Seat support layer assembly
AssigneeLear Corporation
InventorsDirk Benthaus, Zvonko Van Der Meer
Life of this patent
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Abstract
A seat back assembly and method of manufacture is provided. The seat back includes a foam cushion layer. A support sub-assembly is formed including a rigid support layer with a plurality of cavities and channels defined on a rear surface for receiving components and a generally smooth front surface. At least one component is retained in one of the cavities and a second component is secured on the front surface of the support layer. A trim material covers the cushion layer and secures the sub-assembly to the seat back.
Claims18
A seat back assembly comprising:
- a seat back adapted to be mounted to a seat bottom, the seat back comprising:
- a foam cushion layer;
- a support sub-assembly comprising:
- a rigid support layer formed of structural foam, providing structural support for the seat back assembly;
- and
- at least one component retained on the rigid support layer,
- wherein the support sub-assembly is retained in the seat back assembly without any fasteners attached to the rigid support layer.
A vehicle seat assembly comprising:
- a seat back configured for attachment to a vehicle and having a foam cushion layer defining a seating surface;
- a rigid expanded polymer layer disposed adjacent the foam cushion layer and providing structural support for the seat back;
- an inflatable support system retained on the rigid expanded polymer layer, wherein the inflatable support system comprises:
- an air pump retained in at least one cavity defined along a rear surface of the rigid expanded polymer layer with an interference fit;
- and
- at least one air bladder mounted to a front surface of the rigid expanded polymer layer;
- and
- a trim material covering the foam cushion layer and securing the rigid expanded polymer layer to the seat back,
- wherein the rigid expanded polymer layer is retained in the seat back without any fasteners attached to the rigid expanded polymer layer.
A method of manufacturing a seat back:
- molding a rigid support layer of structural foam for providing structural support for a seat back;
- forming a sub-assembly by retaining at least one component on the rigid support layer without any fasteners;
- positioning a cushion layer on the sub-assembly so that that the cushion layer covers at least a front surface of the rigid support layer;
- securing a trim material over the cushion layer such that the sub-assembly is retained in the seat back without any fasteners attached to the rigid support layer.
Dependencies are inferred from the claim text.