Foam cord for seating foam stability and rigidity

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.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a vehicle seating assembly, and more particularly to a vehicle seating assembly with a foam cord for seating foam stability and rigidity.

BACKGROUND OF THE DISCLOSURE

Vehicle seating assemblies typically include a seatback to support a back of an occupant in an upright sitting position and various reclined positions. Similar to other portions of a vehicle seating assembly, seatbacks are commonly designed to support an occupant in the upright sitting position upon acceleration, change in direction, and collision of the vehicle. Accordingly, seatbacks are substantially rigid and sizeable in construction.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, 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.

According to another aspect of the present disclosure, 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. A semi-rigid foam cord is formed in the foam cushion assembly and circumscribes the periphery of the seatback to add additional structural rigidity to the seatback.

According to yet another aspect of the present disclosure, a method of making a vehicle seating assembly includes coupling a seat frame and a seatback with a vehicle floor. A foam cushion assembly is operably coupled to the seat frame and seatback. A semi-rigid foam cord is formed into the seatback that circumscribes a forward periphery of the seatback to provide structural rigidity to the seatback.

According to still another aspect of the present disclosure, a vehicle seating assembly includes a seatback having a frame that supports a seatback having a foam cushion inside a vehicle. The foam cushion is supported by a carrier operably coupled to the frame. The foam cushion assembly includes a continuous semi-rigid foam cord formed into the foam cushion assembly. The foam cord extends through a forward periphery of the seatback and aids in providing structural support to a periphery of the seatback. The foam cord is constructed from one continuous piece of material having no seams or welds. The foam cord provides a softened feel to the posterior of and back of a seated passenger. The foam cord lessens or eliminates the abrupt and oftentimes rigid feel of traditional metallic wires used to support passengers.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring toFIGS. 1-4, reference numeral10generally designates a vehicle seating assembly including a seatback12having a frame14that provides structural integrity to the seatback12and operably couples the seatback12to a vehicle floor16. A carrier18is operably coupled to the frame14. A foam cushion assembly20is operably coupled to the carrier18. The foam cushion assembly20includes an upper portion22, a lower portion24, a first side bolster26, and a second side bolster28. A semi-rigid foam cord30is formed into a continuous loop in the foam cushion assembly20. The foam cord30extends through a forward periphery32of the upper portion22, the lower portion24, the first side bolster26, and the second side bolster28of the foam cushion assembly20. The foam cord30is configured to add structural rigidity to the seatback12.

With reference again toFIG. 1, the foam cord30is generally configured for use in either the seatback12or a seat of the vehicle seating assembly10. The vehicle seating assembly10includes a seat40having first and second side bolsters42,44, as well as a forward thigh support46configured to support the underside of the legs of a passenger. Controls50, such as those shown on the side of the seat40, can be used to adjust a recline angle of the seatback12, as well as adjust lumbar support functions, seat heating/cooling systems, etc. The vehicle seating assembly10also includes a head restraint52disposed at a top portion54of the seatback12.

With reference now toFIGS. 2 and 2A, in the illustrated embodiment, both the seatback12and a seat40of the vehicle seating assembly10include the foam cord30. The foam cord30is semi-rigid in nature and generally constructed from any of a variety of polymeric materials. In one embodiment, the foam cord30is constructed from a polyurethane foam. Traditional seating assemblies for vehicles have used steel wires instead of a polymeric cord. Steel wires add additional weight and cost and can create hard spots in the periphery of the seat40and the seatback12that may be uncomfortable to passengers. Adding the foam cord30utilizing a dual firmness foam manufacturing process provides an affordable lightweight solution to using steel wires. During the dual firmness foam manufacturing process, dual shot injection mold ports can be used to apply foam to a first mold cavity, the first mold cavity being formed from a first mold half and a second mold half. A soft foam can be poured into the first mold cavity and allowed to cure. The first and second mold halves are subsequently separated and the first mold half is positioned proximate a third mold half having a shape defining a cavity in conjunction with the soft foam, which forms the foam cord30. The material that makes up the foam cord30can then be poured into the cavity, creating a dual foam system with a semi-rigid ring defined by the foam cord30. The foam cord30is positioned forward in the upper portion22, the lower portion24, the first side bolster26, and the second side bolster28to provide strength and rigidity to the seat40. Thus, a firmer foam is poured along a perimeter of a part to add desired rigidity, provides for a desirable and comfortable seat without losing the structural integrity of the vehicle seating assembly10as a whole. During the manufacturing process, special care is taken to ensure that the more rigid foam that defines the foam cord30does not bleed through or otherwise seep into the softer foam that defines a seat cushion56or a seatback cushion58of the seat40or the seatback12, respectively. Accordingly, the feel of a harder area on the seat cushion56or the seatback cushion58can be eliminated. The foam cushion in many conventional seats is assembled directly on the seat frame without a carrier or other support in between. It is contemplated that the foam cushion or other support in between may be assembled with the foam cord, on the seat frame, the cushion, and the seatback without a carrier.

The foam cord30, which is formed as a single continuous ring, can be placed into the mold halves of a forming tool in lieu of a wire. The foam cord30includes a higher density and firmness than the softer foam that is poured around the foam cord30and which defines the seat and seatback cushions56,58. When the foam cures, the foam cord30, which is embedded in the foam cushion assembly20, is disposed throughout the part on a forward area of the seat cushion56or the seatback cushion58and the desired structural rigidity is provided. As noted above, the foam cords30can be tooled from conventional polyurethane foam, as well as a multitude of other foams that include a tensile strength that satisfies structural rigidity concerns, while still being flexible enough to eliminate rigidity issues associated with wire rings.

In one embodiment, shape memory polymer fibers are embedded into the foam cord30itself. The shape memory polymer fibers that are utilized generally react to heat, moisture, electrical input, etc. The shape memory polymer fibers are in a resting or contracted state after the foam cord30is manufactured and cooled. When the hot foam that defines the seat or seatback cushion assembly is poured around the foam cord30, the shape memory polymer fibers in the foam cord30are activated and expand. As the part cools, the shape memory polymer fibers in the foam cord30contract and slightly compress the soft foam part around the foam cord30, thereby providing the desired structural rigidity. This solution eliminates the cost and weight of previously used steel wire rings, and minimizes the impact to comfort that a steel wire ring can have on a seated passenger.

The foam cord30is generally designed to include a higher density than the foam cushion assembly20. Accordingly, the foam cushion assembly20can be utilized without the use of any support wires embedded therein. Further, the foam cord30may be generally homogeneous in material or may include a variety of different polymeric foam materials that have a higher standard integrity than the surrounding soft foam and which act in concert to support the periphery of the seatback12and/or the seat40. The foam cord30is generally circular in cross-section. However, alternate cross-section styles, for example, oval, triangular, square, etc., can also be utilized to obtain a desired effect. Additionally, the foam cord30generally protrudes forward at the first and second side bolsters26,28to support the first and second side bolsters26,28in a forward position relative to the upper portion22and the lower portion24of the seatback12. Further, as noted above, the foam cord30is formed in a continuous pour. Accordingly, the foam cord30does not include any breaks, weld lines, adhesion lines, etc. The absence of such breaks provides for a uniformly strong support in the seat40or the seatback12.

With reference now toFIGS. 3 and 4, the foam cord30is generally illustrated as protruding down along the first and second side bolsters26,28forward of the upper portion22and the lower portion24of the central area of the seatback12. Accordingly, a force or rate applied to one of the first and second side bolsters26,28will result in tension in the foam cord30, which helps support the first and second side bolsters26,28in position as the force or weight of a passenger is applied to the first and second side bolsters26,28. Likewise, as illustrated inFIG. 4, the foam cord30extends through the upper portion22and the lower portion24of the seatback12. The foam cord30extends through the upper portion22of the seatback12below the head restraint52, and below a lumbar region of the lower portion24of the seatback12.