Abstract:
A seat cushion structure for use in a vehicle seat including a first outer wall and a second outer wall joined to form a plurality of chambers. The seat cushion includes an energy absorption substance disposed within the chambers to absorb occupant load. The seat cushion also includes a plurality of springs disposed within the chambers to further facilitate occupant support and comfort.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of and priority to U.S. Provisional Application No. 61/261,507, filed Nov. 16, 2009, which is incorporated herein by reference. 
    
    
     BACKGROUND 
     The present disclosure relates generally to the field of seats and more particularly, to a seat cushion structure for use in a seat, such as a vehicle seat. 
     DESCRIPTION OF THE RELATED ART 
     Conventional vehicle seats are typically constructed from a sub-frame and a cushion coupled thereto to provide comfort, isolation from the road induced vibrations not isolated by the vehicle suspension system, and protection for the seat occupant. Known seat cushions come in a variety of designs and are made from a variety of materials. For example, it is known to provide a seat assembly having a suspension mat strung across the sub-frame with a foam cushion located on the suspension mat. Known seat cushion structures can be ineffective in providing comfort and protection. Known seat cushion structures can have complicated designs that hinder manufacturing and assembly. Moreover, known seat cushion structures can be relatively bulky, massive, and expensive. 
     Accordingly, there remains a continuing need to provide an improved seat cushion structure design. 
     SUMMARY 
     Accordingly, the present disclosure relates to a seat cushion structure for use in a vehicle seat including a first outer wall and a second outer wall joined to form a plurality of chambers. The seat cushion includes an energy absorption substance disposed within the chambers to absorb occupant load. A plurality of springs is disposed within the chambers to further facilitate occupant support and comfort. 
     Also provided is a seat cushion structure for use in a vehicle seat including a first outer wall and a second outer wall joined to form a plurality of chambers. The seat cushion includes an energy absorption substance disposed within the chambers to absorb occupant load. A plurality of springs is disposed within the chambers to further facilitate occupant support and comfort. The seat cushion structure also includes a support substrate attached to the second outer wall to provide additional support. 
     Also provided is a seat cushion structure including a cushion member having a first side, a second opposed side, a front side  517 , an opposed rear side  519 , an upper surface  521  having a raised portion at the first and second side bolsters  515 ,  515 ′; and an opposed lower surface  522 . A first set of springs is disposed within the cushion member first side, such that the first set of springs is arranged in a row from the cushion member front side to the cushion member rear side. A second set of springs is disposed within the cushion member second side, such that the second set of springs is arranged in a row from the cushion member front side to the cushion member rear side. The first and second set of springs serve to straddle and support cargo and occupants. 
     An advantage of the present disclosure is that the seat cushion structure provides enhanced comfort. Another advantage of the present disclosure is that the seat cushion structure is more cost effective. A further advantage of the present disclosure is that the seat cushion is relatively lightweight. 
     Other features and advantages of the present disclosure will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle, according to an exemplary embodiment. 
         FIG. 2  is a perspective view of a vehicle seat assembly, according to an exemplary embodiment. 
         FIG. 3  is a perspective view of a vehicle seat frame, according to an exemplary embodiment. 
         FIG. 4  is an exploded view of a vehicle seat frame assembly having a seat cushion structure, according to an exemplary embodiment. 
         FIG. 5  is a front perspective view of a structural support substrate, according to another embodiment. 
         FIG. 6  is a rear perspective view of the structural support substrate of  FIG. 5 . 
         FIG. 7  is an exploded perspective view of a cushion member, according to another embodiment. 
         FIG. 8  is a perspective view of the structural support structure of  FIG. 5  and the cushion member of  FIG. 7  coupled to a seat back frame. 
         FIG. 9  is a perspective view of a structural support structure and seat back frame, according to still another embodiment. 
         FIG. 10  is a perspective view of the structural support structure of  FIG. 9  partially attached to the seat back frame. 
         FIG. 11  is a perspective view of the structural support structure of  FIG. 9  completely attached to the seat back frame. 
         FIG. 12  is a perspective view of a cushion structure attached to a seat assembly, according to still another embodiment. 
         FIG. 13  is a cross sectional view of the cushion structure and seat assembly of  FIG. 12  along the A-A line. 
         FIG. 14  is a perspective view of the cushion structure of  FIG. 12  attached to a seat back frame. 
         FIG. 15  is a perspective view of a cushion structure attached to a vehicle seat assembly, according to still another embodiment. 
         FIG. 16  is a side view of a cushion member design with compression members having different sizes and spring rates. 
         FIG. 17  is a side view of another example of a cushion member design with compression members having different sizes and spring rates. 
         FIG. 18  is a side view of a cushion member design having a plurality of compression members in a top-weld configuration. 
         FIG. 19  is a side view of another example of a cushion member design having a plurality of compression members in a mid-weld configuration. 
         FIG. 20  is a side view of another example of a cushion member design having a plurality of compression members in a bottom-weld configuration. 
         FIG. 21  is a perspective view of a cushion member having a plurality of spring members, according to still another embodiment. 
         FIG. 22  is an elevated view of the cushion member of  FIG. 21  encased in molded foam material. 
         FIG. 23  is a perspective view of the cushion member of  FIG. 21  encased in foam material members. 
         FIG. 24  is a side view of a spring-filled cushion member integrated with a ventilation pad, according to still another embodiment. 
         FIG. 25  is a side view of a spring-filled cushion member having a ventilated heating and cooling mat overlaid thereon, according to still another embodiment. 
     
    
    
     DESCRIPTION 
     Referring generally to the FIGURES and particularly to  FIG. 1 , a vehicle  10  is shown according to an exemplary embodiment. The vehicle  10  can include one or more seat assemblies  12  provided for occupant(s) of the vehicle  10 . While the vehicle  10  shown is a four door sedan, it should be understood that the seat assembly  12  may be used in a mini-van, sport utility vehicle, airplane, boat, or any other type of vehicle. 
     Referring now to  FIG. 2 , a seat assembly  12  is shown. The seat assembly  12  includes a seat frame  13  having a seat back  14  and a seat base  16 . The seat back  14  provides comfort, support and protection to the seated occupant. The seat base  16  is operatively connected to the seat back  14 , and likewise provides comfort, support and protection to the seated occupant. A head restraint  18  is positioned at an upper end of the seat back  14  and also provides comfort, support and protection to the seated occupant. The seat assembly  12  can also include a recliner mechanism  20  operatively connected to the seat back  14  and seat base  16 , to provide rotatable adjustability of the seat back  14  with respect to the seat base  16 . The seat assembly  12  can be secured to the vehicle  10  using a track assembly  22 . The track assembly  22  of this example enables the seat assembly to be repositioned relative the vehicle floor to enhance comfort and utility. The seat back  14  and seat base  16  can also include other components, such as, a trim cover  24 , or the like. The seat assembly  12  also includes a seat cushion structure  26 . 
     Referring next to  FIG. 3 , a seat frame  13  having a seat back cushion structure  26  is shown. The seat frame  13  includes a seat back frame  28  and a seat base frame  30 . 
     The seat frame  13  includes a seat back frame  28 , and a seat base frame  30 . The seat back frame  28  includes an upper cross member  32 , an opposed lower cross member  34 , a first seat back side member  36 , and an opposed second seat back side member  38 . The upper cross member  32  includes a first and a second end  40 ,  42  and the lower cross member  34  includes a first and second end  44 ,  46 . The first seat back side member  36  includes an upper end  48  and an opposed lower end  50  and the second seat back side member  38  includes an upper end  52  and an opposed lower end  54 . The upper ends of the first and second seat back side members  48 ,  52  are coupled together by the upper cross member  32  and the lower ends of the first and second seat back side members  50 ,  54  are coupled together by the lower cross member  34  such that a substantially rectangular frame structure is formed. The seat base frame  30  includes a first seat base side member  56 , an opposed second seat base side member  58 , a front cross member  60 , and an opposed rear cross member  62 . The first seat base side member  56  includes a front end  64  and a rear end  66  and the second seat base side member  58  includes a front end  68  and an opposed rear end  70 . The front cross member  60  includes a first end  72  and a second end  74 , and the rear cross member  62  includes a first end  76  and a second end  78 . The front ends of the first and second seat base side member  64 ,  68  are coupled together by the front cross member  60  and the rear ends of the first and second seat base side member  66 ,  70  are coupled together by the rear cross tube member  30  such that a substantially rectangular frame structure is formed. It should be noted that other seat frame designs can be used with the present disclosure, such as, a one-piece back frame or a one-piece seat base frame, or the like. The seat frame  13  can be made from a variety of materials, such as, metal, aluminum, composite material, or the like. 
     The seat cushion structure  26  includes a structural support substrate  80 , and a cushion member  82 . The structural support substrate  80  includes an upper end  84 , an opposed lower end  86 , a first side  88 , and an opposed second side  90 . The structural support substrate  80  also includes a front surface  92  and a rear surface  94 . The structural support substrate  80  is overlaid and coupled to at least a portion of the seat frame  13 , such as, the seat back frame  28 , the seat base frame  30 , or the like. In this example, the structural support substrate  80  is positioned over and coupled to the seat back frame  28  between the upper cross member  32 , the lower cross member  34 , and the first and second side members  36 ,  38 . The structural support substrate  80  can be connected to the seat frame  13  such that is has a general contour shape reflective of the contour shape of the targeted occupant. The structural support substrate  80  can be coupled to the seat frame  13  in any known or appropriate manner, such as, fastened to the seat frame  13 , draped and stretched over the seat frame  13 , or the like. The structural support substrate  80  can be secured thereto using a variety of techniques, such as, fastening, bolting, welding, or the like, and coupling members, such as, a hog rings, hooks, clips, screws, wire loop, snaps, buttons, or the like. The structural support substrate  80  can be made from a variety of materials, such as, plastic, fabric, polymer, natural fiber, rubber, or the like, having sufficient strength to function as the structural support for an occupant. In this example, the structural support substrate is a plastic shell. 
     The cushion member  82  is generally a rectangular and planar member having an upper end  96 , an opposed lower end  98 , a first side  100 , and an opposed second side  102 . The cushion member  82  also includes a front outer wall  104  and an opposed rear outer wall  106  interconnected by a plurality of inner walls  105 . The inner walls  105  are configured in a predetermined manner to define a plurality of chambers  110  between the inner walls  105  and the outer walls  104 ,  106 . For example, the inner walls  105  may be arranged longitudinally and/or laterally and/or angularly to define chambers  110  having a particular shape, such as, cubed, or the like. The cushion member  82  can also include a plurality of compression members  108 , such as, springs, or the like, distributed throughout the cushion member  82 . For example, some or all of the chambers  110  may contain one or more coil springs, a spring within a spring, multi-layers of springs, or the like. The design is not limited to traditional coil springs and includes any known or future material or composite or assemblies that provide a similar ‘kinematic’ feature, such as, gel, water, plastic, shape changing material, or the like. The cushion member  82  is overlaid and coupled to at least a portion of the structural support substrate  80 , and/or the seat frame  13 , such as, the seat back frame  28 , the seat base frame  30 , or the like. The cushion member  82  can be connected to structural support substrate  80  and/or the seat frame  13  such that is has a general contour shape reflective of the contour shape of the targeted occupant. The cushion member  82  can be coupled to the seat frame  13  in any known or appropriate manner, such as, fastened to the seat frame  13 , draped and stretched over the seat frame  13 , or the like. The cushion member  82  can be secured thereto using a variety of techniques, such as, fastening, bolting, welding, or the like, and coupling members, such as, a hog rings, clips, screws, wire loop, snaps, buttons, or the like. The cushion member  82  can be made from a variety of materials, such as, plastic, fabric, polymer, natural fiber, rubber, propylene mesh, or the like, having sufficient strength and support to function as the cushion member  82  for an occupant. The cushion member  82  can also be encased in foam, attached to other components, such as, the trim cover  24 , or the like, and/or a combination thereof. 
     In this example, the cushion member  82  provides sub-system spring ‘kinematics’ to the seat occupant and is placed on the structural support substrate  80  to overlay a substantial portion of the seat back frame  28 . It is contemplated that the seat cushion structure  26  can be used in other areas of a seat, such as, the seat base, head restraint, side bolsters, or the like, and in other types of seat assemblies, such as, second row seats, seat benches, or the like. The cushion member  82  is a segmented fabric pouch containing a plurality springs  108  within pouches  110 . 
     Referring now to  FIGS. 5-8 , another embodiment of a structural support substrate  180  and cushion member  182  is shown wherein like features are identified using like reference numbers. In this embodiment, the structural support substrate  180  has a contour corresponding to the seat back frame  28 . The first and second sides  188 ,  190  are also contoured to correspond with the side bolsters of the vehicle seat assembly  12 . The structural support substrate  180  can also include areas  212  for attaching energy absorbing members or features  214 . The areas  212  are strategically located around the structural support substrate  180 , such as, the upper end  184 , lower end  186 , sides  188 ,  190 , front surface  192 , rear surface  194 , or the like. The energy absorbing members  212  can be in a variety of forms, such as, absorbing foam, springs, ribs, corrugations, tubular extensions, or the like, and are designed to absorb the energy from a collision impact and to reduce the impact to the seat occupant. The energy absorbing members  212  absorb energy by, changing their shape in a predetermined manner as they absorb the energy, such as, folding, collapsing, crushing, compressing, or the like. For example, the energy absorbing members  212  can be designed to fold in an accordion like manner as the absorb energy from an impact collision. In this embodiment, the cushion member  182  has a multi-piece construction having an outer portion  216  and an inner portion  218 . The outer portion  216  is generally a rectangular frame that encircles the inner portion  218  that is generally rectangular and planar in shape. The outer portion  216  is generally overlaid the individual members of the seat back frame  128  whereas the inner portion  218  is generally overlaid the area spanning between the upper end, the lower end, first side and second side of the seat back frame  128 . 
     Referring next to  FIGS. 9-11 , a structural support substrate  380  and seat back frame  328  according to still another embodiment is shown. In this embodiment, the structural support substrate  380  is generally a rectangular and planar member having an upper end  384 , an opposed lower end  386 , a first side  388 , an opposed second side  390 , a front surface  392 , and a rear surface  394 . The structural support substrate  380  also includes a first and second extension  420 ,  422 , such as, a flap, wing, or the like, that extend from the first and second side  388 ,  390 , respectively. Although two extensions or flaps  420 ,  422  are shown, any number of extensions or flaps can be used. The main body portion of the structural support substrate  380  that is placed on the seat back frame  328 , such as, by positioning it on, over, around, adjacent, the seat back frame  328 , as shown in  FIG. 10 . The structural support substrate  380  can also have a sock-type construction that can be slipped over or onto the seat back frame  328 . The first and second extensions  420 ,  422  are designed to attach to the first and second side frame members  336 ,  338 , such as, by at least partially wrapping around the side frame members, strapping to the side members, or the like, as shown in  FIG. 11 . The structural support structure  380  can be made from a relatively flexible and stretchable material. The structural support substrate  380  can also include a plurality of openings  424 , such as, holes, slots, slits, or the like, for attaching to various seat components, inserting seat components there through, or the like. In this example, the upper end of the structural support substrate  384  includes a pair of openings  424  for attaching to the upper cross member  332 , such as, the attachments for the head restraint  318 . 
     Referring now to  FIGS. 12-14 , a seat cushion structure  526  attached to a seat assembly  512  having a seat back  514 , seat base  516 , and head restraint  518 , according to still another embodiment is shown. In this embodiment, the structural support substrate  580  and the cushion member  582  is integrated into a single unit and coupled to the seat back sub frame  528 . The cushion member  582  can include any number of compression members  608  having various characteristics, such as, size, length, spring rate/force, or the like. Groups of compression members  608  having different characteristics can be strategically positioned throughout the vehicle seat, such as, the seat back  514 , seat base  516 , head restraint  518 , side bolsters, or the like, depending on the particular requirements. For example, a group of larger sized compression members  608  can be placed around the perimeter of the seat back  514 , such as, the upper end and sides of the seat back  514 . A greater number and smaller sized compression members  608  can be placed in the middle portion of the seat back  514 . A fewer number and mid-sized compression members  608  can be placed in the head restraint  518 . Multiple cushion members  526  and/or support structure substrates  580  can be utilized anywhere on the seat frame  513 , such as the seat back frame  528 , seat base frame  530 , or the like. For example, cushion members  582  and compression members  608  can be positioned anywhere on the seat  12 , such as, the head restraint  518 , seat back  514 , seat base  516 , seat back side bolsters, seat base edges, or the like. 
     Referring now to  FIGS. 15-17 , a cushion structure  726  coupled to a seat assembly  712  according to still another embodiment is shown. In this embodiment, cushion structure  726  is adapted to attach to the seat base  716  and includes a cushion member  782  and can also include a structural support substrate  780 . The cushion member  782  includes a plurality of compression members  808 , such as, springs, or the like. The cushion member  782  and compression members  808  can have a variety of predetermined characteristics, such as, shape, profile, layout, design pattern, or the like, depending on the performance requirements needed. Moreover, the compression members  808  can also have various predetermined attributes, such as, length, size, shape, force/rate, tension strength, location, or the like. For example, the compression members  808  can be varied in their length, force/rate, and location to create a contour on the seat base  716  such as used in an insert or a seat bolster. By designing the cushion structure  726  using intelligent, selective application of spring force/details/designs in specific areas of the seat  712  specific objectives can be accomplished. For example, the cushion structure  726  can include spring force/details/designs that are designed and contoured to accommodate a child seat, or cargo and/or personal items, such as, a purse, briefcase, boxes, or the like, as shown in  FIG. 11 . A relatively thin foam cushion material can also be positioned above the spring cushion to further enhance comfort and aesthetic appearance of the seat. In one example, the sides of the cushion member  800 ,  802  include compression members  808  that are larger than those in the middle portion of the cushion member  782  to provide support on the sides of the seat base  716 , as shown in  FIGS. 15 and 16 . In another example, the sides of the cushion member  800 ,  802  and the middle portion of the cushion member  782  include compression members  808  that are larger than the other portions of the cushion member  782  to provide support on the sides and middle of the seat base  716 , as shown in  FIG. 17 . 
     Referring now to  FIGS. 18-20 , a cushion member  782  with compression members  808  joined together in different configurations is shown. The compression members  808  can be joined together using a variety of techniques, such as, by welding, or the like. In one example, the compression members  808  can be welded together in a top-welded configuration such that the compression members  808  extend downward from the lower surface  828  of the cushion member  782  and adjacent the flat planar seat surface  717 , as shown in  FIG. 18 . In another example, the compression members  808  can be welded together at their middle portions in a mid-weld configuration such that the compression members  808  extend upward from the upper surface  826  of the cushion member  782  and adjacent the seat surface  717  and downward from the lower surface  828  of the cushion member  782 , as shown in  FIG. 19 . In another example, the compression members  808  can be welded together in a bottom weld configuration such that the compression members  808  extend upward from the upper surface  826  of the cushion member and into the seat surface  717 , as shown in  FIG. 20 . 
     Referring now to  FIGS. 21-23 , a seat cushion structure  926  including a cushion member  982  having a plurality of spring members  1008  and encased in a structural support structure  980  according to still another embodiment is shown. The spring members  1008  can be arranged in a spring-on-spring arrangement and can also be housed within a segmented pouch  1010 . In this embodiment, the structural support structure  980  can be made from a variety of materials, such as, foam, padding, or the like. The cushion member  982  can also be enclosed completely or partially by the support structure  980  to further enhance performance, comfort, and aesthetic appearance of the seat cushion  982 . In one example, the support structure  980  surrounds the sides  996 ,  998 ,  1000 ,  1002  and lower surface  1028  of the cushion member  980  with the upper surface  1026  exposed, as shown in  FIGS. 22 and 23 . 
     Referring now to  FIGS. 24 and 25 , a cushion structure  1126  including a climate control ventilation mat  1230  and a climate control heating/cooling mat  1232  according to still another embodiment is shown. In this embodiment, the cushion structure  1126  includes a cushion member  1182  having a plurality of compression or spring members  1108 . The springs of the spring-filled cushion member  1182  can be integrated in a ventilation mat  1230  to provide airflow (A) to the seat occupant, as shown in  FIG. 24 . The ventilation mat  1230  is generally a planar rectangular member that can be situated adjacent the cushion member, such as, the lower surface of the cushion member  1228 , or the like. The spring-filled cushion member  1182  can also have a climate controlled ventilated heating/cooling mat  1232  that is also a generally planar and rectangular member. The heating/cooling mat  1232  can be overlaid on the surface of the cushion member  1182 , such as the upper surface  1226  or the like, to provide heating and cooling to the seat occupant, as shown in  FIG. 25 . As the occupant load (L) is applied downward to the pocket coils the trapped air within the pockets cushion the occupant. During this “cushioning effect” the air travels upward facilitating heat transfer, recirculation of air, which thereby improves occupant comfort. 
     Many modifications and variations of the present disclosure are possible in light of the above teachings. Therefore, within the scope of the appended claim, the present disclosure may be practiced other than as specifically described.