Continuously engaged recliner freeplay system and fine-blanked gear hub

1. A recline mechanism for a vehicle seat comprising:

an eccentric carrier having a circumferential portion arranged around an axis and including an inner circumferential surface and an outer circumferential surface, a carrier tab extending radially from said outer circumferential surface, and a drive tab spaced from and extending outwardly along said axis and wherein said inner circumferential surface is approximately circular but not circular;

a unitary rotating adjustment element having a circumferential hub extending outwardly therefrom and configured to engage said eccentric carrier;

a bearing having an inner and outer surface; and

a pair of wedges located on opposing sides of and proximate to said carrier tab and wherein each of said wedges including an outer face and an inner face, said outer face engaging said inner surface of said bearing and said inner face engaging said outer circumferential surface of said carrier;

wherein said inner circumferential surface includes a first profiled portion approximately radially centered about said carrier tab, and said first profiled portion extends for some distance to each side of said carrier tab to under said pair of wedges.

2. The recline mechanism of claim 1 wherein the majority of said inner circumferential surface extends around said axis a first distance from said axis.

3. The recline mechanism of claim 2 wherein said first profiled portion extends a radial distance from said axis which is greater than said first distance.

4. The recline mechanism of claim 2 wherein said first profiled portion includes two opposing ends wherein said inner circumferential surface changes from being spaced greater than said first distance from said axis to being equal to said first distance from said axis.

5. The recline mechanism of claim 1 wherein said first profiled portion includes an arcuate shape and wherein the center of said arcuate shape is not said axis.

6. The recline mechanism of claim 5 wherein said inner circumferential surface includes a second profiled portion located radially opposite said first profiled portion along said inner circumferential surface.

7. The recline mechanism of claim 6 wherein each of said first and second profiled portions are capable of retaining a lubricant.

8. A recline mechanism including:

an inner gear having an axial hub defining an inner race;

a bearing having an inner and outer surface and wherein said outer surface engages said inner race;

an eccentric carrier having a radially extending carrier tab, an outer circumferential surface interrupted by said carrier tab and an inner circumferential surface;

a pair of wedges located on opposing sides of and proximate to said carrier tab and wherein each of said wedges including an outer face and an inner face, said outer face engaging the inner surface of said bearing and said inner face engaging said outer circumferential surface of said carrier;

rotating adjustment element having an outer cover and a circumferential hub extending therefrom and a race support also extending therefrom and wherein said adjusting element, outer cover, circumferential hub and race support are formed as a single member wherein said inner circumferential surface engages said circumferential hub approximately ninety radial degrees from said carrier tab;

wherein said inner circumferential surface includes a first profiled portion approximately radially centered about said carrier tab, and said first profiled portion extends for some distance to each side of said carrier tab to under said pair of wedges.

9. The recline mechanism of claim 8 wherein said eccentric carrier in said first profiled portion does not engage said circumferential hub.

10. The recline mechanism of claim 9 wherein said inner circumferential surface includes inner load areas displaced from said carrier tab.

11. The recline mechanism of claim 10 wherein said inner load areas are located in radial alignment with said pair of wedges.

12. The recline mechanism of claim 9 wherein said inner circumferential surface includes a second profiled portion located radially opposite of said carrier tab along said inner circumferential surface and wherein said second profiled portion does not engage said circumferential hub.

13. The recline mechanism of claim 8 wherein said inner circumferential surface is approximately circular but not circular.

14. The recline mechanism of claim 13 wherein said first profiled portion extends a radial distance from said axis which is greater than said first distance.

15. The recline mechanism of claim 13 wherein said first profiled portion includes an arcuate shape and wherein the center of said arcuate shape is not said axis.

16. The recline mechanism of claim 13 wherein said inner circumferential surface includes a second profiled portion located radially opposite said first profiled portion along said inner circumferential surface.

17. The recline mechanism of claim 8 wherein said eccentric carrier further includes a drive tab extending to engage a toothed shoulder on said rotating adjustment element.

18. A method of forming an outer gear for a seat recline mechanism, said method comprising:

providing a sheet of metal;

forming an enclosed hub on said sheet of metal having an end cap with at least one concave surface extending in a direction toward said enclosed hub;

wherein said concave surface is formed by a convex die flowing material from a center of said end cap to an end surface of the enclosed hub;

removing said end cap from said enclosed hub on said sheet of metal to form a hub;

forming inner rings on said sheet of metal;

forming outer beveled edges on said hub on said sheet of metal;

forming an intermediate member including gear teeth, wherein said gear teeth include female teeth and male teeth on the intermediate member; and

punching an outer gear from said sheet of metal forming an outer portion extending from said intermediate member to an outer edge.

19. The method of forming an outer gear of claim 18 wherein said step of forming an enclosed hub having an end cap with at least one concave surface further includes the steps of partially forming said hub and final forming said hub while creating a concave surface in said end cap to move material from said end cap to said hub.