VEHICLE SEATING FRAME, ASSEMBLY, AND METHOD OF MAKING

• US 20110018329A1
• Filed: 07/27/2009
• Published: 01/27/2011
• Est. Priority Date: 07/27/2009
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Ali, Asad S., Galbreath, Ashford A., Rock, Gary
• Granted Patent: US 8,696,067 B2
• Time in Patent Office: Days
• US Class Current: 297/452.18
• CPC Class Codes: B60N 2/012 The seat support being a part of the vehicle body or chassis
• CPC Class Codes: B60N 2/01508 using quick release attachments
• CPC Class Codes: B60N 2/68 Seat frames
• CPC Class Codes: B60N 2/686 Panel like structures
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: Y10T 29/48 Upholstered article making

Abstract

The present invention relates to a vehicle seat frame made of structural foam having an attachment flange for attaching to a vehicle, and vehicle seat assembly, and methods of making the same. In at least one embodiment, the vehicle seat assembly comprises a seat frame made of structural foam and having a main body portion and at least one attachment flange depending from the main body portion. The attachment flange is attachable to a vehicle floor pan via an interference fit. The attachment flange has a first density and the main body portion has a second density, less than the first density. The vehicle seat assembly further comprises a cushion supported on the frame. The cushion is softer than the seat frame. The vehicle seat assembly further comprises a trim material disposed over the cushion and the frame.

Claims

1. A vehicle seat assembly comprising:

a seat frame made of structural foam, the seat fame having a main body portion and at least one attachment flange depending from the main body portion, the attachment flange attachable to a vehicle floor pan via an interference fit, the attachment flange having a first density and the main body portion having a second density, the first density being greater than the second density;

a cushion supported on the frame, the cushion being softer than the seat frame; and

a trim material disposed over the cushion and the frame.

2. The vehicle seat assembly of claim 1, wherein the main body portion comprises a minimum density region spaced from the attachment flanges and a transition region extending between the minimum density region and the attachment flange.

3. The vehicle seat of claim 1, wherein the at least one attachment flange comprises a plurality of spaced apart attachment flanges, wherein the main body portion comprises at least one minimum density region spaced from the plurality of the attachment flanges, and the main body portion further comprising a plurality of transition regions, with each transition region extending between the at least one minimum density region and a respective one of the attachment flanges.

4. The vehicle seat assembly of claim 1, wherein the first density comprises 3.8 to 11.1 pcf.

5. The vehicle seat assembly of claim 4, wherein the second density comprises less than 3.8 pcf.

6. The vehicle seat assembly of claim 5, wherein the second density comprises 1.0 to 3.25 pcf.

7. The vehicle seat assembly of claim 1, wherein the structural foam comprises expanded polyolefin made of expanded polyolefin beads and the attachment flange has a first bead density and the main body portion has a second bead density lower than the first bead density.

8. The vehicle seat assembly of claim 7, wherein the first bead density is 60 to 180 grams/liter and the second bead density is 10 to 59 grams/liter.

9. The vehicle seat assembly of claim 2, wherein the transition region comprises a third density being less than the first density and greater than the second density, wherein the at least one attachment flange comprises a plurality of spaced apart attachment flanges depending downwardly to be receivable in a respective recess of a vehicle floor pan, and wherein the cushion comprises a foam cushion having a hardness of 175 N/mm² to 400 N/mm².

10. The vehicle seat assembly of claim 9, wherein the frame further comprises a plurality of attachment brackets extending rearwardly from the main body portion to cooperate with the floor pan, and wherein the first density comprises 3.8 to 11.1 pcf, the second density comprises 1.0 to 1.8 pcf and the third density comprises 1.9 to 3.75 pcf, and wherein the flanges and brackets are integral with the main body portion, and the flanges, the brackets and the main body portion are made in the same molding tool.

11. The vehicle seat assembly of claim 2, wherein the structural foam comprises expanded polyolefin made of expanded polyolefin beads and the attachment flange has a first bead density, the minimum density region has a second bead density, less than the first bead density, and the transition region has a third density bead less than the first bead density and greater than the second bead density.

12. The vehicle seat assembly of claim 11, wherein the first bead density is 60 to 180 grams/liter, the second bead density is 10 to 29 grams/liter, and the third bead density is 30 to 59 grams/liter.

13. A vehicle seat frame component comprising:

a seat frame made of structural foam, the seat fame having a main body portion and at least one attachment flange depending from the main body portion, the attachment flange attachable to a vehicle, the attachment flange having a first density and the main body portion having a second density, the first density being greater than the second density, the frame having an upper surface capable of supporting a foam cushion.

14. The vehicle seat assembly of claim 13, wherein the main body portion comprises a minimum density region spaced from the attachment flanges and a transition region extending between the minimum density region and the attachment flange.

15. The vehicle seat of claim 13, wherein the at least one attachment flange comprises a plurality of spaced apart attachment flanges, wherein the main body portion comprises at least one minimum density region spaced from the plurality of the attachment flanges, and the main body portion further comprising a plurality of transition regions, with each transition region extending between the at least one minimum density region and a respective one of the attachment flanges.

16. The vehicle seat assembly of claim 13, wherein the structural foam comprises expanded polyolefin made of expanded polyolefin beads and the attachment flange has a first bead density and the main body portion has a second bead density, less than the first bead density.

17. The vehicle seat assembly of claim 14, wherein the structural foam comprises expanded polyolefin made of expanded polyolefin beads and the attachment flange has a first bead density, the minimum density region has a second bead density, less than the first bead density, and the transition region has a third bead density less than the first bead density and greater than the second bead density.

19. The method of claim 14 further comprising providing an vehicle floor pan and securing the attachment flange of the seat frame to the floor pan.

20. The method of claim 15 wherein the attachment flange is secured to the floor pan via an interference fit.

18. A method of making a vehicle seat assembly, said method comprising:

providing a seat frame made of structural foam and having a main body portion and an attachment flange depending from the main body portion, the attachment flange attachable to a vehicle floor pan, the attachment flange having a first density and the main body portion having a second density, the first density being greater than the second density, the varying densities being provided by introducing a first plurality of expanded polyolefin beads having a first bead density into a mold tool to form the attachment flange and introducing a second plurality of expanded polyolefin beads having a second bead density into the mold tool to form the main body portion;

supporting a foam cushion on the frame; and

disposing a trim material over the cushion and the frame.