame of  claim 14  wherein the automotive seatback frame is made from SAE 050XF steel and wherein the automotive seatback frame has a rear load strength to weight ratio of at least approximately 3.0 KN/Kg.  
   
   
       16 . A method of making an automotive seat frame comprising the steps of: 
 providing an automotive seatbottom frame;    providing the automotive seatback frame of  claim 14;  and    connecting the automotive seatbottom frame to the seatback frame.    
   
   
       17 . An automotive seat assembly comprising: 
 an automotive seatbottom comprising an automotive seatbottom frame, an automotive seatbottom cushion supported on the automotive seatbottom frame and an automotive seatbottom cover covering the automotive seatbottom frame and automotive seatbottom cushion;    an automotive seatback comprising an automotive seatback frame, an automotive seatback cushion supported on the automotive seatback frame and an automotive seatback cover covering the automotive seatback frame and the automotive seatback cushion, the automotive seatback frame being connected to the automotive seatbottom frame;    the automotive seatback frame comprising a hydroformed hollow metal tube having a cross-section which varies in shape along its length, the hydroformed hollow metal tube having a first vertical support section having a top end and a bottom end, a second vertical support section having a top end and a bottom end, and a transverse section extending between the respective top ends of the first and second support sections.    
   
   
       18 . The automotive seat assembly of  claim 17  wherein the hydroformed hollow metal tube comprises a wall having substantially uniform thickness along its entire length.  
   
   
       19 . The automotive seat assembly of  claim 17  wherein the bottom ends of the vertical support sections have a cross-sectional shape that facilitates the connection of the seatback frame to the seatbottom frame.  
   
   
       20 . The automotive seat assembly of  claim 17  wherein a portion of at least one of the vertical support sections has a generally triangular cross-section, wherein the transverse section has a front side wherein at least a portion of the front side is depressed to form a recess large enough to receive a person's neck and wherein the transverse section is adapted to receive a headrest.