Abstract:
A school bus seat comprises a pin having a cross-sectional shape selected from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. First and second brackets include an aperture selected correspondingly from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. First and second supports include an aperture selected correspondingly from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. The apertures in the brackets and supports are formed in a fiber reinforced polymer such that the apertures are devoid of knit lines. The pins reside in the apertures of the supports and brackets inhibiting rotation of the brackets with respect to the supports. A seat back is secured to the brackets.

Description:
[0001]     This patent application is a continuation-in-part of co-pending patent application Ser. No. 10/954,782 filed Sep. 30, 2004. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention is in the field of school bus seats which must meet federal regulatory standards to protect school bus riders, in particular, children riding on school buses.  
       BACKGROUND OF THE INVENTION  
       [0003]     Present technology used in school bus seats is quite old. Essentially, school bus seats are presently made using metal or metal and wood. Wood or metal is secured to the metal seat back frame and metal frame bottom. A covering which may include some type of foam is also used. The covering and foam are subject to wear and tear as well as vandalism.  
         [0004]     Some of the problems associated with the present technology are set forth in my U.S. Pat. Nos. 5,609,395 and 6,415,494, which I incorporate herein by reference. U.S. Pat. No. 6,415,494 is a divisional of application Ser. No. 08/530,451 filed on Sep. 18, 1995 now U.S. Pat. No. 5,609,395.  
         [0005]     My U.S. Pat. No. 5,609,395 issued Mar. 11, 1997 disclosed and claimed a modular bus seat and method of retrofitting existing bus seats. My &#39;395 patent discloses a bus seat comprising a metal frame, a bus seat back and a bus seat. My &#39;395 patent discloses a bus seat back which includes a front modular portion, a rear modular portion, and a collar portion. The front modular portion is affixed to the metal frame. The rear modular portion is affixed to the front modular portion. The collar portion is affixed to the front modular portion adjacent the front and rear modular portions. The bus seat is affixed to the metal frame. The modular construction of the bus seat back enables replacement of a specific section or sections of the bus seat. The bus seat back and bus seat can be used in retrofit installations or in new installations using the existing metal frame technology. The bus seat back and bus seat are constructed of an elastomer skinned urethane foam which adheres to front, rear and bottom pieces of plywood. The collar portion is constructed of the elastomer skinned urethane foam but does not include a plywood portion. The collar portion is affixed to the front plywood portion.  
         [0006]     My U.S. patent application Ser. No. 29/204,361 discloses a design for School Bus Seat Back Envelope Cushion and was filed on Apr. 28, 2004.  
         [0007]     Federal Motor Vehicle Safety Standard No. 222 sets forth the safety standards for school bus seats. The safety standard addresses size, loading, energy absorption and deflection requirements.  
         [0008]     U.S. Pat. No. 4,688,662 to Correll discloses an Energy Absorber System utilizing a pair of housings having facing cavities which includes a hollow deformable torsion member interconnecting the housings. One portion of the torsion member is received in the cavity of one housing and another portion of the torsion member is received in the cavity of the other housing. The housing cavities have cross-sectional conformations which receive the torsion member in such a manner that relative rotation therebetween is prevented. Rotation of one housing relative to the other deforms the torsion member elastically and/or plastically. Such deformation absorbs the energy of forces tending to rotate the housings. It will be noticed that Correll discloses a four-sided energy absorber. Use of such an absorber has the effect of creating knit lines in the plastic surrounding the energy absorber or torsion member. At column 5, lines 27 et seq. Correll states: “The torsion member again has a polygonal cross-sectional conformation so as to closely mate with the side walls of the cavities and thereby prevent relative rotation between the torsion member and the housings. As shown in  FIG. 6 , torsion member  90  comprises an elongated hollow tubular member with axial portions thereof received in the housings. The inner periphery  94  of the tubular member closely receives filling areas  96  which extend inwardly thereinto from a pair of opposed end caps  98 . Filling areas  96  conform to the interior of torsion member  90  to shorten the effective length thereof ( FIG. 6 ) for reasons previously described.” Correll teaches that torsion members must be closely mated with respective cavities and that the torsion members may be filled to adjust the tolerance of the energy absorber from a torque standpoint. Correll contemplates use of a stampable fiber reinforced plastic for its housings and other materials. Knit lines are formed when fiber reinforced materials are molded and when obstructions to flow are present. When the flow path involves right angles knit lines are formed as the right angles provide an obstruction to flow. Knit lines do not integrate fibers with the polymeric material. Knit lines do not join the fibers together.  
         [0009]     Although old school bus seats can be retrofitted and new seats can be manufactured as taught by my inventions as set forth in my &#39;395 and &#39;494 patents, it is highly desirable to provide a new school bus seat with superior safety performance and which is attractive and comfortable.  
       SUMMARY OF THE INVENTION  
       [0010]     An energy absorber for a bus seat includes a hexagonally shaped pin which interengages both a hexagonally shaped aperture in a bus seat back and hexagonally shaped aperture in a support for the seat. Alternatively, a pentagonally shaped, heptagonally shaped or octagonally shaped pin may be used. The terms “pin, torsion member and fastener” are used synonymously and interchangeably herein. The hexagonal pin resides in the hexagonal apertures of the support and the bus seat back preventing rotation of the bus seat back with respect to the support. The pin is preferably hollow and is made of Aluminum and the supports and seat backs are made of a polymeric material or a material known as a plastic composite. Under forceful impact applied to the bus seat back, the bus seat will rotate limitedly in the direction of the force causing deformation of both the pin and the polymeric material (or plastic composite). A plastic composite is a combination of a polymer and a material such as a fiber which gives the plastic more strength. The deformation of the pin (torsional member) under forceful impact is a plastic deformation. When this limited rotation occurs, the polymeric material (or plastic composite) of the seat back and/or that of the support is deformed by the forceful rotation of the Aluminum hexagonally shaped pin (torsional member). Depending on the characteristics of the Aluminum pin, it may also deform during the forceful rotation of the seat back with respect to the support. Other pin materials may be used such as other metals and/or any one of a wide variety of polymeric materials may be used. The pins which are sometimes referred to herein as fasteners may also be made of a combination of metal and polymeric material or just a polymeric material. Preferably the seat back and the support are made of a thermoplastic material. However, thermoset materials may be used as the materials for the seat back and the support.  
         [0011]     Each school bus seat has two energy absorbers. One of the energy absorbers is on the aisle side of the seat back and operates between the seat back and aisle leg or support. The other energy absorber is on the window side of the seat back and operates between the seat back and the window side support. The energy absorbers are used as a part of the school bus seat.  
         [0012]     The bus seat includes an aisle support having a hexagonally shaped aperture or cavity and a window side support having a hexagonally shaped aperture or cavity. A bottom substrate or seat is hinged to the aisle support and the window support. The bus seat includes a seat back having a hexagonally shaped apertures or cavities. A hexagonally shaped pin or torsion member interengages the hexagonally shaped aperture or cavity of the aisle support and one of the hexagonally shaped apertures or cavities of the seat back. Another hexagonally shaped pin or torsion member interengages the hexagonally shaped aperture or cavity of the window side support and the other hexagonally shaped aperture or cavity of the seat back. The hexagonally shaped pins or torsion members in combination with the apertures prohibit rotation of the seat back with respect to the aisle and window side supports unless a forceful load as described above is applied. Preferably, the seat back and supports are made of a polymeric material. The hexagonally shaped cavities are manufactured without significant knit lines formed as the flowability of fiber reinforced polymeric material is enhanced.  
         [0013]     Torsion members or pins may be used having a pentagonal, heptagonal or octagonal cross-sectional shape. The pentagonal, heptagonal or octagonal torsion members are preferably hollow and may be manufactured from a variety of metals and plastics. The bus seat includes a seat back and aisle and window supports having correspondingly shaped apertures or cavities so as to receive the torsion members.  
         [0014]     An envelope style bus seat back cushion may be employed over a plurality of seat back configurations. The seat back may comprise a substrate which is solid throughout made from composite thermoplastic or thermoset polymers. Alternatively, the seat back may be made from a reinforced substantially hollow sandwich composite. The sandwich composites may include two polyurethane composite planar surfaces separated by a core material. When sandwich composites are used they may be bolted, adhesively bonded or ultrasonically welded to the brackets.  
         [0015]     Alternatively, it is within the scope of this invention to use a solid reinforced polymer seat back supported by the seat back brackets.  
         [0016]     A school bus seat comprises a pin having a cross-sectional shape selected from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. First and second brackets include an aperture selected correspondingly from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. First and second supports include an aperture selected correspondingly from the group consisting of a pentagon, a hexagon, a heptagon and an octagon. The apertures in the brackets and supports are formed in a fiber reinforced polymer such that the apertures are devoid of knit lines. The pins reside in the apertures of the supports and brackets inhibiting rotation of the brackets with respect to the supports. A seat back is secured to the brackets.  
         [0017]     Two components of the school bus seat, namely, the seat bottom and the seat back can be manufactured by adhering an elastomeric skinned foam directly to a substrate. A mold is first coated by spraying an elastomeric skin on the interior thereof. Next, the seat bottom or the seat back is inserted into the mold and positioned and held properly by devices which are not described herein. Then a polyurethane foam is blown into the cavity between the seat bottom or the seat back and the elastomeric coated mold. The seat bottom or seat back may be a solid reinforced polymer. Alternatively, the seat bottom or the seat back may be a sandwich composite formed by two spaced apart polyurethane substrates separated by and affixed to a low density core.  
         [0018]     A school bus seat comprising a one-piece twin bucket seat with deformable brackets supporting both sides of the seat is also disclosed and claimed.  
         [0019]     A school bus seat comprising a superstructure having vertical left and right side supports for supporting a seat back is also disclosed and claimed. Each of the side supports includes a fuse and the fuses are inelastically deformable upon the application of force to the superstructure.  
         [0020]     A school bus seat comprising a one-piece twin bucket seat having left and right sides thereof is also disclosed and claimed. The bucket seats include a seat bottom portion and a seat back portion. The seat bottom and back portions are primarily isotropic glass. A first strip of directionalized glass and a second stip of directionalized glass are embedded within the seats proximate the left and right sides thereof and extend from the seat bottom portion to the seat top portion. Upon impact the directionalized glass strips are inelastically deformable.  
         [0021]     A method of manufacturing a seat back to be used in a school bus seat is also disclosed and claimed. The interior of the mold is first coated with a spray elastomer. Next, the superstructure of the seat back is attached to the seat back brackets and the seat back and a portion of the seat back brackets is inserted into the mold. Urethane is the injected into the mold and the urethane adheres to the superstructure of the seat back.  
         [0022]     The superstructure of the seat back may comprise a polyurethane composite surface separated by and affixed to a low density core or it may be a solid reinforced polymer. Another component such as a seat bottom may be made from substantially the same process.  
         [0023]     It is an object of the present invention to provide energy absorbers in school bus seats enabling the seats to meet or exceed the Federal Motor Vehicle Safety Standard 222.  
         [0024]     It is a further object of the present invention to provide a school bus seat having a superstructure which is substantial and durable and still has the ability to absorb energy, both forward or rearward to meet or exceed Federal Motor Vehicle Safety Standard 222.  
         [0025]     It is a further object of the present invention to provide a school bus seat having a seat back pinned to supports such that the pins cause deformation of the bus seat back and the supports when large magnitude loads are applied to the school bus seat back.  
         [0026]     It is a further object of the present invention to provide a school bus seat having a seat back fastened to supports such that the fasteners are deformed along with the bus seat back and the supports when large magnitude loads are applied to the school bus seat back.  
         [0027]     It is a further object of the present invention to provide a school bus seat having an energy absorber which includes a hollow hexagonally shaped torsion member.  
         [0028]     It is a further object of the present invention to provide a school bus seat having an envelope style back seat cushion which is molded from polyurethane and elastomers and/or then is over sprayed with an elastomeric polymer spray to reduce surface imperfections.  
         [0029]     It is a further object of the present invention to provide a geometry for the cavities of plastic composite materials such that their flowability is improved reducing the probability of knit lines.  
         [0030]     It is a further object of the present invention to provide a seat back or seat bottom made of a solid reinforced polymer having urethane affixed directly thereto with an elastomeric coating over the urethane.  
         [0031]     It is a further object of the present invention to provide a seat back or seat bottom made of a sandwich composite having urethane affixed directly thereto with an elastomeric coating over the urethane.  
         [0032]     A better understanding of these and other objects will be had when reference is made to the Brief Description Of The Drawings and the Description Of The Invention which follow hereinbelow. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0033]      FIG. 1  is a perspective view of the front of the bus seat.  
         [0034]      FIG. 1A  is a schematic of the Velcro securement of seat cushions to a polymeric substrate or component such as a seat back or a seat.  
         [0035]      FIG. 1B  is a schematic of the Velcro securement of cushions molded to plastic or polymeric substrates or components such as a seat back or a seat.  
         [0036]      FIG. 2  is a side view of the aisle support.  
         [0037]      FIG. 2A  is a front view of the aisle support of  FIG. 2 .  
         [0038]      FIG. 2B  is a top view of the aisle support of  FIG. 2 .  
         [0039]      FIG. 2C  is a side view of another embodiment of an aisle leg or support illustrating a head portion having a cavity therein and an aperture therethrough.  
         [0040]      FIG. 2D  is a cross sectional view taken along the lines  2 D- 2 D of  FIG. 2C  illustrating the head portion thereof having a cavity therein and an aperture therethrough.  
         [0041]      FIG. 3  is a side view of the window side support.  
         [0042]      FIG. 3A  is a top side view of the window side support of  FIG. 3 .  
         [0043]      FIG. 3B  is a rear view of the window side support of  FIG. 3 .  
         [0044]      FIG. 3C  is a side view of another embodiment of a window side support illustrating the head portion thereof having a cavity therein and an aperture therethrough.  
         [0045]      FIG. 3D  is a cross sectional view taken along the lines  3 D- 3 D of  FIG. 3C  illustrating the head portion thereof having a cavity therein and an aperture therethrough.  
         [0046]      FIG. 4  is a front view of the seat back.  
         [0047]      FIG. 4A  is a left side view of the seat back.  
         [0048]      FIG. 4B  is a right side view of the seat back.  
         [0049]      FIG. 4C  is a front view of the seat back illustrating the left coupling head in cross section.  
         [0050]      FIG. 4D  is a front view of the seat back illustrating the right coupling head in cross section.  
         [0051]      FIG. 5  is a top view of the seat.  
         [0052]      FIG. 5A  is a front view of the seat base.  
         [0053]      FIG. 5B  is left side view of the seat base.  
         [0054]      FIG. 6  is a front view of the superstructure of the seat illustrating the aisle support, the window side support, the seat and the seat back.  
         [0055]      FIG. 6A  is a side view taken along the lines  6 A- 6 A of  FIG. 6 .  
         [0056]      FIG. 6B  is a cross-sectional view taken along the lines  6 B- 6 B of  FIG. 6 .  
         [0057]      FIG. 6C  is an enlarged view of a portion of  FIG. 6  illustrating the hinging of the seat to the aisle support.  
         [0058]      FIG. 7  is an enlarged front view of one of the energy absorbers illustrating a set screw in the neck portion of the aisle support as well as portions of the seat back.  
         [0059]      FIG. 7A  is an enlarged cut-away front view of the energy absorber of  FIG. 7 .  
         [0060]      FIG. 7B  is an enlarged cut-away front view of the energy absorber of  FIG. 7  illustrating pin holes and pins for securing the hexagonal pin in place.  
         [0061]      FIG. 7C  is an enlarged cut-away front view of the energy absorber illustrating a threaded pin and nuts for securing the pin in place.  
         [0062]      FIG. 7D  is an enlarged cut-away front view of a hollow hexagonal torsion member positioned within cavities of the head portion of the aisle leg support and the coupling head of the seat back with a threaded rod and nuts securing the torsional member in place.  
         [0063]      FIG. 7E  is an enlarged cut-away front view of a hollow hexagonal torsion member positioned with cavities of the head portion of the aisle leg support and the coupling head of the seat back with a bolt and a threaded rod securing the torsional member in place.  
         [0064]      FIG. 8  is a cross-sectional view taken along the lines  8 - 8  of  FIG. 7  illustrating the energy absorber.  
         [0065]      FIG. 8A  is a cross-sectional view taken along the lines  8 A- 8 A of  FIG. 7 .  
         [0066]      FIG. 9  is an assembly view of the aisle side energy absorber illustrating the hexagonally shaped pin, the aperture in the seat back and the aperture in the aisle support.  
         [0067]      FIG. 9A  is an assembly view of the aisle side energy absorber illustrating a hollow hexagonally shaped pin, the threaded rod, and the cavity in the aisle support leg.  
         [0068]      FIG. 10  is a schematic diagram illustrating the steps for producing an envelope style bus seat.  
         [0069]      FIG. 11  is a front perspective view of a bus seat employing a sandwich composite with an integrally molded skin applied to the cushion of the seat back and the seat bottom.  
         [0070]      FIG. 11A  is a cross-sectional view taken along the lines  11 A- 11 A illustrating a hexagonal pin, the seat back cushion and the seat back bracket.  
         [0071]      FIG. 11B  is a cross-sectional view illustrating a pentagonal pin.  
         [0072]      FIG. 11C  is a cross-sectional view illustrating a heptagonal pin.  
         [0073]      FIG. 11D  is a cross-sectional view illustrating a octagaonal pin.  
         [0074]      FIG. 11E  is an enlargement of the bottom portion of  FIG. 11A .  
         [0075]      FIG. 12  is a perspective view of one of the brackets illustrated in  FIG. 11 .  
         [0076]      FIG. 12A  is a side view of one of the brackets illustrated in  FIG. 11 .  
         [0077]      FIG. 12B  is a front view of one of the brackets illustrated in  FIG. 11 .  
         [0078]      FIG. 13  is a diagram of the process steps of forming an elastomeric skinned foam over a seat back.  
         [0079]      FIG. 14  is a perspective view of a one-piece plastic seat mounted directly onto the aisle support and the window support.  
         [0080]      FIG. 15  is a perspective view of a seat frame employing fuses in the rear frame portion thereof for deforming upon impact of the seat back.  
         [0081]      FIG. 16  is a perspective view of seat manufactured from isotropic glass with two directionalized glass mats embedded therein to absorb energy applied to the seat back. 
     
    
       [0082]     A better understanding of the drawings will be had when reference is made to the Description Of The Invention and Claims which follow hereinbelow.  
       DESCRIPTION OF THE INVENTION  
       [0083]      FIG. 1  is a perspective view  100  of the front of the bus seat positioned in a bus. Aisle  111  and bus window  104  are illustrated in  FIG. 1 . Seat base or support  120  is hingedly affixed to aisle leg or support  101  and window leg or support  102 . The floor beneath the bus seat is denoted by reference numeral  110 , the side of the bus is denoted by reference numeral  113 , and the window side rail  103  sits beneath support  102 .  
         [0084]     Aisle support  101  includes a fastener portion  107  which is fastened to seat back  105  by hexagonally shaped pin  109 . Window side support  102  includes a fastener portion  106  which is fastened to seat back  105  by hexagonally shaped pin  108 . Aisle support  101  is affixed to the floor and window support  102  is affixed to the window side rail  103 . Preferably the supports are thermoplastic materials (or plastic composite materials) which are fastened to the floor with staple items of commerce such as nuts and bolts. Preferably the seat  120  and seat back  105  are thermoplastic materials or plastic composite materials.  
         [0085]     Still referring to  FIG. 1 , reference numeral  112  is an envelope style bus seat back cover which is affixed to the seat back  105  through the use of Velcro®, which is believed to be a registered trademark of Velcro Industries, B. V. of the Netherlands. Referring to  FIG. 1A , a schematic  100 A of the usage of Velcro to affix the cushion to the seat back and seat bottom, adhesive  160  is applied to the polymeric substrate such as the seat back  105 . Velcro  170  is thus affixed to the bus seat back  105 . Similarly, Velcro is also affixed to the polyurethane foam  191  of seat back cushion  112  by adhesive  190 . When the respective strips of Velcro interengage, the seat back cushion is securely affixed to the seat back. Removal and replacement of the envelope style seat back cushion is facilitated by this attachment structure and method.  
         [0086]     Still referring to  FIG. 1 , strips  150  of Velcro may be strategically placed on the seat back  105  so as to ensure a tight and snug fit of the seat back cushion. Similarly, Velcro strips  140  may be placed on the seat  120  to secure the seat cushion  114  to the seat  120 .  FIG. 1B  is a schematic  100 B of the Velcro securement of a seat cushion to a polymeric or polymeric substrate or component such as a seat back or a seat wherein the Velcro has been molded to the substrate and to the cushion.  FIG. 1B  illustrates the Velcro strips  170 ,  180  molded into the back support  105  and the cushion  112 .  
         [0087]      FIG. 2  is a side view  200  of the aisle support  101  illustrating a bottom  204  and a top  202 . Aperture  213 , which is located generally in the frontal hinge portion of the aisle support  101 , cooperates with a bolt or pivot  507  as best shown in  FIG. 6A  to enable seat  120  to be rotated in a clockwise direction to enable cleaning of the seat. Bottom  204  of the aisle support  101  is fastened to the floor of the school bus as illustrated in  FIG. 1 . Those skilled in the art will recognize that there are many techniques for fastening or securing the aisle support  101  to the floor of the school bus. For instance, it may be bolted, strapped, screwed or fused to the floor of the school bus.  
         [0088]     Referring still to  FIG. 2 , the central portion  230  of the school bus seat is thinner in cross section than the feet illustrated by reference numerals  203 ,  205  and  206 . Having broad feet,  203 ,  206 , adds stability to the seat structure. Reference numeral  201  illustrates a rim portion slightly wider than the foot portion  203 . This can be viewed in  FIG. 2A , which is a front view  200 A of the aisle support  101  of  FIGS. 1 and 2 .  
         [0089]      FIG. 2B  is a top view  200 B of the aisle support  101  of  FIGS. 1 and 2 . Referring to  FIGS. 2, 2A  and  2 B, aperture  208  is illustrated in head portion  207 . In  FIG. 2 , the aperture  208  is illustrated as hexagonally shaped in cross section and aperture  208  extends the length of head portion  207 . In other words aperture  208  extends through the head portion  207 . A neck portion defined by rims  209  and  210  are illustrated in  FIGS. 2, 2A  and  2 B and this neck portion supports the head portion  207 . It will be noted that head portion  207  includes a flat portion  211  which allows clearance with respect to reciprocally flat shaped portion  420  of the seat back as illustrated in  FIG. 6 . Additionally, these reciprocal flat portions also limit the degree of rotational movement of the seat back with respect to the aisle support  101  upon forceful impact to the seat. Forceful impact is that impact which would occur in accident conditions and is defined in Federal Motor Vehicle Safety Standard 222.  
         [0090]      FIG. 2C  is a side view  200 C of another embodiment of an aisle leg or support illustrating a head portion  207  having a hexagonally shaped cavity  291  therein and an aperture or bore  295  therethrough.  FIG. 2D  is a cross sectional view  200 D taken along the lines  2 D- 2 D of  FIG. 2C  illustrating the head portion  207  thereof having a hexagonally shaped cavity  291  therein and an aperture or bore  295  therethrough. It will be noted that the cavity does not extend through the head  207 , rather, it terminates in a substantially flat face  290 . Cavity  291  is sometimes referred to herein as the first cavity. First cavity  291  is hexagonally shaped and it is shaped this way so as to eliminate knit lines which are formed when composites are made with abrupt surfaces configurations.  
         [0091]      FIG. 3  is a side view  300  of the window side support  102 . Apertures illustrated in the window side support enabling affixation to the school bus side rail  103 . The window side rail may be affixed to the bus side rail  103  as described above. Referring still to  FIG. 3 , a neck portion defined by reference numerals  309 ,  310  supports head portion  301 . Head portion  301  includes a hexagonally shaped in cross section aperture  302  which extends the length of the head. In other words, the aperture  302  extends through the head portion  301 . Similar to flat portion  211  of head  207  of the aisle leg, a flat portion  304  cooperates with flat portion  425  of the seat back to limit the rotational movement of the seat with respect to the window support  102 .  
         [0092]     Referring to  FIG. 3 , reference numeral  303  illustrates a molded cavity in the window support  102 .  
         [0093]      FIG. 3A  is a top side view  300 A of the window side support of  FIG. 3 .  FIG. 3B  is a rear view  300 B of the window side support of  FIG. 3 . Referring to  FIG. 3  and  3 A, bolt  305  is illustrated in an unnumbered aperture. The head of the bolt is not shown and is molded as part of the window support  102 . Bolt  305  extends through side support  102  and passes through aperture  512 . See  FIGS. 5A and 6B .  
         [0094]      FIG. 3C  is a side view  300 C of another embodiment of a window support illustrating the head portion  301  thereof having a second hexagonally shaped cavity  391  therein and an aperture or bore  395  therethrough. Cavity  391  terminates in a substantially flat face  390 .  FIG. 3D  is a cross sectional view  300 D taken along the lines  3 D- 3 D of  FIG. 3C  illustrating the head portion  301  thereof having cavity  391  therein and an aperture  395  therethrough. Cavities  391  and  291 , previously described above, receive hexagonally shaped pins or torsion members as will be described below.  
         [0095]      FIG. 4  is a front view  400  of the seat back  105  illustrating protrusions  403 ,  404  and land  406  on the front side thereof. Referring to  FIG. 4A , a left side view  400 A of the seat back, coupling head portions  405  and  435  are illustrated. Apertures  401 ,  431  of coupling heads  405 ,  435  are hexagonally shaped and extend the length of the head portions  405 ,  435  of the seat back  105 . Apertures  401 ,  431  align with the apertures  208 ,  302  of head portions  207 ,  301  of the aisle support  101  and window support  102 , respectively. Hexagonally shaped pins  109 ,  108  are inserted through the aforementioned apertures so as to make a tight fit. The pins may be slightly oversized necessitating a slight pressure to push them through the respective apertures during assembly of the seat. For molding the respective heads, it has been found that a hexagonal shape is practical and works well and improves the flowability of fiber reinforced polymers.  
         [0096]      FIG. 4B  is a right side view  400 B of  FIG. 4 . Referring again to  FIGS. 4 and 4 B, flat surface  425  corresponds to flat surface  304  on window support  102 . It will be noticed from  FIGS. 1 and 6  that coupling head  435  is located interiorly with respect to head portion  301  while coupling head  405  is located exteriorly with respect to head portion  207 . This orientation is being illustrated by way of example only and those skilled in the art will readily recognize that the coupling head  425  could also be located exteriorly with respect to head  301  of the window support. In other words coupling head  425  could be located closer or adjacent to the side of the bus wall  113 . Further, those skilled in the art will readily recognize that both couplings heads could be located interiorly with respect to the head portions of the supports.  
         [0097]      FIG. 4C  is a front view  400 C of the seat back  105  illustrating the left coupling head  405  in cross section. Cavity  491 C, sometimes referred to herein as third cavity  491 C terminates in substantially flat face  490 C. Bore or aperture  495 C extends through head  405 . Third cavity  491 C faces first cavity  291 . See  FIGS. 7D and 7E .  FIG. 7D  is an enlarged cut-away front view  700 D of a hollow hexagonal torsion member  777  positioned within the first  291  and third  491 C cavities of head portion  207  of the aisle leg support and the coupling head portion  405  of the seat back  105  with a threaded rod  772  and nuts  773 ,  774  securing the torsional member  777  in place. Torsional member  777  is hexagonally shaped and hollow. Alternatively, torsional member  777  may be shaped so as to provide an aperture therethrough just large enough for rod  772  to pass therethrough. The preferred embodiment of torsional member  777  includes a hexagonally shaped in cross section aperture  771  therethrough.  FIG. 9A  illustrates the torsional member  777  and its hexagonally shaped aperture  771  which extends therethrough. Torsional member  777  may be slightly oversized such that its outer hexagonal perimeter exceeds the perimeter of the hexagonally shaped first and second cavities. In other words, the cross sectional area of the torsional member is larger than the cross sectional areas of the first and second cavities. In this instance, the torsional member may have to be forcefully urged into the first and second cavities.  
         [0098]      FIG. 7E  is an enlarged cut-away front view  700 E of a hollow hexagonal torsion member  777  positioned within the cavities  491 C,  291  of the head portion  207  of the aisle leg support  101  and the coupling head  405  of the seat back  105  with a bolt  772 A, a threaded rod  772  extending from the bolt, and a nut  773  securing the torsional member  777  in place.  
         [0099]      FIG. 4D  is a front view  400 D of the seat back  105  illustrating the right coupling head  435  in cross section. Fourth cavity  491 D terminates in substantially flat face  490 D. Aperture or bore  495 D extends through coupling head  435  enabling the securement of torsional member  777  between the coupling head  435  and the head portion  301  of the window support as illustrated by way of example in  FIGS. 7D and 7E . Fourth cavity  491 D is in facing relationship to second cavity  391 .  
         [0100]      FIG. 5  is a top view  500  of the seat  120 . Surface  510  is a polymeric planar surface supported by latitudinal ribs  501 ,  502 ,  503  and  504 . Longitudinal ribs  507 A,  507 B,  506 A and  506 B also support the surface  510 . Hinge  511  of seat  120  coacts with the frontal hinge portion of the aisle support  101 . Hinge  511  includes aperture  507  therein and is aligned with aperture  213  in the frontal hinge portion of the aisle support  101 . See,  FIG. 6A . Hinge  508  includes aperture  512  therein and includes bolt  305  as illustrated in  FIGS. 6 and 6 B.  FIG. 5A  is a front view  500 A of the seat base  120  and  FIG. 5B  is left side view  500 B of the seat base.  
         [0101]      FIG. 6  is a front view  600  of the superstructure of the seat illustrating the aisle support  101 , the window side support  102 , the seat  120  and the seat back  105 . Just the superstructure of the bus seat is illustrated in  FIG. 6 . Cushions  112 ,  114  are illustrated in phantom in  FIGS. 6A and 6B .  
         [0102]      FIG. 6A  is a side view  600 A taken along the lines  6 A- 6 A of  FIG. 6  illustrating the aisle support  101  and the seat hinge.  FIG. 6B  is a cross-sectional view  600 B taken along the lines  6 B- 6 B of  FIG. 6  illustrating the window support  102  and the seat hinge. The seat  120  hinges forward to rotate in a clockwise direction to enable cleaning beneath the seat. Protrusions in the seat  120  mate with corresponding unnumbered apertures in the aisle and window supports. This adds stability to the seat and helps to keep it in place. The protrusions in the bottom of the seat may be oversized with respect to the mating apertures in the supports so as to provide an interference fit.  
         [0103]      FIG. 6A  provides a view of the pin  109  residing partially in aperture  401 . When a force of sufficient magnitude is applied to the seat back  105 , it tends to cause rotation of the seat in the direction of the force. For instance, if the force is applied from the rear of the seat toward the front of the seat, the seat back  105  is urged to be rotated in a clockwise direction against the fasteners or pins  109 ,  108 . If the force is applied from the front of the seat toward the rear of the seat, the seat back  105  is urged to be rotated in a counterclockwise direction against the fasteners or pins  109 ,  108 . In any event, if the seat back  105  is rotated relative to the aisle support, the polymeric material surrounding the pin will be deformed by the pin. Additionally, the pins, although manufactured of metal, will also be deformed depending on their hardness and the hardness of the polymeric material.  FIG. 6B  provides a view of the pin  108  residing partially in aperture  431 . Depending on the geometry of the pin or torsion member, the deformation of the torsion member is controlled. The size and material of the pin are factors as well as the geometry (i.e., a hollow hexagonal geometry as illustrated in  FIG. 9A ).  
         [0104]      FIG. 6C  is an enlarged view of a portion of  FIG. 6  illustrating in greater detail the hinging of the seat to the aisle support.  
         [0105]      FIG. 7  is an enlarged front view  700  of one of the energy absorbers illustrating a set screw  701  in the neck portion  210  of the aisle support  101  as well as portions of the seat back  105 . Set screw  701  secures pin  109  in place within the respective apertures of the seat back and the head of the aisle support. Further, as explained above, flat portion  211  of head  207  of the aisle support, if mounted closely enough to flat portion  420  of the seat back  105 , will minimize gap  703  and result in support of the flat portions upon the rotational movement of the seat back with respect to the aisle support. As mentioned hereinabove, the pin  109  may be oversized with respect to the apertures in which it resides. As such, the installation of the pins may require pressure or force to force fit the pin into its respective aperture.  
         [0106]      FIG. 7A  is an enlarged cut-away front view  700 A of the energy absorber of  FIG. 7 .  FIG. 7B  is an enlarged cut-away front view  700 B of the energy absorber of  FIG. 7  illustrating pin holes and pins  704 ,  705  securing pin  109  in place. With both pins in place the pin  109  cannot move in either the leftward or the rightward direction.  
         [0107]      FIG. 7C  is an enlarged cut-away front view  700 C of the energy absorber illustrating a threaded pin and nuts  706 ,  707  for securing the pin  109  in place. In this embodiment nut  706  would be threaded onto pin  109  as pin  109  is urged rightwardly so as to accommodate for the clearance between head  207  of the aisle support and the back seat  105 .  
         [0108]      FIG. 8  is a cross-sectional view  800  taken along the lines  8 - 8  of  FIG. 7  illustrating the hexagonally shaped pin in cross section. Hexagonally shaped pins and apertures are used as it has been found practical to mold hexagonally shaped apertures. As the number of the sides of the apertures increase the moldability of the polymeric material increases.  FIG. 8A  is a cross-sectional view  800 A taken along the lines  8 A- 8 A of  FIG. 7  illustrating pin  109  in aperture  208  and set screw  701  securing pin  109  in place.  
         [0109]      FIG. 9  is an assembly view  900  of the aisle side energy absorber illustrating the hexagonally shaped pin  109 , the aperture  401  in the seat back  105 , the aperture  208  in the aisle support  101 , and the threaded set screw  701  in the aisle support.  
         [0110]      FIG. 9A  is an assembly view  900 A of the aisle side energy absorber illustrating a hollow hexagonally shaped pin or torsional member  777 , threaded rod  772 , and the cavity  291  in the aisle support leg  101 . Hexagonally shaped torsional member  777 , if slightly oversized, will have to be forcefully urged into hexagonal cavity  291  and hexagonal aperture  491 C.  
         [0111]      FIG. 10  is a schematic diagram  1000  illustrating the steps for producing an envelope style bus seat. First, the proper mold having a core must be utilized in order for the envelope to be created. If desired, Velcro may be molded directly into the foam which is injected  1001  into the mold having a core. After the foam has been formed into an envelope shape, it is extracted  1002  from the mold. Next, the extracted foam is over sprayed with an elastomeric spray to remove the imperfections from the foam. In this way a seat is formed having a smooth contour without holes in its surface. Holes are sometimes caused in making foam parts by the off gassing of the urethane.  
         [0112]     Although thermoplastics are preferred for the supports, seat back and seat, thermoset materials may be used as well. Aluminum is preferred for the pins or fasteners but other metals or even polymeric materials may be used. The seat pivots or hinges are preferably metal studs and bolts but may be made from polymeric material. Similarly, the seat back is illustrated and described herein as a solid polymeric but other configurations are contemplated by the invention.  
         [0113]     Additionally, the polymeric materials used in the invention may be made from fire retardant materials and/or from polymeric materials which will not burn. Some of the structural components used in the invention may be made from light weight metal alloys.  
         [0114]      FIG. 11  is a front perspective view  1100  of a bus seat employing a sandwich composite as a seat back  1101  and seat bottom  1102  with an integrally molded skin  1150  integrally affixed to the urethane cushion  1151 . The urethane cushion is affixed to the seat back  1101  and the seat bottom  1102 .  FIG. 11A  is a cross-sectional view  1   100 A taken along the lines  11 A- 11 A illustrating a hexagonal pin  1170  residing in a hexagonal aperture  1160 . Seat back bracket  1202  is illustrated in cross section in  FIG. 11A . Corrugated core  1152  separates rigid polyurethane plates  1153  and  1154  and is attached thereto. Reference numeral  1173  represents a discontinuity in the cushion so as to enable assembly of the back seat brackets  1201 ,  1202  to the aisle supports  107 ,  106 , respectively. A slot  1216 , best viewed in  FIGS. 12 and 12 A receives the composite seat back superstructure. Alternatively, slot  1216  may receive a solid reinforced polymer substrate with the cushion affixed thereto. Any of the cushions may be oversprayed with elastomer to ensure homogeneous surface finishes. Reference numerals  1180  and  1181  illustrated in  FIG. 11A  signify the adhesive attachment of the composite seat back superstructure.  
         [0115]      FIG. 11B  is a cross-sectional view  100 B illustrating a pentagonal pin  1191  residing in a respective pentagonal aperture  1161  of a back bracket support.  FIG. 11C  is a cross-sectional view  1100 C illustrating a heptagonal pin  1192  residing in a respective pentagonal aperture  1162  of a seat back bracket support.  FIG. 11D  is a cross-sectional view  1100 D illustrating an octagonal pin  1193  residing in a respective pentagonal aperture  1163  of a seat back bracket support.  FIG. 11E  is an enlargement  1100 E of the bottom portion of  FIG. 11A  illustrating in better detail the composite seat back ( 1152 ,  1153  and  1154 ) residing in the slot  1216  of the seat back bracket. Pins  1191 ,  1192 , and  1193  are preferably hollow but may be solid. Pins  1191 ,  1192  and  1193  are preferably made of Aluminum but also can be made of an inelastically deformable plastic.  
         [0116]      FIG. 12  is a perspective view  1200  of one of the brackets  1202  illustrated in  FIG. 11 . Each bracket has a front side panel denoted by reference numerals  1211 A,  1211 B which is generally planar and a rear side panel denoted by reference numerals  1212 A,  1212 B which is also generally planar. These front and rear panels form slot  1216  and are supported by tapered ridges  1213 ,  1214  which terminate in a flat outer surface located at the top of bracket  1202  and denoted by reference numeral  1210 . Slot  1216  includes a bottom  1217  upon which a substrate rests when assembled as illustrated in  FIG. 11 . Bracket  1202  includes a bottom portion  1215  as best illustrated in  FIG. 12A . An aperture  1160  resides in the bottom portion and it is this aperture which interconnects a hexagonal pin (not shown in  FIGS. 12-12B ). A pentagonal, heptagonal or octagonal aperture may be used as well as set forth in  FIGS. 11B-11D . Preferably, the brackets  1201 ,  1202  are made from fiber reinforced polymers.  
         [0117]      FIG. 12A  is a side view  1200 A of one of the brackets illustrated in  FIG. 11 . A threaded bolt  1250  having a head  1251  and a nut  1252  is illustrated in  FIG. 12A  as an alternate attachment of the composite sandwich or the solid substrate to the bracket. It should be noted that if a solid substrate is used then the bracket may, alternatively, be deleted and the seat back structure can be constructed as set forth in  FIG. 1  above.  FIG. 12B  is a front view  1200 B of one of the brackets illustrated in  FIG. 11  wherein the bottom  1219  thereof is indicated.  
         [0118]      FIG. 13  is a diagram  1300  of the process steps of forming an elastomeric skinned foam over a seat back or a seat bottom. The elastomeric skinned foam may be formed over a composite sandwich having two rigid substrates separated by a core or it may be formed over a solid fiber-reinforced substrate. First, the interior of the mold is coated  1301  with a spray elastomer. Next, the superstructure of the seat back is attached  1302  to the seat back brackets and inserted  1303  into the mold. The mold can be designed so as to accommodate voids therein to permit formation of the elastomeric skinned cushion over just the back brackets. The voids will accommodate the areas where the back brackets attach directly to the aisle or window supports. Some voids are necessary so that the brackets  1201 ,  1202  may be attached using the pins to the aisle  101  and window  103  supports. Urethane foam is then injected  1304  into the mold forming an elastomeric skinned  1150  cushion  1151  integrally attached to the substrate  1154 ,  1152 . The completed component is then removed from the mold and assembled as part of a bus seat.  
         [0119]      FIG. 14  is a perspective view  1400  of a one-piece plastic seat mounted  1408 / 1407  directly onto the aisle support  101  and the window support  103 . Brackets  1401 ,  1402  engage the seats and the aisle and window supports. Two seats are provided  1403 ,  1405  and  1404 ,  1406 . Upper portions  1403  and  1404  of the seats engage bracket portions  1401 ,  1402 . When the upper portions  1403 ,  1404  of the seats sustain a sufficient impact load from behind, brackets  1401 ,  1402  inelastically deform and absorb the energy of the impact. Deformable energy absorbing brackets  1401 ,  1402  are threaded directly into the seats  1405 ,  1406  and the supports  101 ,  103 . The seats ( 1405 ,  1406 ) and seat backs ( 1403 ,  1404 ) are preferably made of fiber reinforced polymer.  
         [0120]      FIG. 15  is a perspective view  1500  of a seat frame ( 1501 ,  1502 ,  1505 ,  1506 ,  1507 ,  1508 ) employing fuses  1503 ,  1504  in the rear frame portion ( 1501 ,  1502 ) thereof for deforming upon impact of the seat back. Vertical left  1501  and right  1502  side supports for supporting a seat back are deformable upon the application of force to the superstructure. Fuses  1503 ,  1504  include notches in the front and rear thereof which create weak areas due to reduced cross-sectional area. The seat superstructure as shown in  FIG. 15  is preferably made of fiber reinforced polymer.  
         [0121]      FIG. 16  is a perspective view  1600  of a seat manufactured from isotropic glass  1601  with two directionalized glass mats  1602 ,  1603  embedded therein to absorb energy applied to the seat back. Directionalized glass mats  1602  and  1603  are 0.145 inches thick. The one-piece school bus seat include seat portions  1604 ,  1605  secured to the aisle  101  and window  103  supports and seat back portions. Upon sufficient impact from behind, directionalized glass mats  1602 ,  1603  inelastically deform.  
         [0122]     While the invention has been described herein by way of Example only, those skilled in the art will readily recognize that changes may be made to the invention without departing from the scope of the appended claims.