Patent Publication Number: US-2012032486-A1

Title: Vehicle seat construction

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/140,742, filed Dec. 24, 2008, titled: VEHICLE SEAT CONSTRUCTION, in the name of Baker, et al. which is incorporated by reference herein. 
    
    
     BACKGROUND 
     The present disclosure relates generally to the field of vehicle seating. More specifically, this disclosure relates to a vehicle seat construction including a seat frame cushion support and insert assembly. 
     Generally, known vehicle seats are constructed from a number of elements including internal structural support mechanisms coupled to a seat frame assembly. These known vehicle seats also include a system of steel springs coupled to the seat base and seat back frame. A cushion or padding layer made of expanded urethane foam is positioned on top of the steel spring system to support the weight of and provide comfort for the occupant. The seat is then generally covered by a fabric, vinyl or leather upholstery cover member to provide protection and an acceptable aesthetic appearance. The design of these known vehicle seats renders the seat relatively heavy with a bulky profile which leaves little space beneath the seat and generally occupies an exorbitant amount of space in the vehicle. These known vehicle seats also tend to have high manufacturing and assembly costs and hinder vehicle fuel efficiency. 
     There remains a significant and continuing need to provide an improved vehicle seat assembly that provides improved design, performance and lower cost assembly while providing enhanced comfort for the occupant while meeting ever increasing performance requirements. There also remains a significant and continuous need to provide an improved vehicle seat assembly that has a lower manufacturing and assembly cost and is lighter in weight (reduced mass) to enhance vehicle fuel efficiency while meeting ever increasing performance requirements. 
     SUMMARY 
     A seat construction, for providing support to a seat, includes a planar member and an elastomeric fastener. The planar member is positioned on a portion of the seat and stretched thereon to create tension on the planar member and for providing structural support for an occupant of the seat. The elastomeric fastener is coupled to the planar member and to the seat for fastening the flexible planar member to the seat and maintaining the tension on the planar member. 
     A vehicle seat assembly, for use in a vehicle, includes a seat back frame, a seat base frame, a seat construction having a planar member and an elastomeric fastener. The seat back frame includes a first side frame member, a second side frame member, an upper cross member, and a lower cross member. The seat base frame includes a first side frame member, a second side frame member, a front cross member, and a rear cross member. The seat back frame is pivotably coupled to a seat base frame. The planar member is positioned on a portion of the seat and is stretched thereon to create tension on the planar member and provide structural support for an occupant of the seat. The elastomeric fastener is coupled to the planar member and to the seat to thereby fasten the flexible planar member to the seat and maintain tension on the planar member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle having a vehicle seat assembly according to an exemplary embodiment. 
         FIG. 2  is a perspective view of the vehicle seat assembly of  FIG. 1  according to an exemplary embodiment. 
         FIG. 3  is a perspective view of the vehicle seat assembly of  FIGS. 1 and 2  showing the seat trim cover partially removed and disclosing a seat frame support insert coupled thereto according to an exemplary embodiment. 
         FIG. 4  is a perspective view of a seat back frame assembly having a seat frame support insert coupled thereto according to an exemplary embodiment. 
         FIG. 5  is cross-sectional view of the seat back frame assembly of  FIG. 4  further detailing the seat frame support insert coupled thereto according to an exemplary embodiment. 
         FIG. 6  is an enlarged view of the seat frame side member of  FIG. 5  according to an exemplary embodiment. 
         FIG. 7  is an alternate cross-sectional view of the seat back frame assembly of  FIG. 4  detailing the seat frame support insert thereto coupled and cushion pad according to an exemplary embodiment. 
         FIG. 8  is a partial, front schematic view of a connector member of the seat frame support insert and material of  FIG. 4  according to an exemplary embodiment. 
         FIG. 9  is a perspective view of the connector member of the seat frame support insert of  FIG. 4  according to an exemplary embodiment. 
         FIG. 10  is a partial, cross-sectional view of a seat base assembly having a seat frame support insert coupled thereto according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the figures and in particular to  FIG. 1 , a vehicle  10  is shown according an exemplary embodiment. The vehicle includes one or more vehicle seats  12  provided for occupants of the vehicle  10 . While the vehicle  10  shown is a 4-door sedan, it should be understood that the vehicle seat  12  may be used in a mini-van, sport utility, cross-over or any other type of vehicle or any other means in or by which someone travels or something is carried or conveyed for any market or application including everything from office seating and transportation to planes and space travel and everything in between. The vehicle seat  12  shown includes a seat frame  13 , a seat back  14  in the form of a seat back assembly  16  and a seat cushion  18  in the form of a seat cushion assembly  20 . An exemplary embodiment of an upholstered vehicle seat structure  12  according to the exemplary embodiment is shown in  FIG. 2 . The vehicle seat  12  may, and typically does, include a head restraint  22  and a seat base portion  24  for supporting the seat cushion  18 . Generally, the head restraint  22  extends upward from the seat back  14  and is configured to restrain the head of an occupant during an impact. The seat cushion  18  and/or base portion  24  may be configured to allow the vehicle seat  12  to be selectively adjusted and positioned (manually or motor driven) relative to the vehicle interior via a track assembly  26 . The vehicle seat  12  may also include a recliner mechanism  28  for pivotably adjusted the seat back  14  relative to the seat base portion  24 . The vehicle seat  12  may also include a trim cover  30  and other additional components, such as, foam padding, and the like, to further enhance comfort and aesthetic appearance of the vehicle seat. 
     Referring now to  FIG. 3 , a vehicle seat assembly  12  with the seat trim cover  30  and cushion  18  partially removed and having a seat frame support insert  32  coupled thereto is shown. The seat frame support insert  32  includes, inter alia, a support member  34  (e.g., a generally planar material made from an appropriate flexible and stretchable fabric or material, etc.) coupled to an elastomeric fastener  36  for connecting the support member  34  to the seat frame  13 . The seat frame support insert  32  may be coupled to the seat back frame  16  (e.g., first and second vertical side members, upper and lower cross members, etc.) and/or the seat base frame  20  (e.g., inboard and outboard side members (b-brackets), front and rear cross members, etc.) via the elastomeric fasteners  36  which will be described in further detail below. The periphery of the seat back frame  16  and seat base frame  20  may be covered with material (e.g., foam, etc.) to provide further support, comfort, protection, and the like, to an occupant and may also be covered with a seat cover (i.e., trim cover)  30  made of a suitable material (e.g., fabric, leather, a faux leather, vinyl, or any other known or appropriate material). 
     Referring now to  FIG. 4 , a seat back frame assembly  16  having a high tension support insert coupled thereto is shown. The seat back frame assembly  16  includes a pair of opposing first and second vertical side members  38 ,  40 , an upper horizontal cross member  42 , and a lower horizontal cross member  44 . However, the seat frame assembly  16  may be made using virtually any known or appropriate construction and collection of members which may be combined to function as a vehicle seat frame assembly. The upper end of the first vertical side member  46  and the upper end of second vertical side member  48  are each coupled to the first and second end of the upper horizontal cross member  50 ,  52 , respectively. The lower end of the first vertical side member  54  and the lower end of the second vertical side member  56  are each coupled to the first and second end of the lower horizontal cross member  58 ,  60 , respectively, such that a substantially rectangular frame is constructed  16 . The seat frame support insert  32  is positioned within/on the seat back frame assembly  16  and is coupled to the seat back frame  16  via the elastomeric fasteners  36  (and fastener extensions  37 ) to create relatively high tension on the planar member  34  (e.g., fabric, material, etc.) of the seat frame support insert  32  such that the insert  32  provides structural support and comfort for the occupant of the vehicle seat  12 . The elastomeric fasteners  36  may be created in various configurations (e.g., number of fasteners, elasticity, length, size, dimension, orientation, location of fastener extensions/nodules, etc.) to provide varying support along the vertical and horizontal axis of the high tension support insert  32 . The generally planar member  34  of the high tension support insert  32  may have a variety of dimensions, shapes, sizes, thicknesses, textures, patterns, weaves, colors, and be made from any variety of suitable and appropriate materials including, among other things, woven natural and synthetic fibers, fiber reinforced plastic sheeting, fabric, mesh, plastic, leather, vinyl, pleather, rubber, and the like. 
     Referring now to  FIGS. 5 through 7 , a top cross-sectional view of the lumbar area of a seat back frame assembly  16  having a high tension support insert  32  coupled thereto is shown. The high tension support insert  32  is drawn or “stretched” from the first vertical side member  38  to the second vertical side member  40  and from the upper cross member  42  to the lower cross member  44  via the elastomeric fastener  36 . Side bolsters  62 ,  64  are coupled to the first and second vertical side members  38 ,  40  such that the three sides of the vertical side members  38 ,  40  are enclosed. The side bolsters  62 ,  64  may have a variety of dimensions, shapes, sizes, thicknesses, textures, patterns, colors, and be made from a variety of suitable materials including, among other things, foam, woven natural and synthetic fibers, fiber reinforced plastic sheeting, fabric, mesh, plastic, rubber, and the like. According to one embodiment, a foam pad insert  66  may also be included on the seat back  14  and/or the seat base/cushion  18  for added comfort and support, as best shown in  FIG. 7 . 
     Referring now to  FIG. 8 , a seat back frame assembly  16  having a high tension support insert  32  coupled thereto via an elastomeric fastener  36  is shown. Tension on the high tension support insert  32  may be tuned vertically (longitudinally) along the strip of the elastomeric fastener  36  as needed and/or as appropriate by, among other things, creating an elastomeric fastener  36  that is less elastic on the front side, altering the thickness of the elastomeric fastener  36  and/or the fastener extensions  37 , altering the location of where the elastomeric fasteners  36  are coupled to the seat frame  13 , etc. The fastener  36  may also be configured to be less elastic in the lumbar zone  68  by using more rigid extensions  37  (i.e., less compliant ties) to create a higher pressure zone and by using additional extensions  37  (ties) that “tie off” or couple toward the rear of the seat assembly and thereby further stabilize the high tension support insert  32  in the lumbar zone  68 . 
       FIG. 9  shows the elastomeric fastener of  FIG. 8 . The elastomeric fastener (tie down strip)  36  has a U-shaped channel  70  that receives and securely retains (e.g., sewn, adhered, glued, etc.) the peripheral edges of the planar member  34  (e.g., fabric, material, etc.). The elastomeric fastener  36  also includes a plurality of extensions  37  that enable the high tension support insert  32  to be drawn or stretched and coupled to the seat back frame assembly  16  to provide a force in the material of the insert  32 . The extensions  37  have coupling nodules (members, bodies, etc.)  72  that are inserted into apertures  74  (openings, notches, slots, slits, windows, receivers, etc.) on the seat frame  13  to facilitate coupling thereto. While a tab and slot type coupling nodule  72  is disclosed it should be understood that any type of coupling may be used provided it couples the elastomeric fastener  36  to the seat frame  13  and couples the planar member thereto  34 . 
     Referring now to  FIG. 10 , a front cross-sectional view of a seat base frame assembly  20  having a high tension support insert  32  coupled thereto is shown. The high tension support insert  32  is positioned within/on the seat base frame  20  and is drawn or “stretched” from the one side member  76  to the second side member  78  and from the front cross member  80  to the rear cross member  82  and coupled thereto via the elastomeric fastener  36  which is coupled (e.g., sewn, glued, adhered, etc.) to the planar member  34  (e.g., fabric, material, etc.). The elastomeric fastener  36  is coupled to the seat base frame  20  by the elastomeric fastener  36  such that the support insert  32  provides structural support and comfort for the occupant. The bolster trim flap  80  of the seat base cushion  18  may be coupled (e.g., sewn, etc.) to the planar member  34  (e.g., fabric, material, etc.) of the high tension support insert  32  to further secure the high tension support insert  32  to the seat base  18  and to provide additional support and comfort for the occupant. 
     For purposes of this disclosure, the term “coupled” means the joining of two components (mechanical and/or electrical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. 
     It is also important to note that the construction and arrangement of the elements of the vehicle seat as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present innovations.