Seating assembly and method of making same

Details Seating assembly and method of making same Seating assembly and method of making same

2000-01-20

2001-05-22

Brown, Peter R. (Department: 3636)

Chairs and seats

Bottom or back

Having fluent material

C297S452560, C297S452650

Reexamination Certificate

active

06234578

ABSTRACT:

TECHNICAL FIELD
The subject invention generally relates to the manufacture and design of structures for supporting at least a portion of a human body and, more particularly, seats for use in vehicles.
BACKGROUND OF THE INVENTION
Vehicular seats generally include a rigid, metal frame supporting a foam cushion against which a passenger in the vehicle will rest. The frame typically includes a horizontal platform having a central opening therein. A series of sinuous metal springs extend across the opening to provide resilient support for the weight of the passenger, and the foam cushion is disposed on top of the platform. An upholstery cover is placed over the foam cushion and secured to the frame.
The central opening in the platform allows the springs to deflect downwardly as a passenger sits on the seat. Although the metal springs provide shock absorption and resilient support, a significant amount of foam is required to ensure that the seat is sufficiently comfortable, increasing the bulkiness of the seat. Further, both the metal seat frame and the foam add undesirable weight to the vehicle seat and, consequently, to the vehicle itself.
Therefore, it is desirable to provide a vehicular seat which provides sufficient comfort to a passenger without requiring a bulky foam cushion. It is also desirable to provide a vehicular seat including a suspension system which provides sufficient comfort and support for a passenger to reduce the amount of foam or other cushioning required by the standard spring construction.
SUMMARY OF THE INVENTION
The present invention provides a seat component comprising a frame including a cavity defined by a bottom panel and at least one side wall. The bottom panel includes a central cut-out region having a peripheral edge. A support mat is joined to the bottom panel and extends across the central cut-out region. An inflatable cushion is disposed within the cavity and supported by the support mat.
The present invention also provides a seat component comprising a blow molded shell with an intermediate layer of thermoplastic elastomer placed over at least a portion of an outer surface of the shell. A flexible cover is disposed over the intermediate layer and joined to the shell.
The present invention also involves a method of forming a seat component including blow molding a shell within a mold and placing an intermediate layer of thermoplastic elastomer over at least a portion of an outer surface of the shell. A flexible cover is attached to the shell over the intermediate layer.
Therefore, the present invention provides a seating concept that does not require the use of expensive and bulky urethane foam and eliminates the need for the standard metal spring suspension system in a vehicular seat.


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