# US 10,501,190 B2 · Method for homogenous thermoplastic seat back assembly

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- Number: US 10,501,190 B2
- Document ID: US10501190B2
- Status: Granted
- Kind: B2
- Application number: 15/921,423
- Filed: 2018-03-14
- Published: 2018-09-27
- Granted: 2019-12-10
- Earliest claimed: 2014-05-02
- Assignees: Reliant Worldwide Plastics, LLC
- Applicants: Reliant Worldwide Plastics, LLC
- Inventors: William H. Maslakow
- Web page: https://patentgrep.com/patent/US10501190B2

## CPC

- B64D 11/0649: {Seats characterised by special features for reducing weight}
- B29C 45/14311: {using means for bonding the coating to the articles (B29C45/14795 takes precedence)}
- B29C 45/14786: {Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material}
- B60N 2/64: Back-rests {or cushions (B60N2/2222 takes precedence)}
- B60N 2/68: Seat frames
- B60N 2/682: {Joining means}
- B60N 2/686: {Panel like structures}
- B64D 11/0647: {Seats characterised by special upholstery or cushioning features}
- B29C 2045/14319: {bonding by a fusion bond}
- B29K 2703/00: Use of resin-bonded materials for preformed parts, e.g. inserts
- B29L 2031/771: {Seats}
- Y02T 50/40: Weight reduction
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B60N: SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A seat back assembly that includes a composite seat back cover. The composite seat back cover includes at least one composite layer, that includes a layer of reinforcing fibers and a thermoplastic layer surrounding the reinforcing fibers. The thermoplastic layer is coextensive with the layer of reinforcing fibers. In various embodiments, the seat back includes a seat back frame. The seat back frame includes a side rail, a top rail main section, and a top rail cap. The side rail, the top rail main section, and the top rail cap are fused to each other by a homogenous chemical bond. A homogenous chemical bond is formed between the seat back cover and the seat back frame creating a unitary seat back assembly.

## Claims

### Claim 1

A method of forming a thermoplastic homogenous seat back assembly, the method comprising:
forming a thermoplastic seat back cover;
assembling a thermoplastic seat back frame;
arranging the seat back frame on the seat back cover;
forming a homogenous chemical bond between the seat back cover and the seat back frame; and
wherein the assembling the seat back frame comprises:
assembling a side rail to a top rail main section and a top rail cap;
injecting thermoplastic material such that a homogenous chemical bond is formed
between the side rail, the top rail main section, and the top rail cap.

### Claim 2 (depends on 1)

The method of claim 1, wherein the forming the seat back cover comprises:
shaping a first composite layer into a shape of a seat back cover;
shaping a second composite layer into a shape of a seat back, the second composite layer being chemically compatible with the first composite layer; and
applying at least one of heat and pressure to the first composite layer and the second composite layer to create a homogenous chemical bond between the first composite layer and the second composite layer.

### Claim 3 (depends on 2)

The method of claim 2, wherein the shaping the first composite layer and the shaping sharing the second composite layer comprise forming a perimeter flange in the first composite layer and the second composite layer.

### Claim 4 (depends on 1)

The method of claim 1, comprising applying an outer layer to at least one of the first composite layer and the second composite layer.

### Claim 5 (depends on 4)

The method of claim 4, comprising applying at least one of color and texture to the outer layer.

### Claim 6 (depends on 1)

The method of claim 1, wherein at least one of the first composite layer and the second composite layer comprise a plurality of reinforcing fibers oriented in a plurality of directions.

### Claim 7 (depends on 1)

The method of claim 1, wherein the forming the seat back cover comprises utilizing injection molding.

### Claim 8 (depends on 1)

The method of claim 1, wherein the forming the seat back cover comprises applying at least one of color and texture to the seat back cover.

### Claim 9 (depends on 1)

The method of claim 1, wherein the forming the seat back cover comprises utilizing an integrated thermoplastic positioning system.