Cushion pad for car seat

• US 9,266,455 B2
• Filed: 02/20/2013
• Issued: 02/23/2016
• Est. Priority Date: 02/22/2012
• Status: Active Grant

• Current Assignee: Toyobo MC Corp.
• Original Assignee: Toyobo Company Limited, Toyota Boshoku Kabushiki Kaisha
• Inventors: Uramichi, Hideki, Imagawa, Masayuki, Makiguchi, Fumiya, Harada, Hirotaka
• Primary Examiner(s): Allred, David E
• Application Number:
  US13/771,327
• Publication Number:
  US 20130214583A1
• Time in Patent Office: 1,098 Days
• Field of Search: 297/452.27, 297/452.53, 297/452.57, 297/452.21, 297/452.22, 297/452.23, 297/452.55, 297/452.56, 297/452.51, 297/452.52, 297/452.37
• US Class Current: 1/1
• CPC Class Codes: A47C 27/122 with special fibres, such as acrylic thread, coconut, horsehair
• CPC Class Codes: A47C 27/20 with springs moulded in, or situated in cavities or openings in foamed material
• CPC Class Codes: A47C 27/22 with both fibrous and foamed material inlays
• CPC Class Codes: A47C 31/006 Use of three-dimensional fabrics
• CPC Class Codes: A47C 5/12 of plastics, with or without reinforcement
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: A47C 7/185 with a stiff, rigid support
• CPC Class Codes: A47C 7/20 with reinforcement in the foam layer
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: B60N 2/7035 Cushions
• CPC Class Codes: B60N 2/707 with rubber blocks
• CPC Class Codes: B60N 2/7076 with rubber bands

Abstract

Embodiments of present invention may include a cushion pad for supporting a seated passenger; the cushion pad being divided into a left pad section, a middle pad section and a right pad section; a soft resin foam dispersed throughout the left pad section, the middle pad section and the right pad section; the left pad section having a left holding volume for holding a first volume of an elastic three-dimensional fibrous network and the soft resin foam; the right pad section having a right holding volume for holding a second volume of an elastic three-dimensional fibrous network and the soft resin foam; and the middle pad section not having a volume of an elastic three-dimensional fibrous network contained within.

Claims

1. A cushion pad for a car seat where an occupant is seated, comprising:

a cushion pad for supporting a seated passenger;

the cushion pad being divided into a left pad section, a middle pad section and a right pad section;

a soft resin foam dispersed throughout the left pad section, the middle pad section and the right pad section;

the left pad section having a left holding volume for holding a first volume of an elastic three-dimensional fibrous network and the soft resin foam;

the right pad section having a right holding volume for holding a second volume of an elastic three-dimensional fibrous network and the soft resin foam; and

the middle pad section not having a volume of an elastic three-dimensional fibrous network contained within,

wherein an uppermost surface of each of the left pad section, the middle pad section and the right pad section lies within a common plane, and

in each of the left pad section and the right pad section, an upper width of the elastic three-dimensional fibrous network at the uppermost surface is wider than a lower width of the elastic three-dimensional fibrous network at a lowermost surface, the upper width and the lower width extending from side surfaces of the cushion pad toward the middle pad section.

2. The cushion pad of claim 1, wherein:

a cross-section of the left holding volume has at least one linear side; and

a cross-section of the right holding volume has at least one linear side.

3. The cushion pad of claim 1, wherein:

the first volume of elastic three-dimensional fibrous network spans from the uppermost surface to the lowermost surface of the left pad section; and

the second volume of elastic three-dimensional fibrous network spans from the uppermost surface to the lowermost surface of the right pad section.

4. The cushion pad of claim 1,

wherein at least one of the first volume of the elastic three-dimensional fibrous network or the second volume of the elastic three-dimensional fibrous network includes a plurality of filament loops wherein contact portions between the plurality of filament loops are bonded together.

5. The cushion pad of claim 4,

wherein the plurality of filament loops is comprised of at least one polyester, polyamide, polyether or polyolefin thermoplastic.

6. The cushion pad of claim 1, wherein the uppermost surface of the left pad section, the middle pad section and the right pad section comprise a continuous surface.

7. The cushion pad of claim 1, wherein each of the left pad section, the middle pad section and the right pad section have a same thickness.

8. The cushion pad of claim 7, wherein the same thickness of each of the left pad section, the middle pad section and the right pad section is uniform between side surfaces of each of the left pad section, the middle pad section and the right pad section.

9. The cushion pad of claim 1, wherein, in each of the left pad section and the right pad section, the elastic three-dimensional fibrous network is configured in a straight bar shape aligned in a depth direction of the left pad section and the right pad section.

10. The cushion pad of claim 1, wherein, in each of the left pad section and the right pad section, the elastic three-dimensional fibrous network is configured in an outwardly bent bar shape aligned in a depth direction of the left pad section and the right pad section, the outwardly bent bar shape having a middle portion disposed further from the middle pad section than end portions of the outwardly bent bar shape.

11. The cushion pad of claim 1, wherein, in each of the left pad section and the right pad section, the elastic three-dimensional fibrous network is disposed in an upper portion adjacent the uppermost surface and not disposed in a lower portion adjacent the lowermost surface.

12. A cushion for a vehicle comprising:

a cushion having a main pad section and two lateral support sections; and

the main pad section being divided into a left pad section, a middle pad section and a right pad section;

wherein the two lateral support sections contain soft resin,

the main pad section contains a combination of soft resin and a volume of elastic, fibrous material,

an uppermost surface of each of the left pad section, the middle pad section and the right pad section lies within a common plane,

the volume of elastic, fibrous material of the main pad section is confined to the left pad section and the right pad section, and

in each of the left pad section and the right pad section, an upper width of the elastic three-dimensional fibrous network at the uppermost surface is wider than a lower width of the elastic three-dimensional fibrous network at a lowermost surface, the upper width and the lower width extending from side surfaces of the cushion pad toward the middle pad section.

13. The cushion for the vehicle of claim 12, wherein a spacing between an inner side of the left pad section and an inner side of the right pad section is at least 200 mm.

14. The volume of elastic, fibrous material used in the cushion for the vehicle of claim 12, wherein the volume of the elastic, fibrous material includes a plurality of filament loops wherein contact portions between the plurality of filament loops are bonded together.

15. The volume of elastic, fibrous material of claim 14, wherein the plurality of filament loops is comprised of at least one polyester, polyamide, polyether or polyolefin thermoplastic.

16. The cushion for the vehicle of claim 12, wherein the uppermost surface of the left pad section, the middle pad section and the right pad section comprise a continuous surface.

17. The cushion for the vehicle of claim 12, wherein each of the left pad section, the middle pad section and the right pad section have a same thickness.

18. A cushion pad for a car seat where an occupant is seated, comprising:

a cushion pad for supporting a seated passenger;

the cushion pad being divided into a left pad section, a middle pad section and a right pad section;

a soft resin foam dispersed throughout the left pad section, the middle pad section and the right pad section;

the left pad section having a left holding volume for holding a first volume of an elastic three-dimensional fibrous network and the soft resin foam;

the right pad section having a right holding volume for holding a second volume of an elastic three-dimensional fibrous network and the soft resin foam; and

the middle pad section not having a volume of an elastic three-dimensional fibrous network contained within,

wherein an uppermost surface of each of the left pad section, the middle pad section and the right pad section lies within a common plane,

in each of the left pad section and the right pad section, the elastic three-dimensional fibrous network is disposed non-uniformly from the uppermost surface to a lowermost surface, and

in each of the left pad section and the right pad section, an upper width of the elastic three-dimensional fibrous network at the uppermost surface is wider than a lower width of the elastic three-dimensional fibrous network at a lowermost surface, the upper width and the lower width extending from side surfaces of the cushion pad toward the middle pad section.