Method of forming a seat frame of a vehicle seat, seat frame for use in vehicle seat, and vehicle seat having the seat frame

Abstract

A plate is continuously press-bent, into a shaped member having a recess opening at one surface (i.e., lower surface). Then, the plate is bent back by pressing, at the front and rear ends, covering the openings of the recess and a side frame having open cross sections, each with a gap, is thereby formed. In the forming step, the side frame is not welded and has open cross sections, each with a gap. The side frames are then subjected to the next step (i.e., step of assembling the seat frame). In the step of assembling the seat frame, the side frames and coupling members are welded together, constituting a substantially rectangular seat frame. As the side frames are so welded in step of assembling the seat frame, a rigid structure each having closed cross sections with no gaps is formed.

What is claimed is: 
     
         1 . A method of forming a seat frame of a vehicle seat, by arranging coupling members between left and right side frames formed of plates, welding the coupling members to the left and right side frames, thereby assembling a substantially rectangular seat frame, the method comprising:
 bending the front and rear ends of each side frame formed of a plate, providing open cross sections, each with a gap, at the front and rear ends of the side frame; and   welding each side frame in a step of assembling the seat frame, providing closed cross sections and thereby forming a rigid structure having no gaps.   
     
     
         2 . The method according to  claim 1 , wherein the front and rear ends of each side frame are press-bent, providing U-shaped recesses, and are then bent back, covering the recesses, thereby providing cross sections having a gap, at the front and rear ends of side frame;
 and the ends of the side frame are welded, while held together by a push jig in the step of assembling the seat frame, providing closed cross sections and hence forming the rigid structure.   
     
     
         3 . The method according to  claim 1 , wherein the front and rear ends of each side frame are first press-bent and are then bent back, providing U-shaped recesses, and the front and rear ends of each side frame, which define the ends of the U-shaped recesses, are inclined inwards, thus closing the recesses; and
 the side frame so inclined are welded, while held together by a push jig in the step of assembling the seat frame, thereby providing closed cross sections and hence forming the rigid structure.   
     
     
         4 . The method according to  claim 2 , wherein a part of the push jig is inserted into a substantially rectangular recess through a hole made in a sidewall of the recess and clamp the side frame jointly with another push jig, and still another jig pushes the front and rear ends of the side frame, and the side frame so clamped is welded in the step of assembling the seat frame, thereby providing closed cross sections and hence forming the rigid structure. 
     
     
         5 . The method according to  claim 3 , wherein a part of the push jig is inserted into a substantially rectangular recess through a hole made in a sidewall of the recess and clamp the side frame jointly with another push jig, and still another jig pushes the front and rear ends of the side frame, and the side frame so clamped is welded in the step of assembling the seat frame, thereby providing closed cross sections and hence forming the rigid structure. 
     
     
         6 . The method according to  claim 4 , wherein the welding performed in the step of assembling the seat frame is laser welding. 
     
     
         7 . The method according to  claim 5 , wherein the welding performed in the step of assembling the seat frame is laser welding. 
     
     
         8 . A seat frame of a vehicle seat, shaped like a rectangular frame and comprising left and right side frames, each made by processing one plate, and coupling members extending between the left and right side frames and welded thereto,
 wherein the left and right side frames are formed by press-bending, first bending and then bending back the front and rear ends of a plate, providing open cross sections, each with a gap, at the front and rear ends of the plate; and   coupling members are arranged, each extending between the left and right side frame, and are welded to the side frames in a step of assembling the seat frame, closing the open cross sections, thereby providing closed cross sections and hence forming a rigid structure.   
     
     
         9 . A vehicle seat comprising a seat cushion composed of a seat cushion frame functioning as skeleton, a seat pad mounted on the seat cushion frame and a trim cover covering the seat pad, and a seatback composed of a seatback frame functioning as skeleton, a seat pad mounted on the seatback frame and a trim cover covering the seat pad,
 wherein the seat cushion frame or the seatback frame, or both, are composed of left and right side frames and coupling members extending between the left and right side frames;   the left and right side frames are formed by press-bending, first bending and then bending back the front and rear ends of a plate, providing open cross sections, each with a gap, at the front and rear ends of the plate; and   coupling members are arranged, each extending between the left and right ends of the side frames, and are welded to the side frames in a step of assembling the seat frame, closing the open cross sections, thereby providing closed cross sections and hence forming a rigid structure.