Patent Publication Number: US-2016236600-A1

Title: Vehicle seat with structural cover for seat back frame

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/892,969, filed Oct. 18, 2013, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD 
     The present application relates generally to a vehicle seat with a structural cover for use in a seat back within moveable devices. 
     BACKGROUND 
     Typically, the interior space within vehicles is limited due design constraints and vehicle size constraints. More specifically, there may be limited space for knee or leg clearance between the front row seats and the second row seats. 
     The space between the front row seats and the second row seats can be constrained by the thickness or depth of the seat back of the front row seat. A typical vehicle seat  12  with a seat back  14  is shown in  FIG. 11 . Currently, many seat backs include a hard, plastic substrate or back panel  30  in the center of the backside of the seat back  14 , surrounded by foam and trim. The back panel  30  is typically a rigid piece of plastic that must substantially rest on the outside of the seat back  14 . Due to the design of the back panel  30 , a trim/foam combination  18  must wrap around the sides of the seat back  14  to the back of the seat  12  in order to create the proper contours. Accordingly, the trim/foam combination  18  thickens the seat structure and reduces the amount of potential knee clearance. However, without the foam on the seat back  14 , the seat  12  may not be contoured properly or have adequate craftsmanship. 
     Further, a map pocket  16  may be located on the back panel  30  and may stick out from the back panel  30 , away from the seat frame. Accordingly, the map pocket  16  may add to the thickness of the seat back  14  and may further reduce the potential leg room for the occupant behind the vehicle seat. 
     The back panel  30 , the trim/foam combination  18 , and the map pocket  16  all add to the thickness of the seat back  14  and decrease the potential leg and knee clearance behind the seat  12 . 
     SUMMARY 
     According to one embodiment, a vehicle seat may include a seat back frame with a rear surface and a structural cover configured to attach to the seat back frame. The structural cover may have an opening in a center portion of the structural cover and may cover at least a portion of the rear surface of the seat back frame. The structural cover and the portion of the rear surface of the seat back frame may not be covered by any foam. 
     According to another embodiment, a method of attaching a structural cover to a seat back frame may include hooking at least one hook around one of a top portion and a bottom portion of the seat back frame, angling the structural cover to be substantially parallel to a rear surface of the seat back frame, and snapping at least one snap of the structural cover to the other of the top portion and the bottom portion of the seat back frame. The hook may extend from the structural cover. The structural cover may include an opening along a center portion of the structural cover. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle according to one embodiment. 
         FIG. 2  is a perspective front view of a vehicle seat that may be disposed in the vehicle of  FIG. 1 . 
         FIG. 3  is a perspective back view of a vehicle seat with a structural cover that may be disposed in the vehicle of  FIG. 1  according to one embodiment. 
         FIG. 4A  is a perspective back view of a vehicle seat with a structural cover according to one embodiment. 
         FIG. 4B  is a side view of a vehicle seat with a structural cover that may be disposed within the vehicle seat of  FIG. 2 . 
         FIG. 5A  is a front view of a structural cover attached to a seat back frame that may be disposed within the vehicle seat of  FIG. 2 . 
         FIG. 5B  is a back view of the structural cover of  FIG. 5A . 
         FIG. 6  is a side view of a structural cover and a back panel with a seat back frame. 
         FIG. 7A  is a cross-sectional, top view of a structural cover and a back panel with a seat back frame. 
         FIG. 7B  is a cross-sectional, top view of a structural cover and a back panel with a seat back frame with seat back pockets attached. 
         FIG. 8  is a perspective view of a structural cover that may be disposed within the vehicle seat of  FIG. 2 . 
         FIG. 9A  is a perspective view of a structural cover that may be disposed within the vehicle seat of  FIG. 2 . 
         FIG. 9B  is a front view of the structural cover of  FIG. 9A . 
         FIGS. 9C-9H  are side and cross-sectional view of the structural cover of  FIGS. 9A-9B . 
         FIGS. 10A-10E  are views of a structural cover being attached to a seat back frame of a vehicle seat. 
         FIG. 11  is a perspective back view of a vehicle seat with a back panel that may be disposed in the vehicle of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the figures, disclosed herein is a vehicle seat with a seat back frame and a structural cover, as shown according to exemplary embodiments. The structural cover may attach to a seat back frame within a seat back of a vehicle seat to reduce or minimize the thickness or depth of the seat back. The structural cover may minimize the depth of the seat back to maximize the space behind the seat and between the rows of seats (e.g. rear seat occupant leg room or knee clearance). The structural cover may add to, improve, or maintain the desired style of the vehicle interior, as well as improve the safety of the vehicle seat. The structural cover may be used within any vehicle seat that has additional seating located behind the vehicle seat, such as on the back of the front row seats or the second or third row seats. 
       FIG. 1  illustrates an exemplary embodiment of a vehicle  20  that may include a vehicle seat  22  with a structural cover. The vehicle  20  may include an interior passenger compartment containing the vehicle seat  22  for providing seating to an occupant. Although a four door sedan automobile is shown in  FIG. 1 , the vehicle seat  22  may be used in a variety of applications, but is particularly useful within a vehicle seat in any type of vehicle, such as a two door or four door automobile, a truck, a SUV, a van, a train, a boat, an airplane, or other suitable vehicular conveyance. 
     According to one embodiment as depicted in  FIG. 2 , the vehicle seat  22  may include a seat back  24  and a seat cushion  21 . As shown in  FIG. 3 , the seat back  24  of the vehicle seat  22  may include various components, such as a seat back frame  25  and a structural cover  50  (as shown further in subsequent figures). The seat cushion  21  may include a seat cushion frame (not shown). The seat back frame  25  may include a rear surface  27 , a front surface  29 , and side surfaces. The side surfaces may be substantially perpendicular to the rear surface  27  and the front surface  29  and may face the sides of the vehicle  20 . The rear surface  27  and the front surface  29  may be substantially parallel and may face the back and the front, respectively, of the vehicle  20 . 
     The structural cover  50  may be particularly useful for reducing the depth of the vehicle seat  22 . For example, the structural cover  50  may bring the rearmost surface of the seat back  24  inward toward the seat back frame to allow for more room within the vehicle  20  without sacrificing the comfort of the vehicle seat occupant. For example, as described further herein, the slim design and attachment of the structural cover  50  to the seat back frame  25 , the reduction or elimination of the trim/foam combination on the back of the seat back  24 , and the recessed map pocket  26  all contribute to the reduction of the seat back thickness and the increase in knee clearance and leg room behind the seat  22 . 
     Referring now to  FIGS. 4A-4B , there is shown the seat  22  with a trim ring, seat back panel, seat back plate, or structural cover  50  at least partially integrated into the seat back frame  25  of the seat back  24 , thereby reducing or minimizing the thickness or depth of the seat back  24  and increasing the potential knee clearance behind the vehicle seat  22 . As shown in  FIGS. 5A-5B , the structural cover  50  may be attached directly or indirectly to the seat back frame  25  of the seat back  24  through a variety of different methods (as described further herein). Accordingly, the structural cover  50  may cover at least a portion of a rear surface  27  of the seat back frame  25 , thus providing the desired contour and shape of the seat back  24 . The structural cover  50  defines the rearmost surface of the vehicle seat  12  and can isolate the occupants from the seat back frame  25  by providing sufficient coverage and structural rigidity. Therefore, at least the structural cover  50  and the portion of the rear surface  27  of the seat back frame  25  (that is covered by the structural cover  50 ) are not covered by and do not require any foam, even when the seat  22  is fully assembled. By eliminating the foam, the structural cover  50  reduces the depth (e.g., along the x-axis, as shown in  FIG. 3 ) of the seat back  24  and provides more room within the vehicle  20 . 
     The contour, size, and shape of the structural cover  50  may allow the structural cover  50  to attach or be secured closer to and be more integrated with the seat back frame  25  than the traditional back panel  30  to minimize the thickness or depth of the seat back  24 .  FIGS. 6 and 7A-7B  show the side of the seat back frame  25  with both the structural cover  50  and the back panel  30  attached for comparison. As shown, the structural cover  50  is able to rest closer to the seat back frame  25  than the back panel  30 . Accordingly, a seat back frame with the traditional back panel  30  attached has a greater depth than the seat back frame  25  with the structural cover  50  attached. The structural cover  50  lies close and essentially parallel to the seat back frame  25 , while the back panel  30  protrudes away from the seat back frame  25 . Since the back panel  30  does not provide all of the desired contours of the seat back  24 , the back panel  30  must protrude away from the seat back frame  25  in order to allow sufficient room for the foam. However, since the structural cover  50  provides the desired contours for the seat back  24  and thus replaces the foam, the structural cover  50  lies very close to the seat back frame  25 , thus minimizing the thickness or depth of the seat back  24 . 
     Further, since the structural cover  50  may span the entire width (e.g., along the y-axis, as shown in  FIG. 3 ) of the seat back frame  25  (as shown in  FIGS. 3, 4A, 5A-5B, and 7A-7B ), the entire width of the seat back  24  may not include any foam along certain portions of the seat back  24 . However, since the traditional back panel  30  does not does not wrap around the side of the seat back frame  25  or even span the entire width of the back of the seat back  24 , the trim/foam combination  18  must wrap around to the back of the seat back  24 , which adds to the thickness or depth of the seat back  24 . 
     Eliminating the need for the trim/foam combination  18  along the back of the seat back  24  or behind the seat back frame  25  also allows for better craftsmanship, structure, shape, contour, and styling. For example, the contour, shape, size, and corners of the structural cover  50  may match, complement, or maintain a customer themed styling theme of the seat (STO), such as clean and crisp corners on the back of the seat back  24 . The structural cover  50  may define the contour of the exposed back of the vehicle seat  22 . For example, the exact shape of the back of the seat back  24  may be determined by the shape of the structural cover  50 . 
     As shown in  FIGS. 4A-4B, 6, 7A-7B, 9A, 9C, and 9D , the structural cover  50  may include side portions  58  that extend along or wrap around at least a portion of at least one side surface of the seat back frame  25 . The side portions  58  may allow the structural cover  50  to provide sufficient support and the proper contours, as well as eliminate the need for the additional trim/foam combination  18  along the back (and sides) of the seat back  24 . Further, by wrapping around at least some of the edges of the seat back frame  25 , the structural cover  50  may provide a clean look (i.e. clean, crisp corners) within the vehicle  20 . The side portions  58  may further interact with the side airbag (SIAB) in such a way to allow the SIAB to fully deploy when needed, while still allowing the structural cover  50  to closely attach to the seat back  24 . 
     The side portions  58  may cover, wrap around, overlap, or scalp a portion of the sides of the seat back  24  to further secure the structural cover  50 , to minimize the need for the foam  23 , and to minimize the depth of the seat back  24 , as shown, for example, in  FIGS. 4A-4B . For example, due to the side portions  58 , the foam  23  of the seat  22  therefore does not need to wrap around to the back of the seat back  24 , thereby reducing the depth of the seat back  24 . According to one embodiment, the edge of the foam  23  may extend to or meet with the edges of the structural cover  50 . According to another embodiment, the foam may extend underneath the structural cover  50 . Optionally, the structural cover  50  may cover portions of other sides of the seat back  24  and/or extend upwards or downwards to eliminate the need for foam  23  on the top or bottom of the seat back  24 . 
     The side portions  58  may be designed in any configuration and may extend from a portion of the length (e.g., along the vertical direction or the z-axis, as shown in  FIG. 3 ) of the structural cover  50  (as shown in  FIGS. 4A-4B  and on the right side of  FIG. 8 ) or may extend from the entire length of the structural cover  50  (as shown in  FIG. 9A  and on the left side of  FIG. 8 ). Further, the side portions  58  may extend along the entire depth of the side of the seat back  24  or along a portion of the depth of the seat back side. Accordingly, the side portions  58  may wrap around or extend along certain portions of the sides of the seat back  24 , along the entire length and/or depth of the sides of the seat back  24 , or none of the sides of the seat back  24  (i.e. the structural cover  50  may only cover the back portion of the seat back  24 ), depending on the desired configuration.  FIG. 9D  depicts cross-sectional, horizontal views of different areas along one embodiment of the structural cover  50 . As shown between the different cross-sections, the side portions  58  may be different sizes (e.g., lengths) along the height of the structural cover  50  and therefore may have different amounts of overlap with the side of the seat back  24 . According to another embodiment, the side portion  58  may have a consistent length along the height of the structural cover  50  (as shown, for example, in  FIG. 4A ). 
     The side portions  58  may wrap around or extend along all, some, or none of the seat back  24  edges or sides. However, it is anticipated that the structural cover  50  may only cover the back of the seat back  24  and may not wrap around the sides or edges of the seat back  24 . Further, the side portions  58  may lie at a variety of distances from the side of the seat back frame  25  (as shown in  FIGS. 7A-7B ). 
     According to one embodiment as shown in  FIGS. 8 and 9A-9B , the structural cover  50  may include an additional hole, cutout, or opening  52  in a center portion of the structural cover  50 . Due to the flexibility of the structural cover  50  within the seat back  24  and the hole provided by the opening  52 , the structural cover  50  may improve the safety of the vehicle by allowing an occupant in the vehicle seat  22  to move further into the seat  22  (e.g. in the event of a rear-end collision) compared to the rigid back panel  30 . For example, the structural cover  50  may help contribute to achieving the safety requirements in federal safety requirement tests, such as the “FMVSS 202A Dynamic Testing”. 
     As shown in  FIG. 5B , the opening  52  of the structural cover  50  may allow the center area of the structural cover  50  to be flexible and therefore may include a support or bladder system  53  to at least support the occupant. The bladder system  53  may be positioned at least within the opening  52  of the structural cover  50  and may be configured to extend along at least a portion of the opening  52 . The bladder system  53  may be flexible within the opening  52  and may bend and flex within the opening  52  of the structural cover, thus supporting the occupant during use. Accordingly, the opening  52  of the structural cover  50 , paired with bladder system  53 , may help further absorb the impact of the collision, may allow the occupant to be further secured within the seat, and may increase the comfort and safety of the user. 
     The bladder system  53  may include springs, a mesh structure  54 , a sheet  56  (which may be at least partially flexible), and/or additional seating content for the comfort and safety of the occupant. According to one embodiment, the mesh structure  54  may be any arrangement or mechanism (e.g., of springs, wires, or rods) to provide resistance to the force from the occupant. The sheet  56  may be a plastic sheet and designed to interact with the mesh structure  54  and/or provide support to the occupant. The mesh structure  54  and the sheet  56  may be used in combination with each other or separately. 
     As shown in  FIG. 3 , the opening  52  may also provide a space to integrate the map pocket  26  without increasing the overall depth of the seat back  24 . Typically, with traditional back panels  30 , the seat map pockets  16  protrude from the back panel  30 , away from the seat back frame and into the knee and leg clearance area within the vehicle  20  (as shown, for example, in  FIGS. 7B and 11 ). However, since the structural cover  50  may be integrated into the seat  22  and may include the opening  52 , the map pocket  26  may be attached to and recessed within the opening  52  of the structural cover  50  to further minimize the depth of the seat back  24  while providing storage features, as further shown in  FIG. 7B . 
     The structural cover  50  may attach to the seat back  24  through a variety of different mechanisms and may utilize existing attachments or attachment sites on the seat back frame  25 , the seat back  24 , or the seat  22 . As shown in  FIGS. 8 and 9A-9B , the structural cover  50  may have hooks  62  and clips or snaps  64  to attach to the seat back frame  25 . The attachment mechanisms, such as the hooks  62  and the snaps  64 , may be located anywhere along the structural cover  50 . For example, the hooks  62  may extend from and be located towards the top of the structural cover  50  and may attach to the top portion or upper cross member  42  of seat back frame  25 . The snaps  64  may be located towards the bottom of the structural cover  50  and may subsequently snap into the rear side of the bottom portion or lower cross member  44  of the seat back frame  25 . Additional attachments or mechanisms, such as plastic fasteners, may be used to further secure the structural cover  50  to the seat back frame  25 . As the structural cover  50  is fastened to seat back frame  25 , it provides a complete compression against the seat back  24  to secure the components of the seat back  24  and to further decrease the depth of the seat back  24 . 
     As shown in  FIGS. 5A-5B , the structural cover  50  may attach to a variety of different portions of the seat back frame  25 , such as the rear surface  27  and/or the front surface  29 . For example,  FIG. 5A  depicts the front side of the seat back frame  25  (with respect to the vehicle  20 ). The hooks  62  of the structural cover  50  may be attached to the upper cross member  42  of the seat back frame  25 . The hooks may at least partially surround an edge of the seat back frame  25  to help secure the structural cover  50  to the seat back frame  25 .  FIG. 5B  depicts the back side of the seat back frame  25  (with respect to the vehicle  20 ). The snaps  64  of the structural cover  50  may attach into (or snap on) the lower cross member  44  of the seat back frame  25 . However, it is anticipated that the hooks  62  may attach to the lower cross member  44  and the snaps  64  may attach to the upper cross member  42 . 
     Although hooks and snaps are shown, it is anticipated that any type of temporary or permanent fastening device or method may be used to attach the structural cover  50  to the seat back frame  25 . For example, screws, clips, double-stick tape, glue, epoxy, hook-and-loop fasteners, nails, sewing, adhesives, or welding may be used. Although a variety of fasteners may be used to attach the structural cover  50  to the seat back frame  25 , they are not required. Instead, the structural cover  50  may employ a simple method of attaching to the seat back frame  25 , as described previously. 
       FIGS. 9A-9H  depict exemplary configurations of the structural cover  50 .  FIGS. 9A-9H  may correspond with the structural cover  50  depicted in  FIGS. 9A-9B . However, the structural cover  50  may be designed to attach with any seat back frame  25 . The attachment mechanisms, such as the hooks  62  and the snaps  64 , may be located anywhere along the structural cover  50 .  FIG. 9A  depicts the attachments towards the top and towards the bottom of the structural cover  50 . 
       FIG. 9B  depicts a cross-section of a hook  62 . The hook  62  may be located in one or more areas along the structural cover  50  and may attach onto an opposite side of the seat back frame  25 . For example, a portion or edge of the seat back frame  25  may fit within crevice  63 . 
       FIG. 9C  depicts a cross-section of a snap  64 . The snap  64  may be located in one or more areas along the structural cover  50  and may attach to the seat back frame  25  through a variety of mechanisms. For example, a portion of the seat back frame  25  may fit through hole  65 . An additional fastener, such as a plastic attachment, may be added to secure the seat back frame  25  within the hole  65 . 
       FIG. 9D  depicts different side portions  58  along the height of the structural cover  50 . The space between the side portions  58  denotes the opening  52  of the structural cover  50 . 
       FIG. 9E  depicts a cross-sectional, vertical view of the structural cover  50 . The separation between the two portions of the structural cover  50  denotes the opening  52  of the structural cover  50  (the separation is shortened relative to the other figures for illustrative purposes). A top  66  is the top portion of the structural cover  50  and a bottom  68  is the bottom portion of the structural cover  50 . The configuration between the top  66  and the bottom  68  may vary according to the shape and size of the structural cover  50  and the seat back frame  25 . The top  66  and the bottom  68  may have lips to help attach to portions of the seat back frame  25 , the seat back  24 , or the foam  23 . 
       FIG. 9F  depicts a close-up view of a portion of the top  66  in  FIG. 9E . An attachment site  67  may be used to attach to the seat back frame  25  or another portion of the seat back  24 , such as the mesh structure  54  or the map pocket  26 . The portion of the seat back  24  may fit through or attach to hole  69 . There may be additional attachment sites through the structural cover  50  to secure items to the structural cover  50 . 
     The structural cover  50  may be constructed out of any material depending on the desired pricing, weight, rigidity, flexibility, hardness, or softness. For example, the materials may include (but are not limited to) plastic, metal, composites, alloys, or polymers. Further, the structural cover  50  may be constructed through a variety of techniques, including 3D printing. 
     Further, according to one embodiment, an exposed portion of the structural cover  50  may be covered in trim to match or correspond with the styling of the rest of the vehicle  20 . According to another embodiment, the exposed portion of the structural cover  50  may not require any trim to be attached. For example, the back surface of the structural cover  50  may exposed and the front surface of the structural cover  50  may face the rear surface  27  of the seat back frame  25  when the structural cover  50  is attached to the seat back frame  25 . Accordingly, the back surface of the structural cover  50  may not require any trim due to the design and/or material of the structural cover  50 . 
     The exact dimensions, configuration, and shape of the structural cover  50  (and various components, such as the opening  52 ) may be such that the depth of the seat back  24  is reduced (compared to using the back panel  30 ) and may be designed in or altered to any size, shape, or configuration in order to correspond and fit with any seat structure, seat back frame  25 , or seat back  24  and according to the desired configuration and styling of the vehicle (i.e. to match the the desired STO). Optionally, the structural cover  50  may be flexible to allow the structural cover  50  to contour to or fit onto any shape of seat back  24 . 
     The structural cover  50  may be attached to the seat back frame  25  through a variety of different mechanisms and methods.  FIGS. 10A-10E  depict the assembly of the structural cover  50  to the seat back frame  25 , according to one embodiment. First, as shown in  FIG. 10A , the hooks  62  on the structural cover  50  are at least partially be secured to, attached to, or hook around the upper cross member  42  of the seat back frame  25  through existing attachment points or locations. An edge or hook of the seat back frame  25  may be secured within the hooks  62 . Due to the configuration of the structural cover  50 , the foam  23  is not required on the back of the seat  22 . As shown in  FIG. 10B , the structural cover  50  is drawn in or angled towards the seat back frame  25  in order to be substantially parallel to, or conform to, the rear surface  27  of the seat back frame  25 . The bottom portion of the structural cover  50 , with the snaps  64 , is drawn in towards the bottom of the seat back frame  25  and the side portions  58  are drawn around the side of the seat back  24  (as shown in  FIG. 10D ) to allow the snaps  64  to snap to the lower cross member  44 .  FIG. 10C  shows the snaps  64  attached to the lower cross member  44  of the seat back frame  25 , fully securing the structural cover  50  along the seat back frame  25  and the seat back  24 .  FIG. 10D  shows a side view of the structural cover  50  attached to the seat back frame  25 .  FIG. 10E  shows the back view of the structural cover  50  attached to the seat back frame  25 . It is anticipated that the snaps  64  could correspond and attach to the upper cross member  42  and the hooks  62  could correspond and attach to the lower cross member  44 . 
     Additionally, the support or bladder system  53  may be attached to at least one of the seat back frame  25  or the structural cover  50  to allow the bladder system  53  to extend along the opening  52  of the structural cover  50  once the structural cover  50  is attached to the seat back frame  25 . The bladder system  53  may be attached through a variety of different mechanisms and methods including, but not limited to, hooks, snaps, and clips. 
     As utilized herein, the terms “approximately,” “about,” “substantially” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and are considered to be within the scope of the disclosure. 
     The embodiments disclosed herein reduce the thickness of a vehicle seat back while improving the safety of a vehicle seat and the overall design of the vehicle seat. Besides those embodiments depicted in the figures and described in the above description, other embodiments of the present invention are also contemplated. For example, any single feature of one embodiment of the present invention may be used in any other embodiment of the present invention. 
     Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present invention within the scope and spirit of the present invention are to be included as further embodiments of the present invention.