Patent Description:
Conventional vehicle seat systems include a seat back assembly connected to a seat base assembly and a headrest assembly connected to the seat back assembly. The assemblies of the seat system typically comprise foam parts. Such foam parts serve as padding for the seat system and provide an occupant of the seat system with a desired level of seating comfort. Generally, the seat system includes a foam part for the seat base assembly and a foam part separate therefrom for the seat back assembly. Each of the two foam parts has a central region and two side bolsters. In the foam part for the seat base assembly, a central region of the foam part supports an underside of a buttocks and a rear thigh region of the occupant, whilst the two side bolsters laterally bear against a respective one of the thighs of the occupant. As a result, the two side bolsters able to absorb transverse forces on the occupant, in particular during cornering. In the foam part for the seat back assembly, a central region of the foam part supports a back of the occupant, whilst the two side bolsters laterally bear against the back and, as a result, are able to absorb transverse forces on the occupant. The foam parts may comprise one or more layers, each having a certain hardness and density. The foam parts may include a plurality of holes formed in the central region for improving properties of the seat system such as to convey moisture or permit a desired compression thereof, for example.

Typically, the foam parts of the seat system are formed from a polyurethane material. A drawback of the polyurethane material is that it adheres to various forming tools used in a forming process of the foam parts. For example, as the foam part is formed, the polyurethane material, and thereby the foam part, undesirably adheres to a mold used to produce the foam parts of the seat system and ventilation pins disposed in the mold for degassing purposes. Currently, a mold release material is deposited over surfaces of the tools (e.g. the mold and the ventilation pins) to combat the undesired adhesion of the polyurethane material.

<CIT>, <CIT> and <CIT> each disclose a coated forming tool for producing a part of a seat system, comprising a mold assembly configured to form at least a portion of the part of the seat system; and a coating deposited over at least a portion of a surface of the mold assembly, wherein the coating comprises a nonstick material.

The coating disclosed in <CIT> has a thickness in a range of <NUM> to <NUM> or <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>. <NUM> to <NUM> or <NUM> to <NUM>.

The coating disclosed in <CIT> has a thickness in a range of <NUM> and <NUM>, in particular <NUM> and <NUM> or <NUM> to <NUM>.

The invention addresses the problem of producing a coated forming tool, which simplifies manufacturability and decreases costs, while improving ease of maintenance.

In concordance and agreement with the present disclosure, a coated forming tool, which simplifies manufacturability and decreases costs, while improving ease of maintenance, has surprisingly been discovered.

In one embodiment, a coated forming tool, as defined in claim <NUM>, for producing a part of a seat system comprising: a mold assembly configured to form at least a portion of the part of the seat system; and a coating deposited over at least a portion of a surface of the mold assembly, wherein the coating comprises a nonstick material.

In another embodiment, a method, as defined in claim <NUM>, of producing a part of a seat system, comprises: providing at least one forming tool having a cavity formed therein, wherein the at least one forming tool includes a coating deposited over at least a portion of a surface thereof, and wherein the coating comprises at least one of a nonstick material and; disposing a forming material into at least a portion of the cavity of the at least one forming tool; and forming the part of the seat system by an expansion of the material in the at least one forming tool.

As aspects of certain embodiments, the coating comprises at least a polytetrafluroethylene (PTFE) material.

The coating has a thickness in a range of about <NUM> (<NUM> thousandths of an inch (<NUM> mils)) to about <NUM> (<NUM> thousandths of an inch (<NUM> mils)).

As aspects of certain embodiments, the mold assembly includes an upper mold and a lower mold configured to cooperate with the upper mold to form a cavity therebetween, and wherein the cavity has a shape, size, and configuration to produce the at least a portion of the part of the seat system.

As aspects of certain embodiments, the at least a portion of the part of the seat system is a cushioning member configured to be disposed on a seat frame of the seat system.

As aspects of certain embodiments, the at least a portion of the part is produced from a polypropylene material.

As aspects of certain embodiments, further comprising at least one ventilation component configured to cooperate with the mold assembly.

As aspects of certain embodiments, the at least one ventilation component includes a coating deposited over at least a portion of a surface thereof.

As aspects of certain embodiments, the coating of the at least one ventilation component comprises a nonstick material.

As aspects of certain embodiments, the coating of the at least one ventilation component comprises at least a polytetrafluroethylene (PTFE) material.

As aspects of certain embodiments, the coating of the at least one ventilation component has a thickness in a range of about <NUM> (<NUM> thousandths of an inch (<NUM> mils) to about <NUM> (<NUM> thousandths of an inch (<NUM> mils)).

The method may include a step of providing at least one forming tool including a cavity having a coating. Furthermore, the method may include a step of disposing a forming material within at least a portion of the cavity. Furthermore, the method may include a step of forming a formed part from expansion of the forming material. Different step sequences are possible. Intermediate steps are possible.

The accompanying drawings are incorporated herein as part of the specification. The drawings described herein illustrate advantageous embodiments of the presently disclosed invention and are illustrative of selected principles and teachings of the present disclosure. However, the drawings do not illustrate all possible implementations of the presently disclosed subject matter, and are not intended to limit the scope of the present disclosure in any way.

It is to be understood that the presently disclosed subject matter may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

<FIG> shows a seat system <NUM> for a motor vehicle (not depicted) according to an embodiment of the presently described subject matter. The seat system <NUM> may comprise a seat base assembly <NUM>, a seat back assembly <NUM>, and a headrest assembly <NUM>. The seat back assembly <NUM> may be coupled to the seat base assembly <NUM> and the headrest assembly <NUM>. In certain embodiments, the seat base assembly <NUM> may be movable relative to a floorboard of the vehicle, the seat back assembly <NUM> may be movable relative to the seat base assembly <NUM>, and the headrest assembly <NUM> may be movable relative to the seat back assembly <NUM>. The seat base assembly <NUM> may be configured to support a buttock portion and thigh portion of an occupant.

The seat back assembly <NUM> may be configured to support a back region of the occupant.

In certain embodiments, each of the seat base assembly <NUM>, the seat back assembly <NUM>, and the headrest assembly <NUM> may include a formed part <NUM> (e.g. a foam part, a printed part, and the like, etc.) disposed on a seat structure (not depicted) and a seat cover <NUM> disposed over the formed part <NUM>. Additional formed parts <NUM> may be used in the seat base assembly <NUM>, the seat back assembly <NUM>, and the headrest assembly <NUM>, if desired. The formed parts <NUM> may be produced from any suitable forming material as desired such as a polyurethane material and a polymer material, for example. Preferably, each of the formed parts <NUM> may be produced from an expandable polyurethane material or resin. It should be appreciated that each of the formed parts <NUM> may have any size, shape, configuration, and thickness as desired.

A method <NUM> for producing the formed part <NUM> shown in <FIG> will be described hereinafter. It is understood that other methods for producing the formed part <NUM> may be employed as desired. The method <NUM> employs at least one forming tool <NUM> for producing at least a portion of the formed part <NUM>. In an embodiment show in <FIG>, the at least one forming tool <NUM> may be or comprise a mold assembly <NUM>. The mold assembly <NUM> may include an upper first mold <NUM> and a lower second mold <NUM>. The mold assembly <NUM> may include more or less molds than shown, if desired. In other embodiments, the at least one forming tool <NUM> may be the mold assembly <NUM> including at least one ventilation component (e.g. a pin <NUM> shown in <FIG> and/or a port element <NUM> shown in <FIG>), disposed therein. It should be appreciated that each of the molds <NUM>, <NUM> and the at least one ventilation components <NUM>, <NUM> may be formed from any suitable material as desired such as a metal material (e.g. aluminum material), for example. In yet another embodiment, the at least one forming tool <NUM> may be a three-dimensional printing machine (not depicted) configured to produce a printed formed part <NUM>.

A cavity <NUM> may be defined in at least one of the molds <NUM>, <NUM> or between the molds <NUM>, <NUM> when the molds <NUM>, <NUM> are closed. The cavity <NUM> has any suitable size, shape, and configuration to allow for an expansion of the forming material, and thereby a molding of the formed part <NUM> when the molds <NUM>, <NUM> are closed. In certain embodiments, the cavity <NUM> is of a size, shape, and configuration of a cushioning member for a vehicle seat.

A coating <NUM> may be deposited over at least a portion of a surface <NUM> of the at least one forming tool <NUM>. In certain embodiments, the coating <NUM> may be deposited over at least a portion of a surface <NUM> of at least one of the first mold <NUM> and the second mold <NUM> of the mold assembly <NUM> shown in <FIG>. In other embodiments, the coating <NUM> may also be deposited over at least a portion of a surface <NUM> of the pin <NUM>, as shown in <FIG>. In yet other embodiments, the coating <NUM> may also be deposited over at least a portion of a surface <NUM> of the port element <NUM>, shown in <FIG>. In yet further embodiments, the coating <NUM> may be deposited over at least a portion of a surface of the three-dimensional printing machine. The coating <NUM> may be deposited over the at least a portion of the surface <NUM> of the mold assembly <NUM>, the surfaces <NUM>, <NUM> of the ventilation components <NUM>, <NUM>, respectively, and/or the surface of the three-dimensional printing machine by any suitable means such as chemical vapor deposition (CVD), physical vapor deposition (PVD), high velocity oxygen fuel coating process, plasma or thermal spray, and the like, for example. The coating <NUM> militates against an adhesion of the forming material to the at least one forming tool <NUM>. More particularly, the coating <NUM> may militate against an adhesion of the forming material to the at least one forming tool <NUM> by sealing the surface <NUM> of the mold assembly <NUM>, the surfaces <NUM>, <NUM> of the ventilation components <NUM>, <NUM>, respectively, and/or the surface of the three-dimensional printing machine. This sealing of the surfaces is especially critical at thinner areas, areas with tighter radiuses, and/or other areas of the at least one forming tool <NUM> and the at least one ventilation component <NUM>, <NUM> where undesired adhesion of the forming material is likely. Accordingly, the coating <NUM> may also reduce volatile organic compound (VOC) emissions, scrap, repair and labor, and failure frequency of the at least one ventilation component <NUM>, <NUM>.

The coating <NUM> comprises a nonstick material. Various nonstick materials may be used for the coating <NUM>. In certain embodiments, the coating <NUM> may comprise a polytetrafluoroethylene (PTFE) material such as Teflon® made by Chemours™, for example. In other embodiments, the coating <NUM> may comprise an ecological coating material such as a coating produced by Cerakote, for example. The coating <NUM> has a thickness in a range of about <NUM> (<NUM> thousandths of an inch (<NUM> mils)) to about <NUM> (<NUM> thousandths of an inch (<NUM> mils)) Preferably, the coating <NUM> has a thickness of about <NUM> (<NUM> thousandths of an inch (<NUM> mils)) to about <NUM> (<NUM> thousandths of an inch (<NUM> mils)) to allow the formed part <NUM> to be easily removed from the coated forming tool <NUM> without affecting the method <NUM> of forming or a final formed part <NUM>.

Claim 1:
A coated forming tool (<NUM>) for producing a part of a seat system (<NUM>), comprising:
a mold assembly (<NUM>) configured to form at least a portion of the part of the seat system (<NUM>); and
a coating (<NUM>) deposited over at least a portion of a surface (<NUM>, <NUM>, <NUM>) of the mold assembly (<NUM>), wherein the coating (<NUM>) comprises a nonstick material,
characterized in that
the coating (<NUM>) has a thickness in a range of about <NUM> (<NUM><NUM> thousandths of an inch (<NUM> mils)) to about <NUM> (<NUM> thousandths of an inch (<NUM> mils)).