Closed Cell Foam Vehicle Interior Component And Method Of Making Same

• US 20100171346A1
• Filed: 09/22/2009
• Published: 07/08/2010
• Est. Priority Date: 09/22/2008
• Status: Active Grant

• Current Assignee: Adient US, LLC (Adient plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Sabbagh, Sheraine, Lee, Joon Kyu, Dluge, Scott E., Gomez, John, Thimm, David, Laframboise, Gregg, Koester, Daniel J., Doerer, Richard P., Potes, Duane JR.
• Granted Patent: US 8,991,930 B2
• Time in Patent Office: Days
• US Class Current: 297/183.100
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: B29C 65/665 using shrinking during cooling
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/742 to metals or their alloys
• CPC Class Codes: B29K 2023/083 EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/046 with closed cells
• CPC Class Codes: B29L 2031/3026 Arm-rests
• CPC Class Codes: B29L 2031/3035 Sun visors
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B60N 2/643 shape of the back-rests B60N2/66 takes precedence
• CPC Class Codes: B60N 2/646 shape of the cushion
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B60N 2/986 Side-rests B60N2/2872, B60N2/885 take precedence
• CPC Class Codes: B60R 7/043 mounted on or under a seat

Abstract

A vehicle seat assembly including at least a component of the seat assembled made of closed-cell foam and having an integral exterior surface. The component may include a backrest, headrest, seat cushion or a component thereof such as an armrest. A method of forming a seat assembly including a first seat component and a second seat component wherein at least one of the first and the second components are made of closed-cell foam.

Claims

1. A seat assembly comprising;

a seat cushion;

a backrest; and

a foam shell being formed from a closed-cell foam and having an integral exterior surface for use on one of said seat cushion and said backrest.

2. A seat assembly of claim 1 wherein said foam shell is defined to cover at least a portion of both of said seat cushion and said backrest.

3. A seat assembly of claim 1 wherein the seat assembly includes a headrest and said foam shell is defined to cover at least a portion of said headrest.

4. A seat assembly of claim 3 wherein said foam shell is defined to cover at least a portion of all of said seat cushion, said bracket and said headrest.

5. A seat assembly of claim 1, wherein said foam shell includes a predetermined hardness.

6. A seat assembly of claim 5, wherein said hardness is predetermined based on the location of the foam shell on the seat assembly.

7. A seat assembly of claim 6, wherein said foam shell includes a first surface having a predetermined hardness and a second surface having a predetermined hardness different than said hardness of said first surface.

8. A seat assembly of claim 7 wherein said first surface hardness and said second surface hardness are predetermined based on a desired resultant hardness for the foam shell.

9. A seat assembly of claim 7 wherein said first surface and said second surface are interchangeable to permit either of said first surface and said second surface to be used as said exterior surface.

10. A seat assembly of claim 1 wherein said backrest includes a channel retaining said foam shell on said backrest.

11. A seat assembly of claim 1 wherein said seat cushion includes a channel retaining said foam shell on said seat cushion.

12. A seat assembly of claim 1 wherein said seat cushion includes a seat cushion frame assembly.

13. A seat assembly of claim 12 wherein said foam shell includes attachment features, formed integral with said foam section, for attaching said foam shell to said seat cushion frame assembly.

14. A seat assembly of claim 1 wherein said backrest includes a frame assembly.

15. A seat assembly of claim 14 wherein said foam shell includes attachment features, formed integral with said foam section, for attaching said foam shell to said backrest frame assembly.

16. A seat assembly of claim 15 wherein said foam shell includes a backpanel.

17. A seat assembly of claim 16 wherein said backpanel includes at least one hinge formed integral with said foam shell.

18. A seat assembly of claim 17 wherein said backpanel includes at least one pocket-like panel formed integral with said foam shell.

19. A seat assembly of claim 7 wherein said foam shell includes apertures extending between said first surface and said second surface of said foam shell.

20. A seat assembly of claim 19 wherein said apertures are defined to permit the flow of air therethrough.

21. A seat assembly of claim 1 wherein said foam shell includes a bolster portion formed integral with said foam shell.

22. A seat assembly of claim 21 wherein said bolster portion including at least one cavity.

23. A seat assembly of claim 21 wherein said cavity includes at least one plug.

24. A seat assembly of claim 1 wherein said foam shell includes a lumbar portion formed integral with said foam shell.

25. A seat assembly of claim 24 wherein said lumbar portion including at least one cavity.

26. A seat assembly of claim 25 wherein said cavity includes at least one plug.

27. A seat assembly of claim 25 wherein said cavity is defined to form a bladder holding air.

28. A seat assembly of claim 1 wherein said foam shell includes a textured surface.

29. A seat assembly of claim 1 wherein said foam shell used with said seat cushion includes a compartment formed integral with said foam shell for use in storing articles.

30. A seat assembly of claim 29 wherein said compartment includes a hinge formed integral with at least a portion of said compartment.

31. A seat assembly of claim 1 wherein said foam shell is disposed to cover at least a portion of another component attached to one of said seat cushion and said backrest.

32. A seat assembly of claim 31 wherein said component is a handle.

33. A seat assembly of claim 31 wherein said component is a recliner mechanism.

34. A seat assembly of claim 31 wherein said component is a bracket.

35. A seat assembly of claim 31 wherein said component is a frame.

36. A seat assembly of claim 35 wherein said foam shell includes a pocket-like panel formed integral with said foam shell.

37. A seat assembly of claim 31 wherein said component is a switch.

38. A seat assembly of claim 31 wherein said foam shell includes an aperture for receiving electrical components.

39. A seat assembly of claim 31 wherein said component is an armrest.

40. A seat assembly of claim 39 wherein said armrest includes a pocket-like panel formed integral with said foam shell.

41. A seat assembly of claim 1 wherein one of said backrest and said seat cushion includes a mesh carrier.

42. A headrest assembly of claim 41 wherein said foam shell includes a first portion and a section portion.

43. A headrest assembly of claim 42 wherein said first portion and said second portion are formed with integral attachment features for attaching said first portion to said second portion.

44. A headrest assembly of claim 41 wherein said foam shell includes a cavity for receiving said frame.

45. A headrest assembly of claim 41 wherein said foam shell includes a cavity for receiving said attachment rod.

41-1. A headrest assembly comprising:

a frame;

an attachment rod;

a cushion; and

a foam shell being formed from a closed-cell foam and having an integral exterior surface for use with at least a portion of said cushion.

46. A method of forming a seat assembly comprising the steps of:

forming a first seat component from a closed-cell foam in a mold;

ejecting said first seat component from said mold;

inserting a second seat component into at least a portion of said first seat component prior to said first seat component reaching a predetermined temperature; and

holding said second seat component and said first seat component together for a predetermined duration permitting the first seat component to reach said predetermined temperature.

47. The method of claim 46 wherein said second seat component is formed from a closed-cell foam in a mold.

48. A sunvisor comprising;

a visor;

an attachment rod; and

a foam shell being formed from a closed-cell foam and having an integral exterior surface for use with at least a portion of said visor.

49. The sunvisor of claim 48 wherein said foam shell includes at least one pocket-like portion for holding articles.

50. The sunvisor of claim 48 wherein said foam shell is shrunk-fit to said visor.

51. A method of assembly a sunvisor including the steps of:

forming a foam shell from a closed-cell foam in a mold;

ejecting said foam shell from said mold;

inserting a visor into at least a portion of said foam shell prior to said foam shell reaching a predetermined temperature; and

holding said visor and said foam shell together for a predetermined duration permitting the foam shell to reach said predetermined temperature.

52. The method of claim 51 wherein at said predetermined temperature said foam shell has shrunk thereby retaining said foam shell on said visor.