Composite seat structure

Abstract

A vehicle seating assembly is provided that includes a seatback and a seat base operably connected to the seatback. The seat base includes a seat base frame having a rear tube extending laterally between at least two side members, a seat cushion assembly, and a composite seat pan positioned between the seat cushion assembly and the seat base frame and having a plurality of recessed features configured to couple over the rear tube and side members. The seat pan integrally defines a flexible cross bar extending laterally between the recessed features. A plurality of hooks integrally defined by the seat pan are operably coupled to the seat cushion assembly.

Description

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a vehicle seating assembly, and more particularly to the seat structure for a vehicle seat.

BACKGROUND OF THE DISCLOSURE

Modern vehicle seats are becoming more and more comfortable as a further understanding of human ergonomics, posture, and comfortability is studied. Vehicle seating assemblies that include comfort components in the vehicle seatback and the vehicle seat can provide the driver and passengers with improved comfort and increased endurance for extensive vehicle rides. Additionally, safety concerns for passengers during collision events are considered in vehicle seat design. Accordingly, vehicle seating assemblies that include components to accommodate the different sizes and shapes of drivers and passengers, as well as maintain safety of drivers and passengers, have become increasingly important.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, a vehicle seating assembly is provided that includes a seatback and a seat base operably connected to the seatback. The seat base includes a seat base frame having a rear tube extending laterally between at least two side members, a seat cushion assembly, and a composite seat pan positioned between the seat cushion assembly and the seat base frame and having a plurality of recessed features configured to couple over the rear tube and side members. The seat pan integrally defines a flexible cross bar extending laterally between the recessed features. A plurality of hooks integrally defined by the seat pan are operably coupled to the seat cushion assembly.

According to another aspect of the present disclosure, a vehicle seat base is provided that includes a seat base frame having at least two side members, a seat cushion assembly, and a seat pan positioned between and operably coupled to both the seat base frame and the seat cushion assembly. The seat pan integrally defines a cross bar extending between the two side members. The cross bar is configured to flex laterally and vertically.

According to yet another aspect of the present disclosure, a vehicle seat base is provided that includes a seat base frame having a rear tube extending laterally across the frame between two side members and a seat pan defining a plurality of recessed features configured to operably couple with the rear tube and the side members such that the seat frame is at least partially nested within the seat pan.

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 top perspective view of a vehicle seating assembly of the present disclosure disposed in a vehicle;

FIG. 2 is an enlarged top perspective view of the vehicle seating assembly of FIG. 1;

FIG. 3 is a top perspective partial exploded view of a seat of the vehicle seating assembly of the present disclosure;

FIG. 4A is a top perspective view of a seat pan of the present disclosure;

FIG. 4B is an enhanced top view of the seat pan of the present disclosure;

FIG. 4C is a bottom perspective view of the seat pan of the present disclosure; and

FIG. 5 is a top perspective view of the seat pan of FIG. 4A coupled with a seat frame of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the present embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof, shall relate to the disclosure as oriented in FIG. 1, unless stated otherwise. However, it is to be understood that the 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. Additionally, embodiments depicted in the figures may not be to scale or may incorporate features of more than one embodiment.

As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring to the examples illustrated in FIGS. 1-5, reference numeral 10 generally designates a vehicle which includes a seating assembly 14. The seating assembly 14 includes a seatback 18 and a seat base 22 operably connected to the seatback 18. The seat base 22 includes a seat base frame 26 having a rear tube 30 extending laterally between at least two side members 34. The seat base 22 further includes a seat cushion assembly 38 and a seat pan 42. The seat pan 42 is positioned between the seat cushion assembly 38 and the seat base frame 26. The seat pan 42 has a plurality of recessed features 46 configured to couple over the rear tube 30 and side members 34. The seat pan 42 integrally defines a flexible cross bar 50 extending laterally between the recessed features 46. A plurality of hooks 54 may be integrally defined by the seat pan 42 and may operably couple the seat pan 42 to the seat cushion assembly 38.

Referring now to FIGS. 1-3, the illustrated vehicle seating assembly 14 is configured for use in a vehicle of any type, including, without limitation, cars, vans, trucks, buses, etc. The vehicle seating assembly 14 is suspended on rails 62 that allow movement of the vehicle seating assembly 14 in fore and aft directions within the vehicle 10. In addition, the vehicle seating assembly 14 may include a variety of comfort controls, including, for example, thigh support using independent thigh supports 66, lumbar support, and upper thoracic support. The seatback 18 includes both an upper seatback 70 and a lower seatback 74. The vehicle seating assembly 14 includes a head restraint 78 that is disposed on the upper seatback 70. The head restraint 78 is moveable between forward and rearward positions to accommodate various sized heads of passengers, as well as different heights of passengers. The vehicle seating assembly 14 also includes controls specifically configured to adjust an upper thoracic portion 82 of the upper seatback 70 or a lower thoracic portion 86 of the lower seatback 74.

The seat base 22 includes the seat pan 42 that is operably coupled with the seat base frame 26, and which is configured to support the seat cushion assembly 38 and a cover stock 94 disposed thereon. The seat pan 42 is positioned between the seat base frame 26 and the seat cushion assembly 38. A climate control system may be provided, which can draw air from, or blow air through, the seat cushion assembly 38 and cover stock 94. The seat cushion assembly 38 includes a main cushion 98, seat side bolsters 102 and forward thigh support cushions 106. The thigh support cushions 106 are configured to wrap over the thigh supports 66 to provide comfort while supporting the passenger's thighs. The main cushion 98 and/or side bolsters 102 may include a plurality of ventilation holes 110 configured to allow air to pass through the seat base 22. Disposed between the seat pan 42 and the seat cushion assembly 38 is a suspension member 114 configured to provide support to a passenger in the seating assembly 14. The suspension member 114 includes a plurality of suspension hooks 116 positioned at a rear of the suspension member 114.

With further reference to FIG. 3, the vehicle seating assembly 14 includes the seat base 22. The seatback 18 (FIG. 2) is operably coupled to a rear of the seat base 22. Each of the first and second independently moveable thigh supports 66 are independently laterally translatable forward and rearward relative to the seat base 22. A spring assembly may be used to urge each thigh support 66 to a fully forward lateral position. Each of the first and second independently moveable thigh supports 66 are rotatable relative to the seat base 22. The thigh supports 66 may be coupled to the seat pan 42 at thigh attachment points 118 positioned on a vehicle forward location of the seat pan 42. The thigh attachment points 118 may be integrally defined by the seat pan 42 or may be coupled thereto. As noted above, the thigh supports 66 are configured to rotate upward and downward relative to the seat base 22 between raised and lowered positions, and are also configured to translate laterally between extended and retracted positions relative to the seat base 22. The moveable thigh supports 66 are independent such that one thigh support 66 may be at the raised position, while the other thigh support 66 may be at the lowered position, or at any position in between the raised and lowered positions.

Referring now to FIG. 4A, the seat pan 42 may be formed of a metal, plastic, or composite material. In composite material examples of the seat pan 42, the seat pan 42 may be formed of a fiber filler and resin combination. The fiber filler volume fraction within the resin may be between about 1% and about 60%, or between about 15% and about 40%, or between about 30% and about 40%. In a specific example, the fiber filler volume fraction within the seat pan 42 may be about 35%. The fibers may be composed of materials including carbons, aramids, aluminum metals, aluminum oxides, steels, borons, silicas, silicon carbides, silicon nitrides, ultra-high-molecular-weight polyethylenes, A-glasses, E-glasses, E-CR-glasses, C-glasses, D-glasses, R-glasses, and S-glasses. The fibers may be continuous or chopped to a particular length. The length of the chopped fibers can be between about 1 mm and about 20 mm, or between about 3 mm and about 11 mm, or between about 5 mm and about 7 mm. Typically, the fibers are randomly oriented in the resins within the seat pan 42. However, the fibers may also be substantially aligned directionally in areas of the seat pan 42 subject to high directional stresses or areas of anticipated stress (e.g., connections or transitions between parts of the seat pan 42). The seat pan 42 may incorporate one or more preformed fiber mats which may include woven or non-woven fibers that are held together using the same or different resins as employed in the seat pan 42. The resin employed in the seat pan 42 may include a nylon, a polypropylene, an epoxy, a polyester, a vinyl ester, a polyetheretherketone, a poly(phenylene sulfide), a polyetherimide, a polycarbonate, a silicone, a polyimide, a poly(ether sulfone), a melamine-formaldehyde, a phenol-formaldehyde, and a polybenzimidazole, or combinations thereof. The use of a composite material such as a fiber filled resin may allow the seat pan 42 to be formed via injection molding, thermoforming, and other processes for forming a polymeric member. The use of a fiber composite material for the seat pan 42 may allow for increased durability and fatigue loading of the seat pan 42.

In the depicted example, the seat pan 42 includes side bolsters 126. The side bolsters 126 may be integrally formed with the seat pan 42 or may be attached thereto. The side bolsters 126 are configured to support and flex under stress to provide resiliency to the seat side bolsters 102 (FIG. 3). Additionally, integrally forming the side bolsters 126 with the seat pan 42 increases the structural support for the passenger during ingress/egress from the seating assembly 14, as well as during jounce and abuse loading circumstances. The side bolsters 126 are configured to deflect or flex in an X-direction, a Y-direction, and/or a Z-direction. The side bolsters 126 may deflect greater than about 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or greater than about 100 mm in any or all of the X-, Y-, or Z-directions without breaking or breakage during a stress or loading event (e.g., front end collision of the vehicle 10 or movement of a passenger within the seating assembly 14 of FIG. 1). Extending across the seat pan 42 and between the recessed features 46 is the cross bar 50. The cross bar 50 may include a wall 134 and a plurality of ribs 138. The plurality of ribs 138 extend in a direction perpendicular to that of the wall 134. The positioning of the ribs 138 along the wall 134 provides a stress relief design for the cross bar 50 such that it may flex or deflect. The cross bar 50 may take a variety of cross-sectional shapes including square, rectangular, circular, ellipsoid, or other shapes configured to define the wall 134. The cross bar 50 is configured to deflect or flex in the X-direction, the Y-direction, and the Z-direction. The cross bar 50 may deflect greater than about 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or greater than about 100 mm, in any or all of the X-, Y-, or Z-directions without breaking or breakage during a stress or loading event (e.g., a front end collision) under temperature conditions as high as 70° C. and humidity as high as 60%. In some examples, the temperature and/or humidity of the environment surrounding the seat pan 42 may affect (e.g., increase) the deflection amount of the cross bar 50. By configuring the cross bar 50 to be flexible, it allows the cross bar 50 to deflect during an impact or sudden deceleration event for the vehicle 10. During forward impact or sudden deceleration of the vehicle 10, a passenger of the seating assembly 14 may be forced into the seat base 22 (FIG. 1) due to continued forward motion of the passenger relative to the seating assembly 14. Movement of the passenger into the seat base 22 may cause submarining, or movement of the passenger below a safety belt of the seating assembly, to occur. By configuring the cross bar 50 to flex and deflect under stress, but not break, a passenger of the seating assembly 14 may be decelerated safely such that submarining is minimized or eliminated.

As explained above, the seat pan 42 defines a plurality of hooks 54 disposed about the seat pan 42. In the depicted example, each of the side bolsters 126 integrally define a pair of rearward hooks 144. In other examples, the rearward hooks 144 may be otherwise joined to the side bolsters 126. The rearward hooks 144 are configured to face in a vehicle rearward direction and are configured to engage the seat cushion assembly 38 of FIG. 3 and retain it against the seat pan 42. The seat cushion assembly 38 may define a plurality of recesses or retention features on an underside of the main cushion 98 and seat side bolsters 102 configured to engage and retain the rearward hooks 144. Additionally, the rearward facing nature of the rearward hooks 144 resists the motion of the seat cushion assembly 38 in a vehicle forward direction during an impact or sudden deceleration event. In some examples, the rearward hooks 144 may include a snap feature such that the seat cushion assembly 38 is locked to the seat pan 42. In addition to the rearward hooks 144, the plurality of hooks 54 also include at least one downward hook 152. In the depicted example, the seat pan 42 integrally defines two downward hooks 152. The downward hooks 152 include an angled surface 156 and a retention lip 160. The downward hooks 152 are configured to retain the seat cushions assembly 38 downward against the seat pan 42. During an exemplary assembly method of the seat cushion assembly 38 to the seat pan 42, the seat cushion assembly 38 is engaged (e.g., snapped) to the rearward hooks 144 by applying vehicle forward motion to the seat cushion assembly 38. Once the seat cushion assembly 38 is attached to the rearward hooks 144, the rear of the seat cushion assembly 38 is forced downward under the downward hooks 152. During the downward motion of the seat cushion assembly 38, the seat cushion assembly 38 contacts and slides along the angled surface 156. The seat cushion assembly 38 is then slid under the retention lip 160. The retention lip 160 extends over the seat cushion assembly 38 such that the seat cushion assembly 38 is rotationally and vertically locked under the downward hooks 152.

Referring now to FIGS. 4A-4C and 5, in addition to the plurality of hooks 54 and the cross bar 50, the seat pan 42 additionally defines the plurality of recessed features 46. The plurality of recessed features 46 include a rear recessed feature 168 and side recessed features 172. The rear recessed feature 168 extends the width of the seat pan 42 and has a generally curved structure. The curved structure of the rear recessed feature 168 is configured to couple with the rear tube 30 of the seat base frame 26. The rear recessed feature 168 is configured to partially surround, or nest, over the rear tube 30 such that the rear tube 30 supports the seat pan 42 through the rear recessed feature 168. The rear tube 30 may be any lateral cross member that is hollow or solid, and may take a variety of cross-sectional shapes including rectangular, square, circular, ellipsoid or others configured to provide structural rigidity to the seat base frame 26. In examples where the rear tube 30 is a shape other than circular, the rear recessed feature 168 may be complimentarily shaped to couple or nest over the rear tube 30. As depicted, the downward hooks 152 are defined on the rear recessed feature 168. Additionally, the rear recessed feature 168 may define one or more attachment apertures 176 which may be utilized with a fastener for securing the rear recessed feature 168 to the rear tube 30. The rear recessed feature 168 defines a plurality of locking features 178. The locking features 178, in the depicted example, include a plurality of teeth. The locking features 178 protrude into the recessed portion of the rear recessed feature 168 and are configured to engage the rear tube 30 (FIG. 3). The locking features 178 define upwardly curved surfaces 178A configured to mate with the rear tube 30. The upwardly curved surfaces 178A extend partially under the rear tube 30, such that the rear tube 30 may be snap fit into the rear recessed feature 168 and the seat pan 42 is secured to the seat base frame 26. Additionally or alternatively, the locking features 178 may be used to help locate the seat pan 42 onto the correct location on the rear tube 30. Further, the rear recessed feature 168 defines a plurality of locking apertures 178B which may allow one or more fasteners to fasten the seat pan 42 to the rear tube 30. In another example, a portion of the rear tube 30 may extend through the locking apertures 178B.

Further, the rear recessed feature 168 may define one or more suspension attachment features 170. The suspension attachment features 170 include a suspension clip 170A, a suspension channel 170B, and a suspension retainer 170C. The suspension attachment features 170 are configured to engage the suspension hooks 116. The suspension clips 170A may be snap features, clips, hook and loop attachments or other features configured to grip the suspension hooks 116 to provide retention between the suspension member 114 and the seat pan 42. The suspension channels 170B are sized to accept the suspension hooks 116 to create a low profile appearance. The suspension hooks 116 wrap over the rear recessed feature 168 through the suspension channel 170B and suspension clips 170A, and engage the suspension retainers 170C. The suspension retainers 170C retain the ends of the suspension hooks 116 in place. Positioned proximate the suspension retainers 170C are retaining flanges 182. The retaining flanges 182 are configured to accept a fastener to further secure the seat pan 42 to the seat base frame 26 or other seating relating structures. Positioned on top of the rear recessed feature 168 may be a plurality of fasteners 184.

The side recessed features 172 are positioned proximate the side bolsters 126 along sides of the seat pan 42. The side recessed features 172 are shaped complimentary to that of the side members 34 and have sufficient width such that the side recessed features 172 may couple over, or nest on, the side members 34. The side recessed features 172 may define attachment points 180 through which a bolt or other fastener may be used to secure the seat pan 42 to the side members 34 of the seat base frame 26. Cooperation of the bolts or fasteners through the attachment points 180 and the attachment apertures 176 aid in securing the seat pan 42 to the seat frame 26.

Use of the recessed features 46 may allow for easy assembly of the seat pan 42 to the seat frame 26. In an exemplary assembly method, the seat pan 42 is positioned over the seat frame 26 such that the recessed features 46 are aligned with the side members 34 and the rear tube 30. The seat pan 42 is then placed on the seat frame 26 such that the recessed features 46 are nested on the side members 34 and the rear tube 30. Finally, fasteners may be secured through the attachment points 180 and the attachment apertures 176 to secure the seat pan 42 to the seat frame 26.

Use of the present disclosure may offer several advantages. For example, use of the present disclosure may allow the seating assembly 14 to meet various testing standards including static strength, dynamic strength, vibration and durability/fatigue, dynamic pulses, safety crashes, passenger jounce as well as ingress/egress, squeak/rattle, abuse loading, thigh support, life cycle and others. Additionally, use of the present disclosure may increase the modularity of the seating assembly 14 which may decrease costs associated with shipping, overhead, and assembly while correspondingly increasing the customization of the seating assembly 14. Further, the present disclosure may offer a weight neutral or weight savings alternative as compared to traditional seating assemblies while increasing structural performance. Finally, use of the composite seat pan 42 structure allows for the integral molding of connection and attachment points for electrical, mechanical and/or pneumatic systems which may save on assembly time, cost, packaging space, and weight, as well as manufacturing cost.

It will be understood by one having ordinary skill in the art that construction of the described 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 moveable 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.

It is also important to note that the construction and arrangement of the elements of the 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 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 conditions, 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 disclosure, 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.

Claims

1. A vehicle seat base comprising: a seat base frame having two side members and a rear tube;a seat cushion assembly; anda seat pan coupled to the seat cushion assembly, the seat pan comprising a one-piece frame element comprising two opposing side elements, a pair of side bolsters extending upwardly and outwardly from the side elements, a front cross bar and a rear cross bar, wherein the side elements and the rear cross bar define recesses opening downward on an underside and configured to receive the side members and rear tube, respectively; andwherein the seat pan comprises a suspension member having hooks extending over a top of the rear cross bar to support the suspension member in the seat pan.

2. The vehicle seat base of claim 1, wherein the front cross bar is positioned at a vehicle forward location on the seat pan.

3. The vehicle seat base of claim 1, wherein the front cross bar is configured to deflect greater than about 30 mm in a vertical direction before breakage.

4. The vehicle seat base of claim 3, wherein the front cross bar is configured to deflect greater than about 50 mm in a vertical direction before breakage.

5. The vehicle seat base of claim 1, wherein the front cross bar comprises a plurality of ribs spaced along the cross bar.

6. The vehicle seat base of claim 1, wherein the seat pan integrally defines a plurality of hooks configured to attach the seat cushion to the seat pan.

7. The vehicle seat base of claim 1, wherein a portion of the hooks are vehicle rear facing.

8. A vehicle seat base comprising: a seat base frame having a rear tube extending between two side members;a seat pan comprising a one-piece frame element having two side elements and a cross bar extending between the two side elements, the cross bar and the two side elements respectively having recessed features into which the rear tube and the side members nest, wherein the seat pan comprises two side bolsters that extend upwardly and outwardly from the two side elements, respectively; andwherein the seat pan comprises a suspension member having hooks engaging a top of the cross bar to support the suspension member in the seat pan.

9. The vehicle seat base of claim 8, wherein the seat pan defines at least one retaining hook on at least one of the recessed features.

10. The vehicle seat base of claim 8, wherein at least one of the recessed features is positioned on an outboard side of the seat pan.

11. The vehicle seat base of claim 8, further comprising: a front cross bar extending between the two side members, the front cross bar configured to flex.

12. The vehicle seat base of claim 9, wherein the front cross bar is configured to deflect greater than about 30 mm in a vertical deflection before breakage.