Soft padding section for vehicle seat assembly

Abstract

This disclosure provides a "cushion segment for a vehicle seat assembly". A method of manufacturing a cushion segment for a vehicle seat assembly includes: providing a first metal support element including a tubular portion; and overmolding the tubular portion of the first metal support element with foam. Before overmolding the tubular portion of the first metal support element with foam, the tubular portion of the first metal support element is bent into a predetermined shape. A second layer of foam may be applied on the foam overmolded on the tubular portion of the first metal support element. The second layer of foam may be a different type of foam from the foam overmolded on the tubular portion of the first metal support element. A first end of the tubular portion may be flattened and formed with a hole therein to allow the cushion segment to be attached to a structural support member of the vehicle seat assembly.

Description

Technical Field

[0001] The present invention generally relates to a seat assembly for vehicles that utilizes a bolster and a method for manufacturing the same. Background Technology

[0002] Seat assemblies used in vehicles sometimes employ padding to help retain occupants in the seat assembly when the vehicle changes direction. High-performance vehicles, such as those used for racing, can use larger and stronger padding compared to non-high-performance vehicles. Padding used in high-performance vehicles typically consists of metal plates welded to structural supports for the seat and seatback, and the welding is expensive and requires thick metal. The resulting padding can cause discomfort to the occupants. Summary of the Invention

[0003] According to one aspect of the invention, a seat assembly for a vehicle includes: a seat including a structural support member and a cushion assembly attached to the structural support member; and a seat back that cooperates with the seat, the seat back including a structural support member and a cushion assembly attached to the structural support member; the cushion assembly of the seat includes: a main support section; a first cushion section disposed on a side of the main support section, the first cushion section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole receiving fasteners for attaching the seat cushion assembly to the structural support member of the seat; and a second cushion section disposed on a side of the main support section and opposite to the first cushion portion, the second cushion section including a foam portion at least partially surrounding a second metal support element, the second metal support element including a tubular portion. The seat back cushion assembly includes: a main support section; a first cushion section disposed on a side of the main support section, the first cushion section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole, the at least one hole receiving fasteners for attaching the seat back cushion assembly to the structural support element of the seat back; and a second cushion section disposed on a side of the main support section and opposite to the first cushion section, the second cushion section including a foam portion at least partially surrounding a second metal support element, the second metal support element including a tubular portion and at least one hole, the at least one hole receiving fasteners for attaching the seat back cushion assembly to the structural support element of the seat back.

[0004] Embodiments of the first aspect of the present invention may include any one or a combination of the following features:

[0005] ●Regarding the seat cushion assembly, at least one hole of the first metal support element includes a first hole and a second hole separated by a tubular portion of the first metal support element, and both the first hole and the second hole respectively receive fasteners for attaching the seat cushion assembly to the structural support of the seat.

[0006] ●Regarding the seat cushion assembly, at least one hole of the second metal support element includes a first hole and a second hole separated by a tubular portion of the second metal support element, and both the first hole and the second hole receive fasteners for attaching the seat cushion assembly to the structural support of the seat.

[0007] ●Regarding the seat back cushion assembly, at least one hole of the first metal support element includes a first hole and a second hole separated by a tubular portion of the first metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat back cushion assembly to a structural support member of the seat back.

[0008] ●Regarding the seat back cushion assembly, at least one hole of the second metal support element includes a first hole and a second hole separated by a tubular portion of the second metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat back cushion assembly to a structural support member of the seat back.

[0009] ●The main support section of the seat cushion assembly includes the foam portion;

[0010] ●The main support section of the seat back cushion assembly includes the foam portion;

[0011] ●Regarding the seat cushion assembly, the foam portions of the main support section, the first cushion section, and the second cushion section are adjacent;

[0012] ●Regarding the seat back cushion assembly, the foam portions of the main support section, the first cushion section, and the second cushion section are adjacent;

[0013] ●The seat cushion assembly also includes a second layer of foam that covers at least a portion of the adjacent foam portions of the main support section, the first cushion section, and the second cushion section;

[0014] ●The seat back cushion assembly also includes a second layer of foam that covers at least a portion of the adjacent foam portions of the main support section, the first cushion section, and the second cushion section;

[0015] ●Regarding the seat cushion assembly, the second layer of foam is a different type of foam from the adjacent foam portions of the main support section, the first cushion section, and the second cushion section;

[0016] ●Regarding the seat back cushion assembly, the second layer of foam is a different type of foam from the main support section, the foam portion of the first cushion section, and the adjacent foam portion of the second cushion section;

[0017] ●Regarding the seat cushion assembly, the second layer of foam is polyurethane foam;

[0018] ●Regarding the seat cushion assembly, the adjacent foam portions of the main support section, the first cushion section, and the second cushion section are made of expanded polypropylene foam;

[0019] ●Regarding the seat back cushion assembly, the second layer of foam is polyurethane foam;

[0020] ●Regarding the seat back cushion assembly, the adjacent foam portions of the main support section, the first cushion section, and the second cushion section are made of expanded polypropylene foam.

[0021] ●The center line divides the seat assembly into the first side and the second side;

[0022] ●The structural support components of the seat include at least one hole located on a first side of the centerline and at least one hole located on a second side of the seat assembly;

[0023] ● At least one hole in the first cushion section of the seat cushion assembly and at least one hole in the structural support of the seat are coaxially disposed with each other and receive the same fasteners for attaching the seat cushion assembly to the structural support of the seat.

[0024] ● At least one hole in the second cushion section of the seat cushion assembly and at least one hole in the structural support of the seat on the second side of the seat assembly are coaxially arranged with each other and receive the same fasteners for attaching the seat cushion assembly to the structural support of the seat.

[0025] ●The structural support for the seat back includes at least one hole provided on a first side of the seat assembly and at least one hole provided on a second side of the seat assembly;

[0026] ● At least one hole in the first cushion section of the seat back cushion assembly and at least one hole in the structural support of the seat back are coaxially disposed on the first side of the seat assembly and receive the same fasteners for attaching the seat back cushion assembly to the structural support of the seat back.

[0027] ● At least one hole in the second cushion section of the seat back cushion assembly and the second hole in the structural support of the seat back are coaxially arranged and receive the same fasteners for attaching the seat back cushion assembly to the structural support of the seat back.

[0028] ●The structural support member of the seat is located at least one hole on the first side of the seat assembly that is closer to the center line of the seat assembly than at least one hole in the first cushion section;

[0029] ●The structural support member of the seat is located at least one hole on the second side of the seat assembly that is closer to the center line of the seat assembly than at least one hole in the second cushion section;

[0030] ● The first metal support element of the seat back cushion assembly includes a first end and a second end, wherein the tubular portion of the first metal support element of the seat back cushion assembly is disposed between the first end and the second end of the first metal support element of the seat back cushion assembly; and

[0031] ● The tubular portion of the first metal support element of the seat back cushion assembly includes a plurality of bends, such that the distance between two of the plurality of bends in front of the first end and the second end of the first metal support element of the seat back cushion assembly is greater than the distance between the first end and the second end of the first metal support element of the seat back cushion assembly.

[0032] According to a second aspect of the invention, a cushioning assembly for a vehicle seat assembly includes: a main support section; a first cushioning section disposed on a side of the main support section, the first cushioning section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole configured to receive fasteners to secure the cushioning assembly to a structural support; and a second cushioning section disposed on a side of the main support section and opposite to the first cushioning section, the second cushioning section including a foam portion at least partially surrounding a second metal support element, the second metal support element including a tubular portion and at least one hole configured to receive fasteners to secure the cushioning assembly to a support structure.

[0033] Embodiments of the second aspect of the present invention may include any one or a combination of the following features:

[0034] ●The first metal support element is U-shaped;

[0035] ●The second metal support element is U-shaped;

[0036] ●The first metal support element is configured to receive fasteners to secure the gasket assembly to the support structure. At least one hole includes a first hole and a second hole separated by a tubular portion of the first metal support element.

[0037] ●The second metal support element is configured to receive fasteners to secure the gasket assembly to the support structure. At least one hole includes a first hole and a second hole separated by the tubular portion of the second metal support element.

[0038] ●The foam portion of the first padding segment surrounds at least a portion of the tubular portion of the first padding segment, but not around the first padding segment, and is configured to receive fasteners to secure the padding assembly to at least one hole of the structural support.

[0039] ●The foam portion of the second padding segment surrounds at least a portion of the tubular portion of the second padding segment, but not around the second padding segment, and is configured to receive fasteners to secure the padding assembly to at least one hole in the support structure.

[0040] ●The main support section includes the foam portion;

[0041] ●The foam portions of the main support section, the first cushion section, and the second cushion section are adjacent;

[0042] ●A second layer of foam, which covers at least a portion of the adjacent foam portions of the main support section, the first cushion section, and the second cushion section;

[0043] ●The second layer of foam is a different type of foam from the adjacent foam portions of the main support section, the first cushion section, and the second cushion section;

[0044] ●The second layer of foam is polyurethane foam; and

[0045] ●The adjacent foam portions of the main support section, the first cushion section, and the second cushion section are made of expanded polypropylene foam.

[0046] According to a third aspect of the invention, a method of manufacturing a cushion segment for a seat assembly in a vehicle includes: providing a first metal support element comprising a tubular portion; and molding the tubular portion of the first metal support element with foam.

[0047] Embodiments of the third aspect of the present invention may include any one or a combination of the following features:

[0048] ●Before the tubular portion of the first metal support element is covered with foam, the tubular portion of the first metal support element is bent into a predetermined shape.

[0049] ● Flatten the first end of the tubular section and form a hole through the first end;

[0050] ● Apply a second layer of foam over the tubular portion of the first metal support element;

[0051] ●The second layer of foam is a different type of foam from the foam that is molded over the tubular portion of the first metal support element;

[0052] ●The tubular portion of the first metal support element has a predetermined U-shape; and

[0053] ●The tubular portion of the first metal support element has a predetermined shape with at least five bends.

[0054] After studying the following description, claims and drawings, those skilled in the art will understand and appreciate these and other aspects, objectives and features of the invention. Attached Figure Description

[0055] In the attached diagram:

[0056] Figure 1 It is a perspective view of the vehicle interior, showing the first seat assembly, in which the seat back and seat are positioned above the floor.

[0057] Figure 2 yes Figure 1 A perspective view of the first seat assembly, showing both the seat and the seat back, both of which have structural supports, a padding assembly above the structural supports, and a cover covering the padding assembly.

[0058] Figure 3 yes Figure 2 A front perspective view of the seat cushion assembly, showing a main support section, a first cushion section disposed on one side of the main support section, and a second cushion section disposed on the opposite side of the main support section opposite to the first cushion section.

[0059] Figure 3A yes Figure 2 An enlarged front perspective view of the seat cushion assembly shows a second layer of foam that is positioned above and partially envelops the adjacent foam portions of the main support section, the first cushion section, and the second cushion section.

[0060] Figure 4 yes Figure 2 A front view of the seat cushion assembly, showing a first cushion section and a second cushion section, each having an inward surface that forms an obtuse angle with respect to the top surface of the main support section.

[0061] Figure 5 yes Figure 2 A side view of the seat cushion assembly, showing the front and rear ends and a first metal support element, which is at least partially disposed within the foam portion of the first cushion segment (as a result of the overmolding manufacturing method).

[0062] Figure 6 yes Figure 2 The rear view of the seat cushion assembly shows a second layer of foam that is positioned above and partially surrounded by the adjacent foam portions of the main support section, the first cushion section, and the second cushion section.

[0063] Figure 7 yes Figure 2 Another side view of the seat cushion assembly (with) Figure 5 On the opposite side, a second metal support element is shown, which is at least partially disposed within the foam portion of the second cushion segment (as a result of the overmolding manufacturing method).

[0064] Figure 8 yes Figure 2 A top view of the seat cushion assembly, showing a first cushion section and a second cushion section extending generally upward and outward from the main support section;

[0065] Figure 9 yes Figure 2 The bottom view of the seat cushion assembly shows a first metal support element and a second metal support element, each having a first end and a second end, which extend from the foam portion of the first cushion segment and the second cushion segment, respectively.

[0066] Figure 10 yes Figure 5 A side view of region X, in which the foam portions of the first cushion section and the main support section are shown in dashed lines, showing a first metal support element with a tubular portion between the first end and the second end, and each of the first end and the second end includes a hole to allow the seat cushion assembly to be attached to the structural support of the seat.

[0067] Figure 11 yes Figure 4 A front view of region XI, in which the foam portions of the first cushioning section and the main support section are shown in dashed lines, showing the first metal support element, which includes a generally U-shaped tubular portion;

[0068] Figure 12 yes Figure 7 A side view of region XII, in which the foam portions of the second cushion section and the main support section are shown in dashed lines, showing a second metal support element with a tubular portion between the first end and the second end, and each of the first end and the second end includes a hole to allow the seat cushion assembly to be attached to the structural support of the seat.

[0069] Figure 13 yes Figure 4 A front view of region XIII, in which the foam portions of the second cushion section and the main support section are shown in dashed lines, showing the second metal support element, which includes a generally U-shaped tubular portion;

[0070] Figure 14 yes Figure 2 A front view of the seat back cushion assembly, showing a main support section, a first cushion section disposed on one side of the main support section, and a second cushion section disposed on the other side of the main support section and opposite to the first cushion section.

[0071] Figure 15 yes Figure 2 A perspective view of the seat back cushion assembly, which shows, in dashed lines, a first cushion segment containing a first metal support element and a second cushion segment containing a second metal support element.

[0072] Figure 15A yes Figure 2 An enlarged perspective view of the seat back cushion assembly, showing a second layer of foam that is attached to and surrounded by the main support section, the first cushion section, and the adjacent foam portions of the second cushion section.

[0073] Figure 16 yes Figure 2 A side view of the seat back cushion assembly, showing at least part of a foam portion surrounding (as a result of an overmolding manufacturing method) a first cushion segment of a first metal support element;

[0074] Figure 17 yes Figure 2 Rear view of the seat back padding assembly, showing the top, bottom and rearward-facing surfaces;

[0075] Figure 18 yes Figure 2 A side view of the seat back cushion assembly, showing at least part of the foam portion surrounding (as a result of the overmolding manufacturing method) the second cushion segment of the second metal support element;

[0076] Figure 19 yes Figure 2 A top view of the seat back cushion assembly, showing a first and second cushion sections each having an inward surface that extends generally forward and outward from the forward-facing surface of the main support section.

[0077] Figure 20 yes Figure 2 A bottom view of the seat back cushion assembly, showing the inward surfaces of the first and second cushion sections, which form an obtuse angle with respect to the forward-facing surface of the main support section.

[0078] Figure 21 yes Figure 16 A side view of region XXI, in which the foam portion of the first cushion segment is shown in dashed lines, showing a first metal support element with multiple bends, and the distance between the first end and the second end is less than the distance between two non-adjacent bends in front of the first end and the second end.

[0079] Figure 22 yes Figure 17 The rear view of area XXII shows the foam portions of the first cushion section and the main support section in dashed lines. It shows a first metal support element including a first bracket attached to a first end and a second bracket attached to a second end, and the first bracket and the second bracket each include holes to allow the cushion assembly to be attached to the support structure of the seat back.

[0080] Figure 23 yes Figure 18 A side view of region XXIII, in which the foam portion of the second cushion segment is shown in dashed lines, showing a second metal support element with multiple bends, and the distance between the first end and the second end is less than the distance between two non-adjacent bends in front of the first end and the second end.

[0081] Figure 24 yes Figure 17 The rear view of area XXIV shows the foam portions of the second cushion section and the main support section in dashed lines. It shows a second metal support element including a first bracket attached to the first end and a second bracket attached to the second end, and the first bracket and the second bracket each include holes to allow the cushion assembly to be attached to the support structure of the seat back.

[0082] Figure 25 yes Figure 2 An exploded perspective view of the seat and seat back shows the seat cushion assembly attached to the seat structural support using fasteners extending through a first metal support element formed by a first cushion segment and a coaxial hole (in-line aperture) provided by a structural support on a first side. It also shows the seat back cushion assembly attached to the seat back structural support using fasteners extending through the first metal support element formed by the first cushion segment and a coaxial hole provided by the structural support on a first side.

[0083] Figure 26 yes Figure 2 An exploded perspective view of the seat and seat back shows the seat cushion assembly being attached to the structural support of the seat using fasteners extending through a second metal support element formed by a second cushion segment and a coaxial hole provided by a structural support on the second side. It also shows the seat back cushion assembly being attached to the structural support of the seat back using fasteners extending through a second metal support element formed by a second cushion segment and a coaxial hole provided by a structural support on the second side. Detailed Implementation

[0084] For the purposes of this description, the terms “above,” “inside,” “outside,” “forward,” “upward,” “backward,” “downward,” and their derivatives should be used interchangeably with those used in this document. Figure 1 This disclosure relates to the orientation of the present invention. However, it should be understood that various alternative orientations may be adopted unless expressly stated to the contrary. It should also be understood that the specific apparatus and processes shown in the drawings and described in the following description are merely exemplary embodiments of the inventive concept defined in the appended claims. Therefore, specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered as limitations unless expressly stated in the claims.

[0085] refer to Figure 1 The vehicle 10 includes an interior 12. A first seat assembly 14 and a second seat assembly 16 disposed adjacent to the first seat assembly 14 are disposed in the interior 12 above a floor 18 and form a first row of seats 20. The first seat assembly 14 may be designated to support the driver occupant (not shown) of the vehicle 10. The second seat assembly 16 may be designated to support the passenger occupant (not shown) of the vehicle 10. For the purposes of this disclosure, the second seat assembly 16 may be identical to the first seat assembly 14 in all respects, therefore only the first seat assembly 14 will be specifically discussed herein. The vehicle 10 may be a high-performance vehicle such as a race car, or any other type of vehicle such as a non-high-performance car, truck, SUV, etc.

[0086] Now for reference Figure 2 The first seat assembly 14 includes a seat 22 and a seat back 24, the seat back cooperating with the seat 22 to support an occupant. The seat 22 includes a structural support 26. The structural support 26 is attached to the floor 18 of the vehicle 10. The structural support 26 may be a frame. The seat 22 also includes a cushion assembly 28 attached to the structural support 26. The cushion assembly 28 provides comfort for the occupant of the first seat assembly 14. The seat 22 may also include a cover 30 disposed above the cushion assembly 28, the cover being a fabric (e.g., cloth, leather).

[0087] The seat back 24 also includes a structural support 32, which may be a frame. The structural support 32 may be pivotally attached to the structural support 26 of the seat 22, thereby allowing the occupant to position the seat back 24 relative to the seat 22 within an angular range. The seat back 24 also includes a padding assembly 34 attached to the structural support 32. The padding assembly 34 provides comfort for the occupant of the first seat assembly 14. The seat back 24 may also include a cover 36 disposed above the padding assembly 34. A centerline 38 divides the first seat assembly 14 into a first side 40 and a second side 42, which may be at least approximately symmetrical to each other. In the illustrated embodiment, the first side 40 is located outside the second side 42.

[0088] Now for reference Figures 3 to 13 The cushioning assembly 28 of seat 22 is functionally divided into a main support section 44, a first cushion section 46, and a second cushion section 48. The main support section 44 is the section of the cushioning assembly 28 that supports the occupants of the first seat assembly 14 when the vehicle 10 is idling or moving in a generally forward direction. The main support section 44 provides a top surface 50 and a bottom surface 52. The top surface 50 generally faces upward. The bottom surface 52 generally faces the floor 18 of the vehicle 10. The main support section 44 includes a front end 54 and a rear end 56. The front end 54 generally faces forward. The rear end 56 generally faces rearward. The main support section 44 includes a foam portion 58.

[0089] A first cushion section 46 is disposed on the side of the main support section 44. A second cushion section 48 is also disposed on the side of the main support section 44, opposite to the first cushion section 46. In other words, the first cushion section 46 may be disposed on the outer side of the main support section 44, while the second cushion section 48 may be disposed on the inner side of the main support section 44. The first cushion section 46 and the second cushion section 48 support the occupant and help to retain the occupant in the first seat assembly 14 when the vehicle 10 changes direction (such as when turning). The first cushion section 46 and the second cushion section 48 respectively provide inward surfaces 60, 62, which are the surfaces closest to the occupant when the first cushion section 46 or the second cushion section 48 respectively supports the occupant. The inward surfaces 60, 62 extend generally upward and outward from the main support section 44 (such as the top surface 50 of the main support section). The inward surfaces 60, 62 face generally inward and upward. The inner surfaces 60 and 62 can form obtuse angles 64 and 66 with the top surface 50 of the main support section 44, respectively (see...). Figure 4 ).

[0090] The first cushion segment 46 includes a first metal support element 68 and a foam portion 70 at least partially surrounding the first metal support element 68. The first metal support element 68 provides a support structure to help the first cushion segment 46 maintain its shape and position and to counteract forces exerted by an occupant on the first cushion segment 46 when the vehicle 10 changes direction. Additionally, the first metal support element 68 provides a structure for attaching the cushion assembly 28 of the seat 22 to the structural support 26 of the seat 22. Figure 10 and Figure 11 As may be best illustrated, the first metal support element 68 may be U-shaped. When the vehicle 10 changes direction and the occupants interact with the first cushioning section 46, the foam portion 70 provides cushioning and comfort to the occupants of the first seat assembly 14.

[0091] The first metal support element 68 may include a tubular portion 72 between the first end 74 and the second end 76. Alternatively, the first metal support element 68 may be rod-shaped without the hollow interior provided by the tubular portion 72. The tubular portion 72 utilizes less material and is therefore less heavy than the rod-shaped first metal support element 68. The first metal support element 68 also includes at least one hole (such as a first hole 78 provided at the first end 74 and a second hole 80 provided at the second end 76), which is configured and positioned (as discussed below, see [link]). Figure 25Fasteners 82a and 82b are received to attach (e.g., fasten) the cushion assembly 28 of the seat 22 to the structural support 26 of the seat 22. A first hole 78 may be provided in front of a second hole 80. A tubular portion 72 separates the first hole 78 and the second hole 80. A foam portion 70 of a first cushion segment 46 surrounds at least a portion of the tubular portion 72 of the first cushion segment 46. In the illustrated embodiment, the foam portion 70 of the first cushion segment 46 does not surround at least one hole of the first cushion segment 46 (e.g., the first hole 78 and the second hole 80), thereby allowing the first hole 78 and the second hole 80 to receive fasteners 82a and 82b (as discussed below) to fasten the cushion assembly 28 to the structural support 26. However, the foam portion 70 surrounds a large portion of the tubular portion 72 between the first hole 78 and the second hole 80.

[0092] The second cushion segment 48 includes a second metal support element 84 and a foam portion 86 at least partially surrounding the second metal support element 84. The second metal support element 84 provides a support structure to help the second cushion segment 48 maintain its shape and position and to counteract forces exerted on the second cushion segment 48 by an occupant when the vehicle 10 changes direction. Additionally, the second metal support element 84, together with the first metal support element 68, provides a structure for attaching the seat 22's cushion assembly 28 to the structural support member 26 of the seat 22. Figure 12 and Figure 13 As may be best shown, the second metal support element 84 may be U-shaped. When the vehicle 10 changes direction and the occupants interact with the second cushioning section 48, the foam portion 86 provides cushioning and comfort for the occupants of the first seat assembly 14.

[0093] The second metal support element 84 may include a tubular portion 88 between the first end 90 and the second end 92. Alternatively, the second metal support element 84 may be rod-shaped without the hollow interior provided by the tubular portion 88. The tubular portion 88 utilizes less material and is therefore less heavy than the rod-shaped second metal support element 84. The second metal support element 84 also includes at least one hole (such as a first hole 94 provided at the first end 90 and a second hole 96 provided at the second end 92), which is configured and positioned (as discussed below, see [link]). Figure 26Fasteners 82c and 82d are received to attach (e.g., fasten) the cushion assembly 28 of the seat 22 to the structural support 26 of the seat 22. A first hole 94 may be generally positioned in front of a second hole 96. A tubular portion 88 separates the first hole 94 and the second hole 96. A foam portion 86 of the second cushion segment 48 surrounds at least a portion of the tubular portion 88 of the second metal support element 84. In the illustrated embodiment, the foam portion 86 surrounds a large portion of the tubular portion 88 between the first hole 94 and the second hole 96. In the illustrated embodiment, the foam portion 86 of the second cushion segment 48 does not surround at least one hole (i.e., the first hole 94 and the second hole 96) of the second metal support element 84, thereby allowing the first hole 94 and the second hole 96 to receive fasteners 82c and 82d (as discussed below) respectively to fasten the cushion assembly 28 to the structural support 26.

[0094] As described above, the main support section 44 of the cushion assembly 28 of the seat 22 also includes a foam portion 58. In the illustrated embodiment, as Figure 3A As may be best illustrated, the foam portion 58 of the main support section 44, the foam portion 70 of the first cushion section 46, and the foam portion 86 of the second cushion section 48 are adjacent, but this is not mandatory. The main support section 44, the first cushion section 46, and the second cushion section 48 of the cushion assembly 28 of the seat 22 may also include a second layer of foam 98, which may also be adjacent and, in the illustrated embodiment, covers at least a portion of the foam portions 58, 70, and 86 of the main support section 44, the first cushion section 46, and the second cushion section 48, respectively. The second layer of foam 98 may be a foam of a different type from the foam portions 58, 70, and 86 of the main support section 44, the first cushion section 46, and the second cushion section 48. For example, the second layer of foam 98 may be polyurethane foam, while the foam portions 58, 70, and 86 of the main support section 44, the first cushion section 46, and the second cushion section 48 may be expanded polypropylene foam, respectively. The inward surfaces 60, 62 of the first cushion section 46 and the second cushion section 48, and the top surface 50 of the main support section 44, may be disposed on (i.e. provided by) the second layer of foam 98. The bottom surface 52 of the main support section 44 may be disposed on (i.e. provided by) the foam portion 58.

[0095] Now for reference Figures 14 to 24The cushioning assembly 34 for the seat back 24 also includes a main support section 100, a first cushion section 102, and a second cushion section 104. The main support section 100 is the section of the cushioning assembly 34 for the seat back 24 that primarily supports the back of the occupant of the first seat assembly 14 when the vehicle 10 is moving in the forward direction or idling. The main support section 100 provides a forward-facing surface 106 and a rearward-facing surface 108. The forward-facing surface 106 is generally forward-facing and faces the occupant of the first seat assembly 14. The rearward-facing surface 108 is generally rearward-facing and faces away from the occupant of the first seat assembly 14. The main support section 100 includes a top 110 and a bottom 112. The top 110 is generally upward-facing, while the bottom 112 is generally downward-facing and positioned closer to the seat 22 than the top 110. The main support section 100 includes a foam portion 114.

[0096] A first cushion section 102 of the padding assembly 34 for the seat back 24 is disposed on the side of the main support section 100. A second cushion section 104 is also disposed on the side of the main support section 100, opposite to the first cushion section 102. In other words, the first cushion section 102 may be disposed on the outer side of the main support section 100, while the second cushion section 104 may be disposed on the inner side of the main support section 100. The first cushion section 102 and the second cushion section 104 support the occupant and help to keep the occupant in the first seat assembly 14 when the vehicle 10 changes direction (such as when turning). The first cushion section 102 and the second cushion section 104 respectively provide inward surfaces 116, 118, which are the surfaces closest to the occupant when the first cushion section 102 or the second cushion section 104 respectively supports the occupant. The inward surfaces 116, 118 extend generally forward and outward from the main support section 100 (such as the forward-facing surface 106 of the main support section). The inward surfaces 116 and 118 generally face forward and inward, respectively. The inward surfaces 116 and 118 may form obtuse angles 120 and 122 with the forward-facing surface 106 of the main support section 100 (see example). Figure 20 ).

[0097] The first cushion segment 102 includes a first metal support element 124 and a foam portion 126 at least partially surrounding the first metal support element 124. The first metal support element 124 provides a support structure to help the first cushion segment 102 maintain its shape and position and to counteract the forces exerted on the first cushion segment 102 by the occupants when the vehicle 10 changes direction. Additionally, the first metal support element 124 provides a structure for attaching the seat back 24 cushion assembly 34 to the structural support member 32 of the seat back 24. When the vehicle 10 changes direction and the occupants interact with the first cushion segment 102, the foam portion 126 provides cushioning and comfort to the occupants of the first seat assembly 14.

[0098] The first metal support element 124 may include a tubular portion 128 between the first end 130 and the second end 132 (see...). Figure 22 Alternatively, the first metal support element 124 may be rod-shaped, without the hollow interior provided by the tubular portion 128. The tubular portion 128 requires less material and is therefore lighter than the rod-shaped first metal support element 124. The first metal support element 124 includes at least one hole (such as a first hole 134 and a second hole 136 in the illustrated embodiment), which is provided and configured to receive fasteners 138a and 138b, respectively (see [link to documentation]). Figure 25 The seat back 24 is attached to the structural support 32 of the seat back 24, with the cushion assembly 34 attached to the seat back 24. A tubular portion 128 separates the first hole 134 and the second hole 136. In the illustrated embodiment, the first metal support element 124 includes a first bracket 140 disposed at a first end 130, and the first bracket 140 includes the first hole 134. Similarly, in the illustrated embodiment, the first metal support element 124 includes a second bracket 142 disposed at a second end 132, and the second bracket 142 includes the second hole 136. The first bracket 140 and the second bracket 142 may each be a bent metal piece welded or otherwise attached to the tubular portion 128. The tubular portion 128 of the first metal support element 124 in the illustrated embodiment includes a plurality of bends 144a-144e. The bends 144a-144e are disposed in front of the first end 130 and the second end 132. The distance 146 between the bends 144a and 144e (see [reference]). Figure 21 The distance 148 between the first end 130 and the second end 132 is greater than the distance between the first end 130 and the second end 132. Instead of including the first support 140 to provide the first hole 134, the first end 130 can be flattened and a first hole 134 can be formed (by drilling, punching, or other means) through the first end 130. Similarly, instead of including the second support 142 to provide the second hole 136, the second end 132 can be flattened and a second hole 136 can be formed (by drilling, punching, or other means) through the second end 132. The foam portion 126 can cover the entire first metal support element 124, except for such a large portion of the first support 140 and the second support 142, to provide access to the first hole 134 and the second hole 136.

[0099] The second cushioning section 104 includes a second metal support element 150 and a foam portion 152 that at least partially surrounds the second metal support element 150. The second metal support element 150 provides a support structure to help the second cushioning section 104 maintain its shape and position and to counteract the forces exerted on the second cushioning section 104 by the occupants when the vehicle 10 changes direction. Additionally, the second metal support element 150 provides additional structure for attaching the cushioning assembly 28 of the seat back 24 to the structural support member 32 of the seat back 24. When the vehicle 10 changes direction and the occupants interact with the second cushioning section 104, the foam portion 152 provides cushioning and comfort to the occupants of the first seat assembly 14.

[0100] The second metal support element 150 may include a tubular portion 154 between the first end 156 and the second end 158 (see...). Figure 24 Alternatively, the second metal support element 150 may be rod-shaped, without the hollow interior provided by the tubular portion 154. The tubular portion 154 requires less material and is therefore less heavy than the rod-shaped second metal support element 150. The second metal support element 150 includes at least one hole (such as a first hole 160 and a second hole 162 in the illustrated embodiment), which is provided and configured to receive fasteners 138c and 138d, respectively (see [link to relevant documentation]). Figure 26 The second metal support element 150 is configured to attach the cushion assembly 34 of the seat back 24 to the structural support 32 of the seat back 24. A tubular portion 154 separates the first hole 160 and the second hole 162. In the illustrated embodiment, the second metal support element 150 includes a first bracket 164 disposed at a first end 156, and the first bracket 164 includes the first hole 160. Similarly, in the illustrated embodiment, the second metal support element 150 includes a second bracket 166 disposed at a second end 158, and the second bracket 166 includes the second hole 162. The first bracket 164 and the second bracket 166 may each be a bent metal piece welded or otherwise attached to the tubular portion 154. The tubular portion 154 of the second metal support element 150 in the illustrated embodiment includes a plurality of bends 168a-168e. The bends 168a-168e are disposed in front of the first end 156 and the second end 158. The distance 170 between the bends 168a and 168e (see [reference needed]). Figure 23The distance 172 between the first end 156 and the second end 158 is greater than the distance between the first end 156 and the second end 158. Instead of including the first support 164 to provide the first hole 160, the first end 156 can be flattened and a first hole 160 can be formed (by drilling, punching, or other means) through the first end 156. Similarly, instead of including the second support 166 to provide the second hole 162, the second end 158 can be flattened and a second hole 162 can be formed (by drilling, punching, or other means) through the second end 158. The foam portion 152 can cover the entire second metal support element 150, except for such a large portion of the first support 164 and the second support 166, to provide access to the first hole 160 and the second hole 162.

[0101] In the illustrated embodiment, as Figure 15A As may be best illustrated, the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104 of the seat back 24 cushion assembly 34 may be adjacent. That is, foam portions 114, 126, and 152 may be the entirety of a single foam element. The seat back 24 cushion assembly 34 may also include a second layer of foam 174. The second layer of foam 174 covers at least a portion of the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104, and these foam portions may be adjacent. For example, as shown in the embodiment, a second layer of foam 174 may be disposed in front of the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104, wherein the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104 support (i.e., surround) the second layer of foam 174. The second layer of foam 174 may be a different type of foam than the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104, and these foam portions may be adjacent to each other. For example, the second layer of foam 174 may be polyurethane foam, while the foam portions 114, 126, and 152 of the main support section 100, the first cushion section 102, and the second cushion section 104 may be expanded polypropylene foam.

[0102] Now for reference Figure 25 and Figure 26The first metal support element 68 and the second metal support element 84 for the cushion assembly 28 of the seat 22 provide a structure for attaching (e.g., fastening) the cushion assembly 28 of the seat 22 to the structural support 26 of the seat 22. More specifically, the first hole 78 and the second hole 80 of the first metal support element 68 of the first cushion segment 46 respectively receive fasteners, namely fasteners 82a and 82b. The structural support 26 of the seat 22 includes a first hole 176 and a second hole 178 disposed at a first side 40 of the first seat assembly 14. The first hole 176 of the structural support 26 of the seat 22 at the first side 40 of the first seat assembly 14 is coaxially disposed with the first hole 78 of the first metal support element 68 of the first cushion segment 46, and therefore both receive the same first fastener 82a to fasten the cushion assembly 28 to the structural support 26. Similarly, the second hole 178 of the structural support member 26 of the seat 22 at the first side 40 of the first seat assembly 14 is coaxially disposed with the second hole 80 of the first metal support element 68 of the first cushion segment 46, and thus both receive the same second fastener 82b to further secure the cushion assembly 28 to the structural support member 26. In the illustrated embodiment, the first hole 176 and the second hole 178 of the structural support member 26 of the seat 22 at the first side 40 of the first seat assembly 14 are closer to the centerline 38 of the first seat assembly 14 than the first hole 78 and the second hole 80 of the first metal support element 68 of the first cushion segment 46. However, the first hole 176 and the second hole 178 are not necessarily so.

[0103] Regarding the second side 42 of the first seat assembly 14, the first hole 94 and the second hole 96 of the second metal support element 84 of the second cushion segment 48 respectively receive fasteners, namely fasteners 82c and 82d. The structural support member 26 of the seat 22 includes a first hole 180 and a second hole 182 disposed at the second side 42 of the first seat assembly 14. The first hole 180 of the structural support member 26 of the seat 22 at the second side 42 of the first seat assembly 14 is coaxially disposed with the first hole 94 of the second metal support element 84 of the second cushion segment 48, and therefore both receive the same fastener 82c to further secure the cushion assembly 28 of the seat 22 to the structural support member 26. Similarly, the second hole 182 of the structural support member 26 of the seat 22 at the second side 42 is coaxially disposed with the second hole 96 of the second metal support element 84 of the second cushion segment 48, and therefore both receive the same fastener 82d to further secure the cushion assembly 28 to the structural support member 26 of the seat 22. In the illustrated embodiment, the first hole 180 and the second hole 182 of the structural support member 26 of the seat 22 located on the second side 42 of the first seat assembly 14 are closer to the centerline 38 of the first seat assembly 14 than the first hole 94 and the second hole 96 of the second metal support element 84 of the second cushion segment 48. However, the first hole 180 and the second hole 182 are not necessarily required to be in this position.

[0104] Similarly, the first metal support element 124 and the second metal support element 150 of the cushion assembly 34 of the seat back 24 provide a structure for attaching (e.g., fastening) the cushion assembly 34 of the seat back 24 to the structural support 32 of the seat back 24. More specifically, the first hole 134 and the second hole 136 of the first metal support element 124 of the first cushion segment 102 each receive fasteners, namely fasteners 138a and 138b, to attach the cushion assembly 34 to the structural support 32. The structural support 32 of the seat back 24 includes a first hole 184 and a second hole 186 disposed at a first side 40 of the first seat assembly 14. The first hole 134 of the first metal support element 124 of the first cushion segment 102 and the first hole 184 of the structural support 32 disposed at the first side 40 are coaxially disposed with each other and receive the same fastener 138a, thereby attaching the cushion assembly 34 to the structural support 32. Similarly, the second hole 136 of the first metal support element 124 of the first cushion section 102 and the second hole 186 of the structural support member 32 located on the first side 40 are coaxially arranged and receive the same fastener 138b, thereby attaching the cushion assembly 34 to the structural support member 32 of the seat back 24.

[0105] Regarding the second side 42 of the first seat assembly 14, the first hole 160 and the second hole 162 of the second metal support element 150 of the second cushion segment 104 respectively receive fasteners, namely fasteners 138c and 138d, to attach the cushion assembly 34 to the structural support member 32 of the seat back 24. The structural support member 32 of the seat back 24 includes a first hole 188 and a second hole 190 provided at the second side 42 of the first seat assembly 14. The first hole 160 of the second metal support element 150 of the second cushion segment 104 and the first hole 188 of the structural support member 32 at the second side 42 are coaxially arranged and receive the same fasteners 138c, thereby attaching the cushion assembly 34 to the structural support member 32 of the seat back 24. Similarly, the second hole 162 of the second metal support element 150 of the second cushion section 104 and the second hole 190 of the structural support member 32 located on the second side 42 are coaxially arranged and receive the same fastener 138d, thereby attaching the cushion assembly 34 to the structural support member 32 of the seat back 24.

[0106] The seat cushion assembly 28 of seat 22 and the seat cushion assembly 34 of seat back 24 (including first cushion segments 46, 102 and second cushion segments 48, 104) can be manufactured by a novel method. Since the first cushion segments 46, 102 and second cushion segments 48, 104 of cushion assemblies 28 and 34 can be manufactured using the same method, this document will specifically discuss only the manufacture of the first cushion segment 46 of the cushion assembly 28 of seat 22, unless otherwise stated. The method includes providing a first metal support element 68, which may include a tubular portion 72. The method also includes overmolding the tubular portion 72 of the first metal support element 68 with foam to form a foam portion 70 of the first cushion segment 46 of the cushion assembly 28. Before overmolding the tubular portion with foam, the tubular portion 72 of the first metal support element 68 may be bent into a predetermined shape, such as the shape used in the illustrated embodiment or another predetermined shape. The predetermined shape may be U-shaped. However, as in the case of the first metal support element 124 of the first cushion segment 102 of the seat backrest 24 cushion assembly 34, the predetermined shape may include a plurality of bends 144a-144e (such as at least five bends 144a-144e) to achieve the desired predetermined shape. The first end 74 and the second end 76 of the first metal support element 68 may be free of overmolded foam. The method may also include flattening the first end 74 and the second end 76 and drilling holes 78, 80 through the flattened first end 74 and the second end 76, respectively, to provide the fastening capability as described above. The method may also include applying a second layer of foam 98 to the overmolded foam portion 70 on the tubular portion 72 of the first metal support element 68. As discussed above, the second layer of foam 98 may be a different type of foam than the overmolded foam portion 70 on the tubular portion 72.

[0107] By utilizing the first metal support element 68 and the second metal support element 84 to provide structural support for the first cushion segment 46 and the second cushion segment 48 of the cushion assembly 28 for the seat 22, and by utilizing the first metal support element 124 and the second metal support element 150 to provide structural support for the first cushion segment 102 and the second cushion segment 104 of the cushion assembly 34 for the seat back 24, the use of uncomfortable and heavy metal plates welded to the structural support members 26, 32 to provide structural support for the first cushion segment 46, the second cushion segment 48, the first cushion segment 102, and the second cushion segment 104 can be avoided. The tubular portions 72, 88, 128, 154 of the first metal support element 68, the second metal support element 84, the first metal support element 124, and the second metal support element 150 can be thin-walled and therefore can be formed from metal materials of smaller dimensions than the heavy metal plates typically welded to the structural support members of the seat 22 and the seat back 24 described above. Because the first metal support element 68, the second metal support element 84, the first metal support element 124, and the second metal support element 150 include holes 78, 80, 94, 96, 134, 136, 160, and 162, they can be attached to the structural supports 26 and 32 without welding. Since the tubular portions 72, 88, 128, and 154 are covered with molded foam as described above, the first metal support element 68, the second metal support element 84, the first metal support element 124, and the second metal support element 150 will not cause discomfort to the occupants of the first seat assembly 14.

[0108] It should be understood that variations and modifications may be made to the foregoing structure without departing from the concept of the invention, and it should also be understood that such concept is intended to be covered by the appended claims unless those claims are otherwise expressly stated in their language.

[0109] According to the present invention, a seat assembly for a vehicle is provided, the seat assembly comprising: a seat including a structural support member and a cushion assembly attached to the structural support member; and a seat back that cooperates with the seat, the seat back including a structural support member and a cushion assembly attached to the structural support member; the seat cushion assembly comprising: a main support section; a first cushion section disposed on a side of the main support section, the first cushion section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole receiving a fastener for attaching the seat cushion assembly to the structural support member of the seat; and a second cushion section disposed on a side of the main support section and opposite to the first cushion section, the second cushion section including a foam portion at least partially surrounding a second metal support element, the second metal support element including... The seat back cushion assembly includes a tubular portion and at least one hole receiving fasteners for attaching the seat back cushion assembly to a structural support member of the seat; and the seat back cushion assembly includes: a main support section; a first cushion section disposed on a side of the main support section, the first cushion section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole receiving fasteners for attaching the seat back cushion assembly to a structural support member of the seat back; and a second cushion section disposed on a side of the main support section and opposite to the first cushion section, the second cushion section including a foam portion at least partially surrounding a second metal support element, the second metal support element including a tubular portion and at least one hole receiving fasteners for attaching the seat back cushion assembly to a structural support member of the seat back.

[0110] According to one embodiment, the invention further features a seat cushion assembly, wherein at least one hole of the first metal support element includes a first hole and a second hole separated by a tubular portion of the first metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat cushion assembly to a structural support member of the seat; wherein, with respect to the seat cushion assembly, at least one hole of the second metal support element includes a first hole and a second hole separated by a tubular portion of the second metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat cushion assembly to a structural support member of the seat; wherein, with respect to the seat back cushion assembly, at least one hole of the first metal support element includes a first hole and a second hole separated by a tubular portion of the first metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat back cushion assembly to a structural support member of the seat back; and wherein, with respect to the seat back cushion assembly, at least one hole of the second metal support element includes a first hole and a second hole separated by a tubular portion of the second metal support element, and each of the first hole and the second hole receives a fastener for attaching the seat back cushion assembly to a structural support member of the seat back.

[0111] According to one embodiment, the main support section of the seat cushion assembly includes a foam portion; and the main support section of the seat back cushion assembly includes a foam portion; wherein, with respect to the seat cushion assembly, the foam portions of the main support section, the first cushion section, and the second cushion section are adjacent; and wherein, with respect to the seat back cushion assembly, the foam portions of the main support section, the first cushion section, and the second cushion section are adjacent.

[0112] According to one embodiment, a seat cushion assembly is provided having a second layer of foam covering at least a portion of adjacent foam portions of a main support section, a first cushion section, and a second cushion section; and a seat back cushion assembly further includes a second layer of foam covering at least a portion of adjacent foam portions of the main support section, the first cushion section, and the second cushion section; wherein, with respect to the seat cushion assembly, the second layer of foam is a foam of a different type from the adjacent foam portions of the main support section, the first cushion section, and the second cushion section; and wherein, with respect to the seat back cushion assembly, the second layer of foam is a foam of a different type from the adjacent foam portions of the main support section, the first cushion section, and the second cushion section.

[0113] According to one embodiment, the invention is further characterized in a seat cushion assembly; wherein the second layer of foam is polyurethane foam; wherein, with respect to the seat cushion assembly, the adjacent foam portions of the main support section, the first cushion section, and the second cushion section are expanded polypropylene foam; wherein, with respect to the seat back cushion assembly, the second layer of foam is polyurethane foam; and wherein, with respect to the seat back cushion assembly, the adjacent foam portions of the main support section, the first cushion section, and the second cushion section are expanded polypropylene foam.

[0114] According to one embodiment, the invention further features: a centerline dividing the seat assembly into a first side and a second side; a structural support member of the seat including at least one hole disposed on the first side of the centerline and at least one hole disposed on the second side of the seat assembly; at least one hole of the first cushion segment of the seat cushion assembly and at least one hole of the structural support member of the seat being coaxially disposed and receiving the same fasteners for attaching the seat cushion assembly to the structural support member of the seat; at least one hole of the second cushion segment of the seat cushion assembly and at least one hole of the structural support member of the seat being coaxially disposed and receiving the same fasteners for attaching the seat cushion assembly to the structural support member of the seat; a structural support member of the seat back including at least one hole disposed on the first side of the seat assembly and at least one hole of the structural support member of the seat assembly being coaxially disposed and receiving the same fasteners for attaching the seat cushion assembly to the structural support member of the seat; and a structural support member of the seat back including at least one hole disposed on the first side of the seat assembly and at least one hole of the first cushion segment of the seat cushion assembly and at least one hole of the structural support member of the seat being coaxially disposed and receiving the same fasteners for attaching the seat cushion assembly to the structural support member of the seat. At least one hole on the second side of the seat back cushion assembly; at least one hole in the first cushion section of the seat back cushion assembly and at least one hole in the structural support member of the seat back are coaxially arranged and receive the same fasteners for attaching the seat back cushion assembly to the structural support member of the seat back; at least one hole in the second cushion section of the seat back cushion assembly and at least one hole in the structural support member of the seat back are coaxially arranged and receive the same fasteners for attaching the seat back cushion assembly to the structural support member of the seat back; wherein at least one hole in the structural support member of the seat is closer to the centerline of the seat assembly than at least one hole in the first cushion section; and wherein at least one hole in the structural support member of the seat is closer to the centerline of the seat assembly than at least one hole in the second cushion section.

[0115] According to one embodiment, a first metal support element for a seat back cushion assembly is provided, the first metal support element having: a first end; and a second end, wherein a tubular portion of the first metal support element of the seat back cushion assembly is disposed between the first end and the second end of the first metal support element of the seat back cushion assembly; and the tubular portion of the first metal support element of the seat back cushion assembly includes a plurality of bends, such that the distance between two of the plurality of bends in front of the first end and the second end of the first metal support element of the seat back cushion assembly is greater than the distance between the first end and the second end of the first metal support element of the seat back cushion assembly.

[0116] According to the present invention, a cushion assembly for a seat assembly of a vehicle is provided, the cushion assembly having: a main support section; a first cushion section disposed on a side of the main support section, the first cushion section including a foam portion at least partially surrounding a first metal support element, the first metal support element including a tubular portion and at least one hole configured to receive fasteners for securing the cushion assembly to a structural support; and a second cushion section disposed on a side of the main support section and opposite to the first cushion section, the second cushion section including a foam portion at least partially surrounding a second metal support element, the second metal support element including a tubular portion and at least one hole configured to receive fasteners for securing the cushion assembly to a support structure.

[0117] According to one embodiment, the first metal support element is U-shaped; and wherein the second metal support element is U-shaped.

[0118] According to one embodiment, the invention is further characterized in that at least one hole of the first metal support element configured to receive a fastener to fasten the gasket assembly to the support structure includes a first hole and a second hole separated by a tubular portion of the first metal support element; and wherein at least one hole of the second metal support element configured to receive a fastener to fasten the gasket assembly to the support structure includes a first hole and a second hole separated by a tubular portion of the second metal support element.

[0119] According to one embodiment, a foam portion of a first padding segment surrounds at least a portion of a tubular portion of the first padding segment, but not around the first padding segment, and is configured to receive fasteners to secure the padding assembly to at least one hole in a structural support; and wherein a foam portion of a second padding segment surrounds at least a portion of a tubular portion of the second padding segment, but not around the second padding segment, and is configured to receive fasteners to secure the padding assembly to at least one hole in a support structure.

[0120] According to one embodiment, the main support section includes a foam portion; wherein the foam portions of the main support section, the first cushion section, and the second cushion section are adjacent to each other.

[0121] According to one embodiment, the invention is further characterized by a second layer of foam that covers at least a portion of the adjacent foam portions of the main support section, the first cushion section, and the second cushion section; wherein the second layer of foam is a type of foam different from the adjacent foam portions of the main support section, the first cushion section, and the second cushion section.

[0122] According to one embodiment, the second layer of foam is polyurethane foam; and wherein the adjacent foam portions of the main support section, the first cushion section, and the second cushion section are expanded polypropylene foam.

[0123] According to the present invention, a method is provided for manufacturing a cushion segment for a seat assembly for a vehicle by: providing a first metal support element including a tubular portion; and molding the tubular portion of the first metal support element with foam.

[0124] According to one embodiment, the invention is further characterized in that the tubular portion of the first metal support element is bent into a predetermined shape before the tubular portion of the first metal support element is covered with foam.

[0125] According to one embodiment, the invention is further characterized in that the first end of the tubular portion is flattened and a hole is formed through the first end.

[0126] According to one embodiment, the invention is further characterized in that a second layer of foam is applied to the foam overlaid on the tubular portion of the first metal support element; wherein the second layer of foam is a different type of foam from the foam overlaid on the tubular portion of the first metal support element.

[0127] According to one embodiment, the tubular portion of the first metal support element has a predetermined shape of U-shape.

[0128] According to one embodiment, the tubular portion of the first metal support element has a predetermined shape with at least five bends.

Claims

1. A seat assembly for a vehicle, the seat assembly comprising: A seat and a seat back that mates with the seat, each of the seat and the seat back including a structural support and a padding assembly attached to the structural support; Each of the cushion assemblies of the seat and the seat back includes: Main support section; A first cushion segment, wherein the first cushion segment is disposed on the side of the main support segment; and The second cushion section is disposed on the side of the main support portion and opposite to the first cushion section. Each of the first and second cushion segments includes a metal support element and a foam portion at least partially surrounding the metal support element; and Each of the metal support elements includes a first end attached to the structural support, a second end attached to the structural support, and a rod-shaped portion or a tubular portion between the first end and the second end.

2. The seat assembly as described in claim 1, in, Each of the metal support elements in the first and second cushion segments of the cushion assembly of both the seat and the seat back includes a first hole at the first end and a second hole at the second end, and both the first and second holes receive fasteners for attaching the metal support element to the structural support.

3. The seat assembly as described in claim 1; Each of the main support sections of the seat cushion assembly, including both the seat and the seat back, includes a foam portion; The foam portions of the main support section, the first cushion section, and the second cushion section of the seat cushion assembly for both the seat and the seat back are adjacent.

4. The seat assembly as claimed in claim 1, wherein, The metal support element is U-shaped.

5. The seat assembly as claimed in claim 1, wherein, The rod-shaped or tubular portion of the metal support element of the cushion assembly of the seat back includes a plurality of bends, such that the distance between two of the plurality of bends in front of the first and second ends of the metal support element of the cushion assembly of the seat back is greater than the distance between the first and second ends of the metal support element of the cushion assembly of the seat back.

6. A cushion assembly for a seat assembly in a vehicle, the cushion assembly comprising: Main support section; The first cushion section is disposed on the side of the main support section; as well as The second cushion section is disposed on the side of the main support portion and opposite to the first cushion section. Each of the first cushion segment and the second cushion segment includes a metal support element and a foam portion that at least partially surrounds the metal support element; Each of the metal support elements includes a first end, a second end, and a rod-shaped portion or a tubular portion between the first end and the second end; Each of the metal support elements of the first cushion segment and the second cushion segment includes a first hole at the first end and a second hole at the second end to allow the cushion assembly to be attached to the structural support of the seat assembly.

7. The gasket assembly as claimed in claim 6, wherein, The metal support element is U-shaped.

8. The gasket assembly as claimed in claim 6, in, The cushion assembly is a seat back cushion assembly, the main support section of the seat back cushion assembly including a bottom and a top, wherein the first end and the second end of the metal support element of the first cushion section and the second cushion section of the seat back cushion assembly are located above the bottom and below the top; or The cushion assembly is a seat cushion assembly, and the main support section of the seat cushion assembly includes a front end and a rear end. The first end and the second end of the metal support element of the first cushion section and the second cushion section of the seat cushion assembly are located behind the front end and in front of the rear end.

9. The gasket assembly as claimed in claim 6, in, The foam portions of the first and second cushion segments surround at least a portion of the tubular portion of the first cushion segment, but not around the first cushion segment configured to receive fasteners to secure the pad assembly to the first and second holes of the structural support.

10. The gasket assembly as claimed in claim 6, The main support section includes a foam component; in, The foam portions of the main support section, the first cushion section, and the second cushion section are adjacent to each other.

11. A method of manufacturing a cushion segment for a seat assembly of a vehicle, said cushion segment comprising a first cushion segment or a second cushion segment in a seat assembly of a vehicle as described in any one of claims 1-5, or comprising a first cushion segment or a second cushion segment in a padding assembly for a seat assembly of a vehicle as described in any one of claims 6-10, said method comprising: Provide metal support elements including tubular sections; as well as The tubular portion of the metal support element is encapsulated in foam.

12. The method of claim 11, further comprising: Before the tubular portion of the metal support element is covered with foam, the tubular portion of the metal support element is bent into a predetermined shape.

13. The method of claim 11, further comprising: The first end of the tubular portion is flattened and a hole is formed through the first end.

14. The method of claim 11, further comprising: A second layer of foam is applied to the foam that is overmolded on the tubular portion of the metal support element; The second layer of foam is a different type of foam from the foam that is formed over the tubular portion of the metal support element.

15. The method as described in claim 12, in, The predetermined shape of the tubular portion of the metal support element is U-shaped.

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