Seat back including integrated backrest and reinforcing composite layer

A seat back comprising:

• a backrest formed of a first polymeric material for supporting an occupant;
• a bracket anchored to said backrest for coupling to a seat cushion and formed of a second material different than said first polymeric material of said backrest;
• a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• and
• wherein said bracket and said reinforcing composite layer each present an inner surface opposing each other and an opposite facing outer surface and wherein said first polymeric material covers at least a portion of one of the outer surfaces to form an uncovered aesthetic show surface.

A seat back comprising:

• a backrest formed of a first polymeric material for supporting an occupant;
• a bracket anchored to said backrest for coupling to a seat cushion and formed of a second material different than said first polymeric material of said backrest;
• a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• and
• wherein said first polymeric material defines a first pillar, a second pillar spaced from said first pillar, and a middle section extending from said first pillar to said second pillar with said reinforcing composite layer elongated in a vertical direction along said first pillar.

A seat back comprising:

• a backrest formed of a first polymeric material for supporting an occupant;
• a bracket anchored to said backrest for coupling to a seat cushion and formed of a second material different than said first polymeric material of said backrest;
• a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• and
• wherein said bracket and said reinforcing composite layer each presents an inner surface opposing each other and an opposite facing outer surface free of first polymeric material and further comprising a mounting bracket abutting said outer surface of said bracket for connecting the bracket to the seat cushion;
• and
• wherein said first polymeric material covers at least a portion of one of the outer surfaces to form an uncovered aesthetic show surface.

A seat back comprising:

• a backrest formed of a first polymeric material for supporting an occupant;
• a bracket anchored to said backrest for coupling to a seat cushion and formed of a second material different than said first polymeric material of said backrest;
• a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• wherein said first polymeric material defines a first pillar, a second pillar spaced from said first pillar, and a middle section extending from said first pillar to said second pillar with said reinforcing composite layer elongated in a vertical direction along said first pillar;
• and
• a mounting bracket mechanically engaged with said first polymeric material of said backrest free of melt bonding between said first polymeric material of said backrest and said mounting bracket.

A method of forming a seat back including a first polymeric material and a reinforcing composite layer formed of a second polymeric material and a plurality of fibers impregnated in the second polymeric material, said method comprising:

• placing the reinforcing composite layer into a mold;
• placing an elongated one-piece bracket for coupling to a seat cushion into the mold adjacent to the reinforcing composite layer;
• heating the first polymeric material to a molten state;
• and
• introducing the first polymeric material in the molten state into the mold between and into contact with the reinforcing composite layer and the bracket to melt bond with the second polymeric material of the reinforcing composite layer and to mechanically engage the bracket for forming the backrest with a first pillar, a second pillar spaced from the first pillar, and a middle section extending from the first pillar to the second pillar with the reinforcing composite layer elongated in a vertical direction along the first pillar and integrating the backrest, the bracket, and reinforcing composite layer.

A seat assembly comprising:

• a seat back including a backrest formed of a first polymeric material for supporting an occupant, a one-piece bracket anchored to said backrest for coupling to a seat cushion and formed of a second material different than said first polymeric material of said backrest, and a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• and
• a seat cushion coupled to said bracket;
• wherein said first polymeric material defines a first pillar, a second pillar spaced from said first pillar, and a middle section extending from said first pillar to said second pillar with said reinforcing composite layer elongated in a vertical direction along said first pillar;
• wherein said bracket is elongated in the vertical direction along said first pillar of said backrest and overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer.

A seat assembly comprising:

• a seat back including a backrest formed of a first polymeric material for supporting an occupant, a bracket anchored to said backrest and formed of a second material different than said first polymeric material of said backrest, and a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• a seat cushion coupled to said bracket;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• and
• wherein said bracket and said reinforcing composite layer each present an inner surface opposing each other and an opposite facing outer surface and wherein said first polymeric material covers at least a portion of one of the outer surfaces to form an uncovered aesthetic show surface.

A seat assembly comprising:

• a seat back including a backrest formed of a first polymeric material for supporting an occupant, a bracket anchored to said backrest and formed of a second material different than said first polymeric material of said backrest, and a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• a seat cushion coupled to said bracket;
• wherein said first polymeric material defines a first pillar, a second pillar spaced from said first pillar, and a middle section extending from said first pillar to said second pillar with said reinforcing composite layer elongated in a vertical direction along said first pillar;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• wherein said bracket and said reinforcing composite layer each presents an inner surface opposing each other and an opposite facing outer surface free of first polymeric material and further comprising a mounting bracket abutting said outer surface of said bracket for connecting the bracket to the seat cushion.

A seat assembly comprising:

• a seat back including a backrest formed of a first polymeric material for supporting an occupant, a bracket anchored to said backrest and formed of a second material different than said first polymeric material of said backrest, and a reinforcing composite layer connected to said backrest and formed of a second polymeric material and a plurality of fibers impregnated in said second polymeric material;
• a seat cushion coupled to said bracket;
• wherein said bracket is overmolded by said first polymeric material and wherein said first polymeric material is melt bonded to said second polymeric material of said reinforcing composite layer integrating said backrest, said bracket, and said reinforcing composite layer;
• wherein said first polymeric material defines a first pillar, a second pillar spaced from said first pillar, and a middle section extending from said first pillar to said second pillar with said reinforcing composite layer elongated in a vertical direction along said first pillar;
• wherein said bracket and said reinforcing composite layer each presents an inner surface opposing each other and an opposite facing outer surface and wherein said first polymeric material covers at least a portion of one of the outer surfaces to form an uncovered aesthetic show surface;
• and
• a mounting bracket mechanically engaged with said first polymeric material of said backrest free of melt bonding between said first polymeric material of said backrest and said mounting bracket.