Rear seat cushion sound reduction mat

• US 8,974,003 B2
• Filed: 03/30/2012
• Issued: 03/10/2015
• Est. Priority Date: 03/30/2012
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Reedy, Lacey A., Vargo, Christopher M., Rutkowski, Paul M.
• Primary Examiner(s): GABLER, PHILIP F
• Application Number:
  US13/435,558
• Publication Number:
  US 20130257133A1
• Time in Patent Office: 1,075 Days
• Field of Search: 297/452.14, 297/452.55, 297/452.15, 297/452.57, 297/452.38, 297/217.1, 296/1.03, 296/39.3, 181/290
• US Class Current: 297/452.38
• CPC Class Codes: B60N 2/68 Seat frames
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: B60N 2/90 Details or parts not otherwise provided for
• CPC Class Codes: G10K 11/162 Selection of materials

Abstract

A sound blocking rear seat assembly for an automotive vehicle. The rear seat assembly includes a seat back adjacent to a seat bottom. The seat bottom also defines at least two passenger seating locations. A seat base of the seat bottom extends the width of the seat assembly and has a non-planar three dimensional contoured upper surface. A nonporous resilient sound blocking layer has a shape substantially conforming to the upper surface of the seat base and is located over the seat base such that it extends substantially continuously and uninterruptedly over the width of the seat assembly. Positioned over the sound blocking layer is a resilient seat cushion, and a trim layer is located over the seat cushion layer.

Claims

1. A sound blocking rear seat assembly for an automotive vehicle, the rear seat assembly comprising:

a seat back located adjacent to and extending generally upward from a seat bottom, the seat bottom defining a width extending laterally relative to a longitudinal axis of the vehicle and further defining at least two seating locations for passengers in the vehicle, the seat bottom further including a seat base extending substantially the width of the seat bottom and beneath each of the seating locations, a sound-blocking layer incorporated into the seat bottom, the sound blocking layer being a nonporous resilient layer extending substantially continuously over the width of the seat bottom, a resilient seat cushion also incorporated into the seat bottom, and a trim layer located over the seat cushion layer, wherein the sound-blocking layer provides a decrease in sound transmission of between about 0.1-2 dB as compared to a seat bottom of the same construction without the sound-blocking layer.

2. The rear seat assembly of claim 1, wherein the scat base has a non-planar three dimensional contoured upper surface and the sound-blocking layer is in contact with the upper surface and has a shape substantially conforming to the upper surface of the seat base.

3. The rear seat assembly of claim 1, wherein the sound-blocking layer is freely resting on the upper surface of the seat base.

4. The rear seat assembly of claim 1, wherein the sound-blocking layer is in surface-to-surface contact with an upper surface of the seat base.

5. The rear seat assembly of claim 1, wherein the seat base defines a base thickness, the seat cushion defines a cushion thickness and the sound-blocking layer defines blocking layer thickness, the thickness of the sound-blocking layer being less than the thickness of the seat base and being less than the thickness of the seat cushion.

6. The rear seat assembly of claim 1, wherein the sound-blocking layer is in registry with the seat cushion.

7. The rear seat assembly of claim 1, wherein the sound-blocking layer extends uninterruptedly over the width of the rear seat assembly.

8. The rear seat assembly of claim 1, wherein the sound-blocking layer has a thickness in the range of 0.5 to 10 mm.

9. The rear seat assembly of claim 1, wherein the sound blocking-layer is formed of ethylene vinyl acetate.

10. The rear seat assembly of claim 9, wherein the seat base is formed of expanded polypropylene.

11. The rear seat assembly of claim 9, wherein the seat cushion is a foam cushion.

12. The rear seat assembly of claim 1, wherein the sound-blocking layer is located between the seat base and the seat cushion.

13. A sound blocking assembly for an automotive vehicle, the sound blocking assembly comprising:

an automotive interior component defining a width extending laterally relative to a longitudinal axis of the vehicle, the interior component further including a base layer material extending substantially the width of the interior component, the base layer material having a non-planar three dimensional contoured surface, a sound-blocking layer attached the base layer material, the sound blocking layer being a nonporous resilient layer extending substantially continuously over the base layer material, wherein the sound-blocking layer provides a decrease in sound transmission of between about 0.1-2 dB as compared to an interior component of the same construction without the sound-blocking layer.

14. The sound-blocking assembly of claim 13, wherein the sound-blocking layer is in surface to surface contact with a surface of the base layer material.

15. The sound-blocking assembly of claim 14, wherein sound-blocking layer has a shape substantially conforming to the lower surface of the base layer material.

16. The sound-blocking assembly of claim 14, wherein sound-blocking layer has a shape substantially conforming to the upper surface of the base layer material.

17. The sound-blocking assembly of claim 13, wherein the base layer material defines a base thickness and the sound-blocking layer defines blocking layer thickness, the blocking layer thickness being less than the base thickness.

18. The sound-blocking assembly of claim 13, wherein the sound-blocking layer extends uninterruptedly over the width of the interior component.

19. The sound-blocking assembly of claim 13, wherein the sound-blocking layer is formed of ethylene vinyl.

20. The sound-blocking assembly of claim 13, wherein the sound-blocking layer is formed of ethylene vinyl acetate and has a thickness in the range of 0.5 to 10 mm.