Foam cord for seating foam stability and rigidity

• US 9,637,034 B2
• Filed: 08/25/2014
• Issued: 05/02/2017
• Est. Priority Date: 08/25/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Hulway, Michael A., Himmel, IV, Joseph August
• Primary Examiner(s): Islam, Syed A
• Application Number:
  US14/467,148
• Publication Number:
  US 20160052434A1
• Time in Patent Office: 981 Days
• Field of Search: 2972849, 2972846, 2972843, 29745227, 29745237, 29745265, 29745252, 29745253, 29745254, 29745218
• CPC Class Codes: A47C 7/029 of non-adjustable shape adapted to a user contour or ergonomic seating positions
• CPC Class Codes: A47C 7/18 having foamed material included in cushioning part foamed material mattresses A47C27/14
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 44/0461 by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
• CPC Class Codes: B29C 44/086 and feeding more material into the enlarged cavity
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B60N 2/64 Back-rests or cushions B60N2/2222 takes precedence
• CPC Class Codes: B60N 2/646 shape of the cushion
• CPC Class Codes: B60N 2/68 Seat frames
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for

Abstract

A vehicle seating assembly includes a seatback having a frame that provides structural integrity to the seatback and operably couples the seatback to a vehicle floor. A carrier is operably coupled to the frame. A foam cushion assembly is operably coupled to the carrier. The foam cushion assembly includes an upper portion, a lower portion, a first side bolster, and a second side bolster. A continuous semi-rigid foam cord is formed in the foam cushion assembly. The foam cord extends through a forward periphery of the upper portion, the lower portion, the first side bolster, and the second side bolster. The foam cord is configured to add structural rigidity to the seatback.

Claims

1. A vehicle seating assembly comprising:

a seatback including a frame that provides structural integrity to the seatback and which operably couples the seatback to a vehicle floor;

a carrier operably coupled to the frame;

a foam cushion assembly operably coupled to the carrier, the foam cushion assembly including an upper portion, a lower portion, a first side bolster, and a second side bolster; and

a continuous semi-rigid foam cord formed in the foam cushion assembly, the foam cord extending through a forward periphery of the upper portion, the lower portion, the first side bolster, and the second side bolster, the foam cord being configured to add structural rigidity to the seatback.

2. The vehicle seating assembly of claim 1, wherein the foam cord has a higher density than the foam cushion assembly.

3. The vehicle seating assembly of claim 1, wherein the foam cushion assembly is free of support wires.

4. The vehicle seating assembly of claim 1, wherein the foam cord is circular in cross-section.

5. The vehicle seating assembly of claim 1, wherein the foam cord is formed from a shape memory polymer.

6. A vehicle seating assembly comprising:

a seatback including a frame that operably couples the seatback to a vehicle floor;

a carrier operably coupled to the frame;

a foam cushion assembly operably coupled to the carrier; and

a continuous semi-rigid foam cord formed in the foam cushion assembly and which circumscribes a forward periphery of the seatback, a tensile strength of the foam cord providing structural rigidity to the forward periphery.

7. The vehicle seating assembly of claim 6, wherein the foam cord protrudes forward at bolsters.

8. The vehicle seating assembly of claim 6, wherein the foam cord has a higher density than the foam cushion assembly.

9. The vehicle seating assembly of claim 6, wherein the foam cushion assembly is free of support wires.

10. The vehicle seating assembly of claim 6, wherein the foam cord is circular in cross-section.

11. The vehicle seating assembly of claim 6, wherein the foam cord is formed from a shape memory polymer.

12. A method of making a vehicle seating assembly comprising:

coupling a seat frame and a seatback with a vehicle floor;

coupling a foam cushion assembly to the seat frame and seatback; and

forming a semi-rigid foam cord into the seatback that circumscribes continuously through a forward periphery of upper and lower portions and first and second side bolsters of the seatback to provide structural rigidity to and maintain a shape of the seatback.

13. The method of claim 12, further comprising:

positioning the foam cord to protrude forward at the first and second side bolsters formed in the seatback.

14. The method of claim 12, further comprising:

constructing the foam cord to have a higher density than the foam cushion assembly.

15. The method of claim 12, further comprising:

constructing the foam cushion assembly to be free of support wires.

16. The method of claim 12, further comprising:

constructing the foam cord to be circular in cross-section.

17. The method of claim 12, further comprising:

forming the foam cord from a shape memory polymer.