Structure for a vehicle seat element, and a method of making such a structure
AssigneeFAURECIA Sièges d'Automobile
InventorsFrancois Fourrey, Babak Eskandanian, Ziyad Nabil
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Abstract
A rigid structure for a vehicle seat element, the structure being formed as a single piece made of a composite material comprising a thermoplastic matrix and reinforcing fibers forming at least firstly first and second rigid sideplates each extending between a first end and a second end, and secondly a rigid horizontal cross-member secured to the second ends of the sideplates. The structure has at least one hinge comprising a first fixing portion overmolded by the first end of the first sideplate.
Claims15
1/ A rigid structure for a vehicle seat element, said structure being formed as a single piece made from a composite material comprising a thermoplastic matrix and reinforcing fibers, the structure comprising at least firstly first and second rigid sideplates each extending between a first end and a second end, and secondly a rigid horizontal cross-member secured to the second ends of the sideplates, the structure further comprising at least one hinge having a first fixing portion secured to the structure, a second fixing portion for fixing to another seat element, and a hinge mechanism interconnecting the first and second fixing portions and actuatable by a control member so that said first and second fixing portions are either free to pivot relative to each other about a pivot axis or else are locked angularly relative to each other, and wherein the first fixing portion of the hinge is overmolded by the first end of the first sideplate.
2/ A structure according to claim 1, in which a portion of the first end of the first sideplate in contact with the first fixing portion of the hinge presents a housing having an end wall pressed against the first fixing portion of the hinge, and a side wall extending from said end wall and covering the first fixing portion of the hinge axially, at least in part.
3/ A structure according to claim 2, in which the side wall of the housing of the first end of the first sideplate presents a curved edge which extends radially towards the pivot axis of the hinge.
4/ A structure according to claim 1, in which the first fixing portion of the hinge comprises a plurality of elements in relief onto which the first end of the first sideplate is overmolded.
5/ A structure according to claim 1, in which the composite material comprises a tubular braid of reinforcing fibers including a segment forming the first end of the first sideplate which presents a section that is substantially flat and double-walled.
6/ A structure according to claim 1, in which the first end of the second sideplate includes a pivot element for pivotally mounting on the other seat element, said pivot element being integrally formed with the first end of the second sideplate.
7/ A structure according to claim 1, in which a second hinge is also overmolded by the first end of the second sideplate of the structure.
8/ A structure according to claim 1, also comprising a second rigid horizontal cross-member having a first end integrally formed with the first end of the second sideplate and a second end overmolded on the first end of the first sideplate.
9/ A structure according to claim 1, formed by a rigid structure for a seat back.
10/ A method of manufacturing a rigid structure for a vehicle seat element, said structure comprising firstly first and second rigid sideplates each extending between a first end and a second ends, and secondly a rigid horizontal cross-member secured to the second end of the sideplates, said cross-member and the sideplates being made as a single piece out of a composite material comprising a thermoplastic matrix and reinforcing fibers, the method comprising the following steps:
- providing a hinge comprising a first fixing portion, a second fixing portion for fixing to another seat element, and a hinge mechanism interconnecting the first and second fixing portions and actuatable by a control member so that the first and second fixing portions are either free to pivot relative to each other about a pivot axis or else are angularly locked relative to each other;
- and
- the composite material portion forming the first end of the first sideplate is overmolded onto the first fixing portion of the hinge.
11/ A method according to claim 10, in which the composite material comprises a tubular braid of reinforcing fibers, said method comprising the following steps:
- inserting an inflatable bladder in the tubular braid;
- placing the hinge in a mold defining a cavity of shape complementary to the outside shape of the structure;
- placing the tubular braid in the mold;
- and
- heating the mold and inflating the inflatable bladder under pressure to compress the tubular braid against the cavity of the mold and to cause the thermoplastic matrix to melt which matrix, after hardening, enables said structure to be obtained, the braid portion forming the first end of the first sideplate being compressed and overmolded onto the first fixing portion of the hinge.
12/ A method according to claim 11, in which prior to the tubular braid hardening, the hinge is moved towards the first end of the first sideplate along the pivot axis to bond together at least two portions of the first end of the tubular braid placed facing each other.
13/ A method according to claim 11, in which prior to placing the tubular braid in the mold, a second hinge is placed in the mold, and while the inflatable bladder is being inflated, the portion of the tubular braid that forms the second end of the second sideplate is pressed against and overmolded onto the second hinge.
14/ A method according to claim 11, in which the tubular braid is of a length that is suitable for forming a second horizontal cross-member having a first end formed integrally with the first end of the second sideplate, and a second end which, during inflation of the inflatable bladder, is compressed and overmolded onto the first end of the first sideplate against which the hinge is overmolded.
15/ A method according to claim 11, in which the mold is provided with at least two projecting members to enable two diametrically opposite portions of the tubular braid to be compressed during inflation of the inflatable bladder respectively against the associated projecting member, thereby forming two blind holes each having an inside wall, each blind hole subsequently being pierced, once the thermoplastic matrix has hardened, so as to form a through housing with an inside wall in the structure of the seat element.