Patent Publication Number: US-9845032-B1

Title: Modular back panel sub-assembly

Description:
FIELD OF THE INVENTION 
     The present disclosure generally relates to a seat back rear panel for a upwardly extending seat back of a seating assembly for a motion vehicle and, more particularly, a decorative seat back rear panel module constructed from multiple panel interchangeable components. 
     BACKGROUND OF THE INVENTION 
     Modern motor vehicle seating assemblies are becoming more and more comfortable as designers improve their understanding of human ergonomics, posture, and comfortability. Vehicle seating assemblies that include comfort components in the motor vehicle seating assembly that can provide the driver and passengers with improved comfort and increased endurance for extensive vehicle rides. Additionally, various sizes and shapes of drivers and passengers can prove challenging when providing motor vehicle seating assemblies. Accordingly, aesthetically attractive motor vehicle seating assemblies that include components optimized to accommodate the different sizes and shapes of drivers and passengers, as well as the desired posture and sitting positions of those drivers and passengers, has become increasingly important. 
     As a consequence, contemporary motor vehicle seating assemblies now incorporate hundreds of discrete parts. The assembly of such contemporary motor vehicle seating assemblies requires bringing together these hundreds of parts to be assembled into a final motor vehicle seating assembly, typically employing so-called “Kanban” or “Just-In-Time” (“JIT”) assembly processes to achieve the completed motor vehicle seat assembly. Using such assembly processes, it has been found to be advantageous to modularize the motor vehicle seating assembly into discrete subassemblies in order to reduce the costs of final assembly. This allows the subassemblies to be sourced from a location independent of the final JIT assembly plant. An improved motor vehicle seating assembly module design to achieve all of the needs of the motor vehicle seating assembly, particularly a decorative seat back rear panel module to provide these assembly advantages, as well as achieving a new and flexible look and styling, was desired. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the present disclosure, a motor vehicle seating assembly for a motor vehicle has a lower seat assembly and an upwardly extending seat back assembly. The upwardly extending seat back assembly comprises a seat back frame, a seat back cushion and suspension module attached to the seat back frame, and a decorative seat back rear panel module having a first seat back rear perimeter panel and a second seat back rear central panel operably connected with the first seat back rear perimeter panel that define a rear exterior surface area of the decorative seat back rear panel module. 
     According to another aspect of the present disclosure, a seat back assembly comprises a decorative seat back rear panel module having a first seat back rear perimeter panel and a second seat back rear central panel that define a rear exterior surface area of the decorative seat back rear panel module, wherein the second seat back rear central panel comprises a molded substrate having an outer surface and a trim covering disposed against the outer surface of the molded substrate. 
     According to yet another aspect of the present disclosure, a motor vehicle seating assembly comprises a lower seat assembly and an upwardly extending seat back assembly, wherein the upwardly extending seat back assembly comprises a seat back frame, a seat back cushion and suspension module, and a decorative seat back rear panel module. The seat back cushion and suspension module is attached to the seat frame, further comprises a one-piece composite inner carrier substrate having a pair of vertically extending side members, an upper transverse member, and a lower transverse member, wherein an outer edge of each of the side members, upper transverse member, and lower transverse member form an outer perimeter, and a seat back trim cover having an outer perimeter having a plurality of seat back trim cover attachment fasteners disposed about a perimeter of the seat back trim cover at locations corresponding to the discrete locations of the outer perimeter of the inner carrier substrate. The decorative seat back rear panel module comprises a first seat back rear perimeter panel and a second seat back rear central panel that define a rear exterior surface of the decorative seat back rear panel module, wherein the second seat back rear central panel comprises a molded substrate having an outer surface and a trim covering disposed against the outer surface of the molded substrate, and the first seat back rear perimeter panel comprises a pair of vertically extending, forward facing, and opposed side edges that each include a plurality of vertically aligned, molded-in attachment receptacles, wherein the outer edge of each of the vertically extending members of the one-piece composite inner carrier substrate includes a plurality of vertically aligned, molded-in attachment fasteners aligned and corresponding with the attachment receptacles of the decorative seat back rear panel module that are received within and are resiliently secured by the attachment receptacles of the decorative seat back rear panel module when the upwardly extending seat back is assembled. 
     These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front side perspective view of motor vehicle provided with the motor vehicle seating assembly of the present disclosure; 
         FIG. 2  is a front side perspective view of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 3  is an exploded front side perspective view of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 4  is a front side perspective view of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 5  is a rear side perspective view of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 6  is a rear perspective view of an upper portion of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 7  is a rear perspective view of a lower portion of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 8  is another rear perspective view of a lower portion of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 8A  is an enlarged perspective view of a seat back trim cover attachment fastener of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 9  is a rear perspective view of a side portion of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 10  is a front side perspective view of the one-piece composite inner carrier substrate of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 11  is a front view of the one-piece composite inner carrier substrate of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 12  is a rear view of the one-piece composite inner carrier substrate of the seat back and suspension module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 13  is a rear side perspective view of the decorative seat back rear panel module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 14  is a rear side perspective exploded view of the decorative seat back rear panel module of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 15  is a front perspective view of the seat back frame of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 16  is a front perspective view of the upper portion of the one-piece composite inner carrier substrate and the upper portion of the seat back frame of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 17  is a rear perspective view of the upper portion of the one-piece composite inner carrier substrate of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 18  is a perspective side cross-sectional view of the upper portion of the one-piece composite inner carrier substrate and the upper portion of the seat back frame of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; 
         FIG. 19  is a side cross-sectional view taken along the line XIX-XIX in  FIG. 18  of the upper portion of the one-piece composite inner carrier substrate and the upper portion of the seat back frame of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure; and 
         FIG. 20  is a perspective top view of the upper portion of the one-piece composite inner carrier substrate and the upper portion of the seat back frame of the motor vehicle seating assembly of  FIG. 1  according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     As referenced in the figures, the same reference numerals may be used herein to refer to the same parameters and components or their similar modifications and alternatives. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the present disclosure as oriented in  FIG. 1 . However, it is to be understood that the present disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. The drawings referenced herein are schematic and associated views thereof are not necessarily drawn to scale. 
     Referring to  FIGS. 1 and 2 , reference numeral  10  generally designates a motor vehicle seating assembly for a motor vehicle  8  having a lower seat assembly  12  and an upwardly extending seat back assembly  14 . The seat back assembly  14  preferably supports a head restraint  16  thereon. The upwardly extending seat back assembly  14  is pivotally coupled with the lower seat assembly  12 , such that the upwardly extending seat back assembly  14  can be moved between upright and inclined positions relative the lower seat assembly  12 . The head restraint  16  is operably, and preferably slidably, connected with the seat back assembly  14  and also positioned in a variety of positions and heights relative to the upwardly extending seat back assembly  14  to support the head and neck of a driver or a passenger. 
     Referring to  FIG. 3 , the lower seat assembly  12  includes a lower seat frame base  18  to which a lower seat cushion and suspension module  20  is attached. A decorative plastic fascia  22  is mounted to the lower seat assembly  12  and about the seat cushion and suspension module  20 . The upwardly extending seat back assembly  14  includes a seat back frame  24 , an upper seat back and suspension module  26 , a decorative seat back rear panel module  28 , and the head restraint  16 , as further discussed herein. 
     It is best shown in  FIG. 4 , the seat back and suspension module  26  includes a one-piece composite inner carrier substrate  30  and a suspension system  32  mounted to and supported by the one-piece composite inner carrier substrate  30 . As shown in  FIGS. 10-12 , the one-piece composite inner carrier substrate  30  is preferably formed as an integrated and unitary structure via an injection molding process from a rigid plastic material containing reinforcing fibers, such as fiber glass fibers. The one-piece composite inner carrier substrate  30  is generally comprised of a pair of vertically extending side members  34 , an upper transverse member  36 , and a lower transverse member  38 . A generally rectangular opening  40  is defined by the vertically extending side members  34 , the upper transverse member  36 , and the lower transverse member  38 . 
     The result is an outer perimeter  42  extending about an outer edge  44  of the vertically extending side members, an outer edge  46  of the upper transverse member  36 , and an outer edge  48  of the lower transverse member  38 . Also, an inner perimeter  50  defining the generally rectangular opening  40  is created by an inner edge  52  of the vertically extending side members  34 , an inner edge  54  of the upper transverse member  36 , and an inner edge  56  of the lower transverse member  38 . A plurality of attachment openings  58  is disposed about the outer perimeter  42  of the one-piece composite inner carrier substrate  30 . 
     The one-piece composite inner carrier substrate  30  of the seat back and suspension module  26  forms a support structure to which a seat back trim cover  60  may be attached, as shown in  FIGS. 6-9 . The seat back trim cover  60  can be formed of any material typically applied to such applications, such as leather, vinyl, cloth, or any combination thereof. The seat back and suspension module  26  further comprises a cushion foam layer  62  concealed beneath and in juxtaposed relation with seat back trim cover  60 . The seat back trim cover  60  has an outer perimeter  64  that is slightly larger than the outer perimeter  42  of the one-piece composite inner carrier substrate  30  of the seat back and suspension module  26 , which allows the outer perimeter  64  of the seat back trim cover  60  to be folded over the outer perimeter  42  of the one-piece composite inner carrier substrate  30 , as discussed further below. 
     A plurality of seat back trim cover attachment fasteners  66 , each preferably comprising a J-retainer, are provided about the outer perimeter  64  of the seat back trim cover  60 , as best shown in  FIG. 8A . As a beneficial feature of the present disclosure, the J-retainer attachment fasteners  66  are located at strategic locations about the outer perimeter  64  of the seat back trim cover  60 . The J-retainer attachment fasteners  66  are also preferably selected of a particular size from among a plurality of J-retainer attachment fastener  66  sizes that corresponds to the tension applied to the position about the outer perimeter  64  of the seat back trim cover  60 . That is, when installed on the one-piece composite inner carrier substrate  30  as described herein, the seat back trim cover  60  experiences a different tension at different locations about its outer perimeter  64  when occupied by a seated occupant. In those locations that experience a higher tension, it is therefore advantageous that a larger J-retainer attachment fastener  66  be selected to provide a more robust attachment of the seat back trim cover  60  to the one-piece composite inner carrier substrate  30 . The attachment openings  58  disposed about and proximate to the outer perimeter  42  of the one-piece composite inner carrier substrate  30  are preferably sized to receive the corresponding J-retainer attachment fastener  66  in the one-piece composite inner carrier substrate  30  at a particular location. 
     The J-retainer attachment fasteners  66 , as are well known in the art, each comprise a plastic clip having a main portion  70  and a hook  72  provided at a distal end  74  of the main portion  70 . The hook  72  preferably has a U-shaped configuration with an engaging portion  76  extending in parallel with the main portion  70 . An inwardly extending gripping barb  78  is preferably provided at a distal end  80  of the engaging portion  76  that resiliently and detachably engages an edge  82  of the perimeter trim J-retainer attachment openings  58 , as shown in  FIG. 8A . Preferably, the plastic from which the J-retainer attachment fasteners  66  are constructed is a non-breakable material, such as polypropylene. The main portion  70  of the J-retainer attachment fasteners  66  is further preferably sewn directly to the outer perimeter  64  of the seat back trim cover  60 , which when attached to a perimeter trim J-retainer attachment opening  58  about the outer perimeter  42  of the one-piece composite inner carrier substrate  30 , keeps the seat back trim cover  60  tight against the one-piece composite inner carrier substrate  30 . 
     During assembly of the seat back and suspension module  20 , the seat back trim cover  60 , with an exposed surface  84  facing forwardly relative the one-piece composite inner carrier substrate  30 , is placed with the cushion foam layer  62  disposed beneath it against a forward surface  86  of the one-piece composite inner carrier substrate  30  and the suspension system  32  mounted to and supported by the one-piece composite inner carrier substrate  30 . The outer perimeter  64  of the seat back trim cover  60 , with the J-retainer attachment fasteners  66  installed at locations about its perimeter  64  corresponding to the discrete locations of the perimeter trim J-retainer attachment openings  58 , is folded over the outer perimeter  42  of the one-piece composite inner carrier substrate  30 . The J-retainer attachment fasteners  66  are then inserted into and received by the perimeter trim J-retainer attachment openings  58  to attach the seat back trim cover  60  at discrete points around the outer perimeter  42  of the one-piece composite inner carrier substrate  30  to maintain the seat back trim cover  60  in a taunt condition. 
     As shown in  FIGS. 6-12 , preferably, each of the perimeter trim J-retainer attachment openings  58  disposed on the vertically extending side members  34  of the one-piece composite inner carrier substrate  30  have a plurality of opening widths that correspond to the size of the J-retainer attachment fastener  66  selected for and applied to that location about the outer perimeter  64  of the seat back trim cover  60 . However, the width of the perimeter trim J-retainer attachment openings  58  can be sized to meet the need of the seat back trim cover  60  at any position about the outer perimeter  42  of the one-piece composite inner carrier substrate  30 . A lower portion  88  of the seat back trim cover  60  is preferably attached to the lower transverse member  38  of the outer perimeter  42  of the one-piece composite inner carrier substrate  30  via a transversely extending integrated comb  90  of J-retainer attachment fasteners  66  received within a transversely extending and corresponding plurality of attachment openings  58  disposed along the lower transverse member  38  of the one-piece composite inner carrier substrate  30 , as best shown in  FIGS. 8 and 9 . 
     As a result of the use of the J-retainer attachment fasteners  66  and perimeter trim J-retainer attachment openings  58  strategically disposed about the outer perimeter  42  of the one-piece composite inner carrier substrate  30 , the seat back trim cover  60  can be easily and readily attached about the outer perimeter  42  of the one-piece composite inner carrier substrate  30 . The perimeter trim J-retainer attachment openings  58  disposed about the outer perimeter  42  of the one-piece composite inner carrier substrate  30  thus allows for the seat back trim cover  60  to be attached at all critical points around the seat back and suspension module  26  from top to bottom to ensure that the seat back trim cover  60  remains taut and maintains a crafted appearance even as the occupant ingresses and egresses the motor vehicle seating assembly  10 . Additionally, the perimeter trim J-retainer attachment openings  58  are purposely located to allow ease of attachment, low assembly efforts, and faster assembly times. 
     The decorative seat back rear panel module  28  represents a further innovation. In the past, most decorative back panels were typically constructed as a one-piece molded component, some of which were vinyl-wrapped. However, this approach tended to limit the ability to deliver unique styling and contrasting materials and surface finishes. In addition, a modular design and assembly concept offers reduced costs and can provide for the inclusion of additional components, such as airbag deployments, within the motor vehicle seating assembly  10 . 
     Accordingly, the decorative seat back rear panel module  28  of the present disclosure comprises a first seat back rear perimeter panel  94  and a second seat back rear central panel  96  that is operably connected with the first seat back rear perimeter panel  94  and that together define a rear exterior surface area  98  of the decorative seat back rear panel module  28 . The second seat back rear central panel  96  in turn comprises a molded substrate  100  having a rearward facing outer surface  102  and a trim covering  104  disposed against and attached to the outer surface  102  of the molded substrate  100 . As best shown in  FIGS. 13 and 14 , the molded substrate  100  further comprises an outer perimeter  106 , where the trim covering  104  is folded over the outer perimeter  106  of the molded substrate  100 . Preferably, the trim covering  104  is attached to the molded substrate  100  at all areas of contact via a thin layer of adhesive to provide a smooth, wrinkle free, surface. Additionally, as noted above, the trim covering  104  can be fabricated from any of the usual materials used for trim coverings for motor vehicle seating assemblies, such as leather, vinyl, cloth, and combinations thereof. Preferably, the second seat back rear central panel  96  also receives a toe kick trim panel  108  depending from a lower portion  110  of the second seat back rear central panel  96 . 
     The first seat back rear perimeter panel  94  is preferably injection molded from a semi-rigid plastic material. As a decorative component, the exposed rear exterior surface area  98  of the first seat back rear perimeter panel  94  represents an A-surface within the interior of the motor vehicle  8  and is preferably finished with a high grade, textured, grained surface to simulate leather or another predetermined surface finish. 
     As shown in  FIG. 14 , the first seat back rear perimeter panel  94  comprises a smaller portion of the rear exterior surface area  98  of the decorative seat back rear panel module  28  and the second seat back rear central panel  96  comprises a larger portion of the rear exterior surface area  98  of the decorative seat back rear panel module  28 . Preferably, the first seat back rear perimeter panel  94  comprises about 30% of the rear exterior surface area  98  of the decorative seat back rear panel module  28  and the second seat back rear central panel  96  comprises a about 70% of the rear exterior surface area  98  of the decorative seat back rear panel module  28 . This ratio between the portions of the rear exterior surface area  98  of the first seat back rear perimeter panel  94  relative the second seat back rear central panel  96  is believed to provide heretofore unattained flexibility in design and styling, in that interchangeable, second seat back rear central panel  96 , each having different features and different coverings, can be readily interchanged to provide a wide range of differing motor vehicle seating assembly designs. For example, as shown in  FIG. 13 , the trim covering  104  for the second seat back rear central panel  96  may comprise a sewn cloth wrap having a sewn-in map pocket  112 . Alternatively, beverage holders and closable compartments (not shown) might be incorporated within the second seat back rear central panel  96  and then merely attached to the first seat back rear perimeter panel  94  for subsequent assembly into the motor vehicle seating assembly  10  for a particular vehicle build, without having to adopt the same second seat back rear central panel  96  for every motor vehicle seating assembly  10  installed in a particular motor vehicle line. 
     For ease of assembly, the first seat back rear perimeter panel  94  has an outer perimeter  114  defining the outer perimeter of the decorative seat back rear panel module  28  and an inner perimeter  116  having a first mounting flange  118 . The second seat back rear central panel  96  has a complementary outer perimeter  120  having a second mounting flange  122  overlapping with and attached to the first mounting flange  118  of the inner perimeter  116  of the first seat back rear perimeter panel  94 . The second mounting flange  122  of the second seat back rear central panel  96  is preferably heat-staked to the first mounting flange  118  of the first seat back rear perimeter panel  94 . Alternatively, the second mounting flange  122  of the second seat back rear central panel  96  may be vibration welded to the first mounting flange  118  of the first seat back rear perimeter panel  94 . 
     With regard to assembly of the upwardly extending seat back assembly  14 , as noted above, the one-piece composite inner carrier substrate  30  has a pair of vertically extending side members  34 . The outer edge  44  of each of the vertically extending side members  34  of the one-piece composite inner carrier substrate  30  preferably includes a plurality of vertically aligned, molded-in attachment fasteners  124 , preferably snap fit fasteners as best shown in  FIGS. 10-11 . The first seat back rear perimeter panel  94  of the decorative seat back rear panel module  28 , shown in  FIG. 14 , is likewise provided with a pair of vertically extending, forward facing, and opposed side edges  126  that each similarly include a plurality of complementary vertically aligned, molded-in attachment receptacles  128  that correspond to, are in alignment with, and receive the vertically aligned, molded-in attachment fasteners  124  of the one-piece composite inner carrier substrate  30 . With the vertically aligned, molded-in attachment fasteners  124  of the one-piece composite inner carrier substrate  30  aligned and corresponding with the molded-in attachment receptacles  128  of the decorative seat back rear panel module  28 , the molded-in attachment fasteners  124  of the one-piece composite inner carrier substrate  30  are resiliently secured by the molded-in attachment receptacles  128  of the decorative seat back rear panel module  28  when the seat back and suspension module  26  is assembled to the seat back frame  24 . Preferably, the perimeter J-retainer attachment fasteners  66  disposed on the vertically extending side members  34  of the one-piece composite inner carrier substrate  30  alternate with the vertically aligned, molded-in attachment fasteners  124  disposed on the one-piece composite inner carrier substrate  30 . 
     Additionally, the side edges  126  of the first seat back rear perimeter panel  94  of the decorative seat back rear panel module  28  are preferably configured to extend forwardly to form a trim panel  130  that abuts the resulting folded over perimeter  64  of the seat back trim cover  60  to form an aesthetically pleasing and finished appearance when attached with the one-piece composite inner carrier substrate  30 . 
     Preferably, the one-piece composite inner carrier substrate supports the suspension system  32  within the generally rectangular opening  40  to resiliently support the weight of an occupant sitting in the motor vehicle seating assembly  10 . The suspension system  32  generally comprises a first set of metal, preferably spring steel, wires  132  having a nominal wire thickness that extend transversely between a second set of metal wires  134  that extend vertically between the vertically extending side member  34 , as best shown in  FIGS. 11-12 . A pair of transversely extending wires  136  operably connects the second set of metal wires  134  to each of the vertically extending side members  34  of the one-piece composite inner carrier substrate  30 . 
     One of the pair of transversely extending wires  136  may be attached to each of the vertically extending side members  34  of the one-piece composite inner carrier substrate  30  via a load cell  138  mounted within a cavity  140  formed along the inner edge  52  of each of the vertically extending side members  34  of the one-piece composite inner carrier substrate  30 , as shown in  FIG. 11 . The result is a suspension system  32  that has a spring web situated within the generally rectangular opening  40  and which provides resilient support against the weight of the occupant in a motor vehicle seating assembly  10 . Further, in the event of a rear impact event, the inertia of an occupant seating in the motor vehicle seating assembly  10  pushes back against the upwardly extending seat back assembly  14  and creates tension in the suspension system  32 . Optionally, the load cell  138  operably connected to the suspension system  32  may be situated to detect this event and transmit an appropriate signal to a motor vehicle controller (not shown). 
     Thus, an additional benefit of the one-piece composite inner carrier substrate  30  and decorative seat back rear panel module  28  of the present disclosure is that they may be readily provided with additional features or structures by changing the molds for the one-piece composite inner carrier substrate  30  or decorative seat back rear panel module  28 . For example, one or more of the vertically extending side members  34  of the one-piece composite inner carrier substrate  30  can be modified and adapted to accept a housing or other mounting structure for a side airbag assembly mounted in the motor vehicle seating assembly  10  (not shown). Similarly, the pair of vertically extending, forward facing, and opposed side edges  126  of the first seat back rear perimeter panel  94  can be configured to include an integrated side airbag mounting chamber (not shown). 
     A further innovation of the present disclosure is the manner in which the one-piece composite inner carrier substrate  30  of the seat back and suspension module  20  is coupled to the seat back frame  24 . In the past, assuring the structural integrity of the upper portion  142  of the vertically extending seat back assembly  14  has been an important design consideration. In accordance with the present disclosure, head restraint guide sleeves  150  are employed as structural members to mechanically lock the one-piece composite inner carrier substrate  30  of the seat back and suspension module  26  to the seat back frame  24 . The head restraint guide sleeves  150  are pushed through aligned openings  152 ,  154  in each of the one-piece composite inner carrier substrate  30  and the seat back frame  24 , respectively, during final seat assembly until fully seated and locked in place. Once installed, the head restraint guide sleeves  150  operate in their usual manner and form guide sleeve cavities  156  within which the head restraint mounting posts  158  of the head restraint  16  can be vertically adjusted. This innovation contributes to the modular design disclosed herein, and provides an assembly concept that offers reduced costs and can provide improved design flexibility. 
     As shown in  FIG. 3 , the head restraint  16  is rather conventional and consists of a head restraint pad  160  and a pair of head restraint mounting posts  158  depending from a lower surface  162  in the head restraint pad  160 . As shown in  FIG. 15 , the seat back frame  24  is the main structural member of the upwardly extending seat back assembly  14  and is comprised of a pair of vertically extending side members  164 , an upper transverse member  166  forming an upper portion thereof, and a lower transverse member  168 . An optional pivot assembly  170  rotationally couples the seat back frame  24  and the upwardly extending seat back assembly  14  to the lower seat base frame. The seat back frame  24  thus forms a forwardly facing surface  172  and a rearwardly facing surface  174  and is provided with a pair of vertically oriented frame openings  154  within the upper transverse member  166  forming the upper portion thereof. Similarly, the upper transverse member  36  of the one-piece composite inner carrier substrate  30  forming the upper portion of the seat back and suspension module  26  is provided with a pair of vertically oriented module openings  152  in the upper portion. The module openings  152  and frame openings  154  are disposed in vertical alignment, one with the other. 
     The pair of head restraint guide sleeves  150  are vertically received and retained within the module openings  152  and frame openings  154 , wherein the head restraint mounting posts  158  are received and adjustably retained within the head restraint guide sleeves  150 , as shown in  FIGS. 15-20 . As further described below, the head restraint guide sleeves  150  are received and retained within the module opening  152  and frame openings  154  of the upper transverse member  36  of the one-piece composite inner carrier substrate  30  and the upper transverse member  166  of the seat back frame  24 , respectively, to mechanically lock the one-piece composite inner carrier substrate  30  to the seat back frame  24 . 
     Vertically oriented openings  148  through each of an upper portion of the seat back trim cover  60  and an upper portion of the cushion foam layer  62  that overlay the upper portion  142  of the upwardly extending seat back assembly  14 . Thus, the head restraint guide sleeves  150  pass through the upper portion of the seat back and suspension module  26 , which includes the upper portion of the seat back trim cover  60 , the upper portion of the cushion foam layer  62 , and the upper transverse member  36  of the upper portion of the one-piece composite inner carrier substrate  30 , and into the upper transverse member  166  of the seat back frame, which receives and locks the head restraint guide sleeve  150  in place subsequent assembly of the upwardly extending seat back assembly  14 . As an injection molded component, the module openings  152  within the upper transverse member of the one-piece composite inner carrier substrate  30  are molded-in to receive the head restraint guide sleeves  150  and lock the head restraint guide sleeves  150  to the upper transverse member  36  of the one-piece composite inner carrier substrate  30  to the upper transverse member  166  of the seat back frame  24 . 
     To this end, the upper transverse member  36  of the one-piece composite inner carrier substrate  30  also includes a pair of molded-in integral resilient locking pawls  176 , preferably disposed at a peripheral position proximate a rear edge  178  of the molded-in module openings  152 , as shown in  FIG. 16 . Each of the resilient locking pawls  176  is disposed adjacent to and extends toward each of the aligned module openings  152  in the one-piece composite inner carrier substrate  30 . Each of the resilient locking pawls  176  also extends upwardly relative an upper surface  180  of the upper transverse member  36  of the one-piece composite inner carrier substrate  30  in a cantilevered fashion and are displaceable between a released position and an engaged position, as discussed further below. Further, each of the resilient locking pawls  176  has an inwardly inclined upper surface  182 , a flat vertical face  184 , and a lower edge  186 . The forward and side edges  188 ,  190  of the molded-in module openings  152  do not necessarily need to be circular and can be oversized relative the frame openings  154  in the upper transverse member  166  of the seat back frame  24 . Most important is that the downwardly extending head restraint mounting posts  158  of the head restraint  16  pass readily through the molded-in module openings  152  in the upper transverse member  36  of the one-piece composite inner carrier substrate  30 . The head restraint guide sleeves  150  are instead rigidly and fixedly retained in position via the frame openings  154  in the upper transverse member  166  of the seat back frame  24 , as discussed below. 
     As best shown in  FIG. 19 , the pair of head restraint guide sleeves  150  each comprises a tubular member  92  having an outer cylindrical surface  194  and the guide sleeve cavity  156  within which the mounting posts  158  of the head restraint  16  are received and restrained. The outer cylindrical surface  194  of each of the head restraint guide sleeves  150  has a locking tab  196 . The outer cylindrical surface  194  of the head restraint guide sleeve  150  also include a stop  198  that engages the frame opening  154  of the upper transverse member  166  of the upper portion  142  of the seat back frame  24  when the head restraint guide sleeve  150  is fully inserted. 
     As each of the head restraint guide sleeves  150  is inserted after the assembled seat back, and suspension module  26  has been assembled with the decorative seat back rear panel module  28 , as described above, the outer cylindrical surface  194  of the head restraint guide sleeve  150  is received within an aligned opening  148  in the seat back trim cover  60  and the cushion foam layer  62 , then module opening  152  of the upper transverse member  36  of the one-piece composite inner carrier substrate  30 , and the frame openings  154  in the upper transverse member  166  of the seat back frame  24 . As it is inserted, the locking tab  196  of the head restraint guide sleeve  150  acts against the inwardly inclined upper surface  182  of the resilient locking pawl  176  and resiliently displaces the resilient locking pawl  176  away from the module opening  152  to the released position until the locking tab  196  moves downward relative to and clears the flat vertical face  184 . With the head restraint guide sleeve  150  fully inserted against the stop  198 , the lower edge  186  of the resilient locking pawl  176  moves to the engaged position and mechanically engages an upper surface  200  of the locking tab  196  to prevent withdraw of the head restraint guide sleeve  150  from the module opening  152  in the upper transverse member  36  of the one-piece composite inner carrier substrate  30 . If it is desired to remove the head restraint guide sleeve  150 , an upper portion  202  of the resilient locking pawl  176  can be manually displaced to the released position, wherein the lower edge  186  of the resilient locking pawl  176  disengages the upper surface  200  of the locking tab  196  and the head restraint guide sleeve  150  can be removed. 
     The two head restraint guide sleeves  150 , when pushed through the molded-in module openings  152  in the upper transverse member  36  of the one-piece composite inner carrier substrate  30  during the final seat assembly and fully seated, act as “mechanical locks” for the one-piece composite inner carrier substrate  30  to the seat back frame  24 . The benefit of the “locks” helps prevent the one-piece composite inner carrier substrate  30  from listing forward during dynamic events and remain “locked” to the seat back frame  24  until manually released. 
     Preferably, the upper transverse member  36  of the seat back frame  24  comprises a U-shaped beam  204  having an upper horizontal flange  206 , a vertical center portion  208 , and a lower horizontal flange  210 , which adds structural support to the seat back frame  24 . Each of the upper horizontal flange  206  and lower horizontal flange  210  has vertically aligned frame openings  154  within which the outer cylindrical surface  194  of the head restraint guide sleeve  150  is fittingly received. Preferably, each of these frame openings  154  has a downwardly curved and flared edge  212  to facilitate insertion of the head restraint guide sleeve  150 , as shown in  FIG. 19 . The upper and lower horizontal flanges  206 ,  210  also provide a mechanical attachment that creates a “line-to-line” contact to ensure that the head restraint guide sleeves  150  do not tilt or move in a longitudinal or lateral direction when installed and provides a pass-through feature for the head restraint guide sleeves  150 . 
     Preferably, an upper portion  214  of the head restraint guide sleeves  150  comprises a trim cover bezel  216 , shown in  FIGS. 15 and 19 . As noted above, the outer cylindrical surface  194  of the head restraint guide sleeve  150  also includes a stop  198  that engages the frame opening  154  on the upper horizontal flange  206  of the upper transverse member  166  of the seat back frame  24  when the head restraint guide sleeve  150  is fully inserted. Preferably, the stop  198  is disposed opposite the locking tab  196  on the outer cylindrical surface  194  of the head restraint guide sleeve  150  and below the trim cover bezel  216  by a distance corresponding to an overall thickness of the seat back trim cover  60  and cushion foam layer  62  disposed beneath the seat back trim cover  60  on the seat back and suspension module  26 . Thus, when assembled, the trim cover bezel  216  conceals the openings  148  in the seat back trim cover  60  and provides an aesthetically presentable appearance. 
     As described above, the seat back and suspension module  26  and seat back frame  24  of the present disclosure provides integrated modular assembly features and supports JIT assembly practices by modularizing the seat back and suspension module  26  into a single module and therefore reduce the costs of final assembly by allowing this assembly to be sourced to a location independent of the traditional JIT assembly plant. The described seat back and suspension module  26  uses a one-piece composite inner carrier substrate  30  that enables the seat back trim cover  60  to be fully assembled and attached around the outer perimeter  42  of the one-piece composite inner carrier substrate  30  to provide a crafted, easier to assemble, and more cost- and time-efficient product for upwardly extending seat back assembly  14 . 
     In order to modularize the upwardly extending seat back assembly  14  and to therefore reduce the costs of final assembly by requiring less trim assembly time and difficulty that accompanying seat trim “stuffing,” as well as the option of allowing this assembly to be sourced to a location independent of the traditional JIT assembly plant, the disclosed one-piece composite inner carrier substrate  30  can be employed. Further, the cushion foam layer  62  disposed beneath the seat back trim cover  60  can reduced, resulting in the use of less material and a lighter weight for the upwardly extending seat back assembly  14 . Also, the use of strategically located trim cover attachment openings  58  and J-retainer attachment fasteners  66  about virtually the entire outer perimeter  42  of the one-piece composite inner carrier substrate  30  and seat back trim cover  60  allows ease of attachment, low assembly efforts, and good retention for craftsmanship. The use of head restraint guide sleeves  150  that are received and retained within module opening  152  and frame openings  154  of the upper transverse member  36  of the one-piece composite inner carrier substrate  30  and the upper transverse member  166  of the seat back frame  24 , respectively, provide a ready and reliable mechanical lock between the one-piece composite inner carrier substrate  30  to the seat back frame  24 . The one-piece composite inner carrier substrate  30  advantageously employs compounding technology to achieve a high strength composite structure, while integrating several benefits and features into a low cost and robust design and achieving a new look for styling. 
     It will be understood by one having ordinary skill in the art that construction of the present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) 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. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     For purposes of this disclosure, the term “operably connected” generally means that one component functions with respect to another component, even if there are other components located between the first and second component, and the term “operable” defines a functional relationship between components. 
     It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the 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, unless otherwise described, 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 shown 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 positions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.