Vehicle seating frame, assembly, and method of making
First Claim
1. A vehicle seat assembly comprising:
- a unitary and integrally formed seat frame made of structural foam having a hardness at 75% deflection of 600 to 1,000 N/mm2 as measured by ASTM test method D3574, 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 resilient foam cushion supported on the unitary and integrally formed seat frame made of structural foam, the cushion being softer than the seat frame and having a hardness at 75% deflection of 175 to 400 N/mm2 as measured by ASTM test method D3574; and
a trim material disposed over the cushion and the frame.
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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.
82 Citations
20 Claims
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1. A vehicle seat assembly comprising:
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a unitary and integrally formed seat frame made of structural foam having a hardness at 75% deflection of 600 to 1,000 N/mm2 as measured by ASTM test method D3574, 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 resilient foam cushion supported on the unitary and integrally formed seat frame made of structural foam, the cushion being softer than the seat frame and having a hardness at 75% deflection of 175 to 400 N/mm2 as measured by ASTM test method D3574; and a trim material disposed over the cushion and the frame. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A vehicle seat frame component comprising:
an integrally formed 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, the structural foam comprising expanded polyolefin made of expanded polyolefin beads, the attachment flange having a first bead density and the main body portion having a second bead density, less than the first bead density, the seat frame being one-piece and the main body portion comprising a minimum density region spaced from the attachment flanges and a transition region extending between the minimum density region and the attachment flange, and 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. - View Dependent Claims (15, 16, 17)
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18. A method of making a vehicle seat assembly, said method comprising:
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forming an integrally formed seat frame made of structural foam in a first mold 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, removing the seat frame from the first mold; forming a foam cushion made in a second mold, removing the foam cushion from the second mold and supporting the foam cushion on the seat frame; and disposing a trim material over the foam cushion and the seat frame. - View Dependent Claims (19, 20)
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Specification