CA1291410C - Vehicle seat with molded in-place suspension system - Google Patents

Vehicle seat with molded in-place suspension system

Info

Publication number
CA1291410C
CA1291410C CA000580815A CA580815A CA1291410C CA 1291410 C CA1291410 C CA 1291410C CA 000580815 A CA000580815 A CA 000580815A CA 580815 A CA580815 A CA 580815A CA 1291410 C CA1291410 C CA 1291410C
Authority
CA
Canada
Prior art keywords
sheet
fabric
mold
vehicle seat
molded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000580815A
Other languages
French (fr)
Inventor
Randy A. Zeilinger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hoover Universal Inc
Original Assignee
Hoover Universal Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hoover Universal Inc filed Critical Hoover Universal Inc
Application granted granted Critical
Publication of CA1291410C publication Critical patent/CA1291410C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C7/00Parts, details, or accessories of chairs or stools
    • A47C7/02Seat parts
    • A47C7/28Seat parts with tensioned springs, e.g. of flat type
    • A47C7/282Seat parts with tensioned springs, e.g. of flat type with mesh-like supports, e.g. elastomeric membranes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/48Upholstered article making
    • Y10T29/481Method
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • Y10T29/49885Assembling or joining with coating before or during assembling

Abstract

ABSTRACT

A vehicle seat assembly including a seat cushion suspension assembly consisting of a flexible elastic fabric sheet having a foam body molded thereto forming a bun. me bun is formed by attaching the fabric sheet to retainers and in turn the retainers to spaced apart receivers on the inside of a mold. The mold is closed, expandable foam is injected, and the positioned fabric sheet is thus molded to and bonded to the fabric. The bun so formed is then positioned on a vehicle seat frame by attaching the retainers to laterally separated side rails of the frame thus forming a support for seating loads.

Description

~` i J ~ Z~L4~

VEHIfT~ SE~T WITH MOLDED IN-PL~CE SUSPENSICN SYST~M

_ ~GROUND AND S~MMARY OE THE INvENTIoN

This invention relates generally to the field of seating and more particularly to vehicle seat asse~blies. Previously, most vehicle seating involved the use of a frame having an arrangement of springs upon which a padding such as foam rubber was positioned. This seat is then covered with a fabric or other sheet material which is attached to the frame. In a co-pendmg application serial no. 437,715, filed October 29, 1982, commonly assigned, a seat assembly is disclosed having a foam encapsulated load ~upporting fibrous matrlx stretched between laterally spaced frame member6 of a seat. In this seat assembly the foam pad is molded in place onto the load supporting fibrous matrLx that is prepo~itioned on the frame. Thus, the foam encapsulation covers both the fibrous matrix or fabric sheet and the side rails of the frame upon which the seat cushion is to be mounted.
The seat assembly of the above mentioned copending application must ~e positioned partially inside a mold cavity where the foam i8 injected to expand the foam pad over the fabric matrix and portions of the frame.
In contrast, the present invention provides a vehicle seat cushion suspension assembly that will be mounted on a frame having laterally separated side rails but which is produced without the necessity of premounting the fabric sheet between the side rails of a vehicle seat frame. The result is a vehicle seat cushion suspension assembly that is more versatile and simpler to produce. In addition, the elimination of the requirement for a mold to accommodate the seat frame permits the mold to be smaller and more compact as well as enabl mg one mold to be utilized for a variety o~ ~eating configurations. me frame thus is not a constraint to the mold configuration in ~he present invention.
me vehicle seat cushion suspension assembly of this invention for carrying seating load~ on a vehicle seat having laterally separated side rails comprises a flexible elastic woven fabric material, generally rectan~ular in ~hape, having a ~oam body integrally molded and bonded thereto. The load supporting fabric sheet is formed of woven flexible elastic filaments. ~ foam cushion body is integrally molded and bonded to the ~abric such that the fabric and the foam body molded together act in concert to elastically support seating loads when the assembly is mounted on and eositioned between side rails of a vehicle seat frame.
The fabric material effectively transfers the loads from the cushion to the side rails while the foam in the body functions to lock all of the filaments together to provide for the desir~d dlstribution of seating load6 throughout the sheet and avoid areas of stress concentration.
m e vehicle seat cushion 6uspension asse~bly of this invention applies equally well to the formation of the vehicle seat back. A seat back assembly having laterally separated side rails may also have a flexible elastic fabric supported between them with a foam body integrally molded and bonded thereto that act together to support seating loads on the seat back.
The seat cushion suspension assembly according to the present invention is produced in a foam mPld. The flexible woven fabric sheet is ~ ~ ;29~4~

mounted inside one-half of a hollow mold, the other half of the mold is closed over the irs~ half, and the expandable foam is injected into the mold cavity. As the foam expands and encapsulate~ the fabric contained therein the fabric i6 effectively bonded to the foam body formed therein.
The mold is then opened and the foam body with fabric attached is removed. ~he abric she2t, with the foam body integrally molded and bonded thereto can then be attached to the side rails d a seat frame.
In addition, once the foam body with the fabric sheet bonded thereto is removed from the mold a seat trim cover may then be bonded to the oam body. This is done by taking a preformed seat trim cover having a complim ntary shape to that of the outside surface o the foam kody, coating the cover or the body with adhesive, and positioning the seat trim cover onto the foam body in complimentary relation and then applying heat and pressure which bonds the seat cover to the foam pad or body The resulting assembly can then ke m~unted on a ~eat frame such hat the fabric sheet is suspended between side rails of the frame and the edges of the æat cover may be wrapped around and attached to the underside of the seat frame thus completing the seat asse~bly.
Further objects, features, and advantages of this invention will become apparent from a consideration of the following detailed description when taken in conjunction with the appended claim~ and accompanyin~ drawings.

BRIEF DESCRIPTICN CF THE DRAWnNGS

Figure 1 is a fragmentary perspective view o~ a portion of a seat assembly of this invention~ w~th ~owe parts broken away and other parts shown in section for the porpose of clarity;

~L~914~
Figure 2 is a fragmentary perspective view of the vehicle seat cushion suspension assembly of thiB invention in a mold 6hown in section or the purpose of clarity;
Figure 3 is a partial sectional view of the vehicle seat suspension a~6emb1y of the present lnvention showing a seat cover in complimentary relation to the foam pad;
Figure 4 iB a fragmentary perspective view of a portion of the completed 6eat assembly of this invention.

DE~AI~D DF~gCRIPTICN OF THE PREFERRED EM~ODIMENT

Turning now to the drawings, the vehlcle seat cushion suspension assembly or bun 10 is shown in Figure 1 mounted on frame assembly 11.
Bun 10 is comprised of flexible elastic fabric sheet 12 which is generally rectangular in shape. Sewn to opposite edges of abric sheet 12 are retainers 14 and 16 constructed frvm a plastic strip haviny a J-6haped cross ~ection. ~olded ~nd bonded to ~heet 12 with retainers 14 and 16 attached, is foam body 18.
Bun 10 is mounted on frame assembly 11 by hooking the short legs of J-shaped retainers 14 and 16 over receivers or ~langes 18 and 20 on side rails 22 and 24 re6pectively of frame assembly 11. Side rails 22 and 24 are maintained in spaced apart relation by horizontal frame l~mber 26.
Retainers 14 and 16 may also be snaps, hooks, rivets, barhed tabs, or other attachment means for connecting to corresponding receivers on side rails 22 and 24. However, in this preferred embodiment, J-strips and flanges are used.

~ ~914~

Bun 10, comprising Eabric sheet 12, retainers 14 and 16, and foam body 18 is ~ormed in mold 28, shcwn in Figure 2. Mold 28 includes a first mold half member 30 having ~paced apart flanges 32 and 34 on the insic~ surface of mold ~ember 30. Flanges 32 and 34 are spaced apart the 6ame distance and are oriented the fiame as flanges 18 and 20 on frame assembly 11. Thus when fabric sheet 12 is attached between flanyes 32 and 34 by hooking retainers 14 and 16 over flanges 32 and 34, fabric 12 i8 positioned in the ~ame configuration within the mold ca~ity as the fabric ~heet will be positioned when attached to frame 11.
A second mold half member 32 is closed against ~ember 30 completing the mold enclosure. An expandable foam material is injected into the mold. m e foam expands to fill the mold interior. In so cloing, foam body 18 is bonded to fabric sheet 12 completing the assembly of the bun 10. Mold halves 30 and 32 are then separated, and the completed bun may then be slid of off flanges 32 and 34 or alternately the bun may be flexed to disengaged the ~ strips 14 and 16 from flanges 32 and 34. This molding operation effectively encapsulates the flexible fabric sheet with the J-shaped retainers attached.
me foam body 18 bonded to fabric sheet 12 functions to lock all of the filaments together to provide for the desired distribution of seating loads throughout sheet 12 and avoid areas of stress concentration when the bun 10 in rnounted on the frame assernbly 11. Fabric sheet 12 is preferably stretched taut between flanges 32 and 34 in rnold rnen~er 30.
Correspondingly~ when the bun is mounted on fra~e assembly 11, fabric 12 wll~ be stretched between side rails 22 and 24.
The completed bun 10, removed from rnold halE 30 may then be placed on a bonding machine die also having spaced apart flanges - ~9~4~

corresponding to the width between side rails 22 and 24. The outer surface 36 of bun 10 may then be coated with a suitable adhesive or the inside surface 38 of a fabric trim cover ~0 BO coated. '~he trim cover 40 iB then applied to bun 10 by positioning the trim cover which has a complimentary shape to the ~hape of the outer surface of the bun onto a bonding machine die 42 and then pressing ~he die against the ~un. In addition, heat may be applied to the trim cover 40 through the bonding machine die to speed the bonding process.
As shcwn in Figure 3, the trim cover positioned in the bonding machine die 42 has a complimentary surface relationship to the surface 36 of bun 10. The completed vehicle seat cushion assembly with trim cover attached can then be positioned on frame 11 as shown in Figure 1. To oomplete the assembly/ ~-shaped retainer strips 44, presewn to the edges of trim cover 40 are then hooked over flanges 46 on frame assembly 11 as shown in Figure 4. The completed assembly may then be mounted on a vehicle seat or back frame and mounted within the vehicle.
Fr~m the above description, it is seen that this invention provides an improv0d versatile vehicle seat with a molded in place suspension system to provide a wide distribution of seating loading forces when applied b~ the seat cushion. A seat or back with improved cG~fort, versatility and ease of manufacture is thus achieved.

Claims (8)

1. A vehicle seat cushion suspension assembly for carrying seating loads on a frame having laterally separated side rails comprising:
a flexible woven elastic fabric material having a foam body integrally molded and bonded to said fabric prior to said fabric being mounted between said side rails; and retaining means for attaching said sheet having said body bonded thereto to receivers on said side rails, said fabric and foam body molded thereto acting together to elastically support seating loads when said assembly is mounted on said receivers.
2. A vehicle seat cushion suspension assembly according to claim 1 wherein said fabric is in a stretched configuration when said body is molded and bonded thereto.
3. A vehicle seat cushion suspension assembly according to claim 1 wherein said retaining means comprises J-strips hooked over said receivers, said receivers comprising flanges protuding from said side rails.
4. A method of manufacturing a vehicle seat cushion suspension assembly for mounting on a frame having laterally separated side rails, said method comprising the steps of:
a) providing a rectangular woven elastic fabric sheet having parallel opposite edges having retaining means attached to each of said edges of said fabric sheet;
b) positioning said sheet within a mold cavity;
c) injecting foam into said mold to form said foam body molded and bonded to said sheet;
d) removing said body from said mold with said fabric molded and bonded to said body;
e) mounting said opposite edges of said fabric with said foam body encapsulated thereto onto the laterally separated side rails of said frame.
5. The method according to claim 4 wherein the step of positioning said sheet further comprises stretching said sheet between and attaching said retaining means to support members fixed within said mold thereby tensioning said sheet.
6. The method according to claim 4 wherein said retaining means comprises a plastic strip having a J-shaped cross section, the method further comprising the step of sewing said strip to each of said edges of said fabric sheet.
7. A method of manufacturtng a vehicle seat assembly comprising a frame having laterally separated side railsl a load supporting elastic fabric sheet stretched between said rails, a foam body molded and bonded in place on said sheet stretched therebetween, and a seat cover positioned over said body and said rails and secured to said frame, said method comprising the steps of:
a) attaching retainers to opposite edges of said fabric sheet;
b) stretching aid sheet and fastening said retainers onto spaced apart mounting members within a first mold member thereby mounting said sheet within said first member ;
c) positioning a second mold member onto said first mold member to form a mold enclosing said sheet;
d) injecting expandable foam into said mold to form said foam body molded and bonded to said sheet;
e) removing said body from said mold with said stretched fabric molded and konded to said body;
f) coating said body with an adhesive;
g) placing a seat trim cover having a complimentary shape to the shape of the outer surface of said foam body in complimentary position on said foam body;
h) bonding said seat cover to said body; and i) attaching said fabric sheet to said rails and said seat trim cover to said frame thereby completing the assembly of said vehicle seat.

.
8. The method of manufacturing a vehicle seat assembly according to claim 7 wherein the step of stretching said sheet tensions said sheet between said spaced apart mounting members within said first mold member.
CA000580815A 1987-10-26 1988-10-20 Vehicle seat with molded in-place suspension system Expired - Fee Related CA1291410C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US113,651 1987-10-26
US07/113,651 US4852228A (en) 1987-10-26 1987-10-26 Method of Manufacturing a vehicle seat with mold-in-face suspension system

Publications (1)

Publication Number Publication Date
CA1291410C true CA1291410C (en) 1991-10-29

Family

ID=22350728

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000580815A Expired - Fee Related CA1291410C (en) 1987-10-26 1988-10-20 Vehicle seat with molded in-place suspension system

Country Status (5)

Country Link
US (1) US4852228A (en)
JP (1) JPH023553A (en)
CA (1) CA1291410C (en)
DE (1) DE3836312A1 (en)
GB (1) GB2211404B (en)

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DE3916698C2 (en) * 1989-05-23 1993-11-18 Daimler Benz Ag Backrest upholstery of a motor vehicle seat
JPH0793228B2 (en) * 1991-04-24 1995-10-09 太陽誘電株式会社 Rare earth silver conductive paste and electronic parts using the same
CA2136967C (en) 1992-06-15 2001-04-03 William E. Stumpf Office chair
US5290093A (en) * 1992-06-15 1994-03-01 Hoover Universal, Inc. Method of seam location using vacuum
US5428249A (en) * 1992-07-15 1995-06-27 Canon Kabushiki Kaisha Photovoltaic device with improved collector electrode
FR2755594B1 (en) * 1996-11-14 1999-02-05 Itw De France DEVICE AND METHOD FOR FIXING A SEAT TRIM, AND SEAT OBTAINED
US6444152B1 (en) * 1999-01-12 2002-09-03 Illinois Tool Works Inc. Method for capturing stretched fabrics in carrier frames
US6296037B1 (en) * 1999-08-10 2001-10-02 Newell Window Furnishings, Inc. Foam core vane for door and window covering
US6994812B1 (en) 1999-10-12 2006-02-07 Intier Automotive Inc. Mold tool and method for forming a trim covered foam substrate of a seat assembly
FR2841509A1 (en) * 2002-06-27 2004-01-02 Cera Decorative trim for an automobile seating, as the seat and/or backrest, has a foam body and a textile covering, with an embedded suspension fitting for attachment to the seat frame
US20040137811A1 (en) * 2003-01-09 2004-07-15 L & P Property Management Company Elastomeric seating composite
ITTO20040115A1 (en) * 2004-02-27 2004-05-27 Fiat Auto Spa VEHICLE SEAT WITH DEFORMABLE BASE
US7585030B2 (en) * 2006-07-20 2009-09-08 Galbreath Ashford A Environmentally friendly layered seating assembly
DE102008022898A1 (en) * 2008-05-08 2009-11-12 Faurecia Autositze Gmbh Vehicle seat i.e. motor vehicle seat, manufacturing method for land vehicle, involves molding dimensionally stable seat cushion subshell made of plastic using injection mold, where seat cushion subshell is padded
DE112008003874B4 (en) * 2008-08-01 2021-07-22 Lear Corporation Durable seat layer with an integrated electrical and mechanical connection system
ES2365581B1 (en) * 2009-05-07 2012-09-17 Centro Tecnologico De Grupo Copo, S.L.U. PROCEDURE FOR OBTAINING A SEAT MODULE SUITABLE FOR ASSEMBLY AND MODULE OBTAINED
US8696067B2 (en) * 2009-07-27 2014-04-15 Lear Corporation Vehicle seating frame, assembly, and method of making
US8662560B2 (en) * 2009-07-27 2014-03-04 Lear Corporation Vehicle seating attachment assembly
DE102012009295A1 (en) 2011-05-12 2013-01-03 W.E.T. Automotive Systems Ag Heating device for seat of vehicle e.g. motor car, has electric conductors connected with electrical function layer that is provided with bus bars which are extended around through-holes for surrounding through-holes
US10384737B2 (en) * 2017-03-23 2019-08-20 Harley-Davidson Motor Company Group, LLC Motorcycle seat assembly with hammock-type suspension

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB934239A (en) * 1961-06-22 1963-08-14 Vitafoam Ltd Improvements in or relating to upholstered furniture
GB1018951A (en) * 1962-05-15 1966-02-02 Humber Ltd Improvements in seats
US3328085A (en) * 1966-02-09 1967-06-27 Gen Tire & Rubber Co Seat suspension
US3932252A (en) * 1974-10-18 1976-01-13 Deere & Company Process for the manufacture of composite foam and fabric articles
GB1600732A (en) * 1978-04-03 1981-10-21 Storey Brothers & Co Seats
US4702522A (en) * 1982-10-29 1987-10-27 Hoover Universal, Inc. Seat assembly with foam encapsulated load-supporting fibrous matrix
US4603907A (en) * 1983-11-30 1986-08-05 Hoover Universal, Inc. J-clip mounting system for load bearing seat members
US4718153A (en) * 1986-04-10 1988-01-12 Steelcase Inc. Cushion manufacturing process
CA1341056C (en) * 1986-04-10 2000-07-25 Donald H. Armitage Cushion manufacturing process

Also Published As

Publication number Publication date
GB8824851D0 (en) 1988-11-30
GB2211404A (en) 1989-07-05
GB2211404B (en) 1990-12-12
DE3836312A1 (en) 1989-05-03
US4852228A (en) 1989-08-01
JPH023553A (en) 1990-01-09

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