Seat support

Abstract

A seat support is provided with a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers are stacked on top of each other. At least one of the plurality of stacked layers has a substantially uniform thickness.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a continuation-in-part of U.S. patent application serial number 17 / 218,663 filed on March 31, 2021, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] Various embodiments are directed to seat supports, methods for making seat supports and seat assemblies, and methods for recycling seat supports and seat assemblies. background

[0004] U.S. Patent No. 10,736,435 B2 to Duncan et al., issued to Lear Corporation on August 11, 2020, teaches a seat component including a non-foam substrate.

[0005] Overview

[0006] According to one embodiment, a seat support is provided with a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers are stacked upon one another, and each of the plurality of stacked layers has a substantially uniform thickness.

[0007] According to a further embodiment, one of the plurality of layers has a first firmness and another of the plurality of layers has a second firmness different from the first firmness.

[0008] According to another further embodiment, one of the plurality of layers has a first thickness. Another of the plurality of layers has a second thickness different from the first thickness.

[0009] According to another further embodiment, in which a plurality of zones are provided, at least two zones differ in thickness, solidity or number of stacked layers.

[0010] According to still further embodiments, the plurality of zones are further provided with a nose, an insert, and a pair of bolsters on laterally opposite sides of the nose and the insert to support the seat bottom.

[0011] According to another further embodiment, the plurality of zones are further provided with an insert, a pair of bolsters on laterally opposite sides of the insert, and a pair of shoulders on laterally opposite sides of the insert to support the seat back.

[0012] According to another further embodiment, each of the plurality of layers is formed from a monofilament textile material.

[0013] According to another further embodiment, each of the plurality of layers is formed from recycled material.

[0014] According to another further embodiment, each of the plurality of layers is formed from polyester.

[0015] According to another further embodiment, a heating pad or a blower is provided.

[0016] According to a further embodiment, a sealed ventilation port is formed through at least one of the layers.

[0017] According to another further embodiment, the area between consecutive pairs of layers is sealed so that ventilation is directed through one of the consecutive pairs of layers.

[0018] According to another further embodiment, a conductive yarn is arranged in one of the monofilament textile material layers.

[0019] According to another further embodiment, a heating mat is positioned between two of the plurality of layers. The heating mat is in electrical communication with the conductive yarn.

[0020] According to another further embodiment, each consecutive pair of layers is welded or sewn together.

[0021] According to another further embodiment, each layer is further provided with one of a hook fastener and a loop fastener for fastening to a sequential layer of the plurality of layers.

[0022] According to another further embodiment, each of the plurality of layers is formed from a similar recyclable material.

[0023] According to a further embodiment, an adhesive is provided between each consecutive pair of the plurality of layers to bond the consecutive layers together. The adhesive is formed from a similar recyclable material.

[0024] According to another embodiment, a seat assembly is provided with a substrate. A seat support is provided with a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers are stacked upon one another, and each of the plurality of stacked layers has a substantially uniform thickness. Each of the plurality of layers is formed of a monofilament textile material. The seat support is attached to the substrate.

[0025] According to a further embodiment, a seat frame is provided. A substrate is attached to the seat frame.

[0026] According to another further embodiment, each of the plurality of layers is formed of a similar recyclable material. The substrate is formed of a similar recyclable material.

[0027] According to another embodiment, a seat assembly is provided with a seat support having a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers are stacked upon one another, and each of the plurality of stacked layers has a substantially uniform thickness. Each of the plurality of layers is formed of a monofilament textile material. Each of the plurality of layers is formed of a similar recyclable material. A trim cover is sized to receive the seat support.

[0028] According to another embodiment, the trim cover is formed from a recyclable material similar to the recyclable material of the plurality of layers.

[0029] According to another further embodiment, the trim cover is formed from a single leather layer without coating.

[0030] According to another further embodiment, a trim clip is provided to connect the trim cover to the seat support. The trim clip is formed of a recyclable material similar to the recyclable material of the plurality of layers.

[0031] According to another embodiment, a method for manufacturing a seat assembly cuts a first seat support portion from a first sheet of monofilament material. The first seat support portion is mounted on a substrate. A trim cover is mounted over the first seat support portion.

[0032] According to a further embodiment, the sheet of monofilament material is unrolled before cutting the first seat support portion.

[0033] According to another further embodiment, the first seat support part is cut with a laser.

[0034] According to another further embodiment, a plurality of seat support portions are cut from the first sheet of monofilament material. The plurality of seat support portions are stacked to form a seat support.

[0035] According to a further embodiment, one of the plurality of seat support portions is sealed to direct ventilation through the seat assembly.

[0036] According to another further embodiment, a duct is formed through one of the plurality of seat support portions to direct ventilation through the seat assembly.

[0037] According to another further embodiment, a plurality of seat support sections are fastened together.

[0038] According to another further embodiment, the second seat support portion is cut from a second sheet of monofilament material having a different solidity or thickness than the first sheet of monofilament material. The first seat support portion and the second seat support portion are stacked to form the seat support.

[0039] According to another further embodiment, a first plurality of seat support portions are cut from a first sheet of monofilament material. A second plurality of seat support portions are cut from a second sheet of monofilament material. The first plurality of seat support portions and the second plurality of seat support portions are stacked to form a seat support.

[0040] According to another further embodiment, the polymeric material is recycled.The first sheet of monofilament material is made from recycled polymeric material.

[0041] According to a further embodiment, the substrate is manufactured from a recycled polymeric material.

[0042] According to another further embodiment, the trim cover is manufactured from a recycled polymer material.

[0043] According to another further embodiment, the plurality of seat support sections are bonded together by a recycled polymer adhesive.

[0044] According to another embodiment, a seat support assembly is provided with a non-foamed monofilament textile material for mounting to and supporting an occupant on a seat frame. A heating pad or blower is provided. The monofilament textile material allows ventilation without the need for an air distribution bag.

[0045] According to a further embodiment, a sealed ventilation port is formed through the monofilament textile material.

[0046] According to another further embodiment, the area through the monofilament textile material is sealed so that ventilation is guided through the monofilament textile material.

[0047] According to another embodiment, a method for recycling a seat assembly includes grinding a seat support made of a polymeric material, grinding a trim clip or a trim cover made of a polymeric material similar to the polymeric material of the seat support, and grinding the trim clip or the trim cover without removing the trim clip or the trim cover from the seat support.

[0048] According to a further embodiment, the trim clip and the trim cover are made of a polymer material similar to the polymer material of the seat support, and the trim clip and the trim cover are ground without removing the trim clip or the trim cover from the seat support.

[0049] According to another further embodiment, the substrate is made of a polymer material similar to the polymer material of the seat support, the substrate being ground without removing the substrate from the seat support.

[0050] According to another further embodiment, the adhesive is made of a polymer material similar to the polymer material of the seat support, the adhesive being ground without being removed from the seat support.

[0051] According to another further embodiment, the roll of monofilament material is manufactured from ground polymeric material.

[0052] According to another embodiment, a seat support is provided with multiple layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The multiple layers are stacked on top of each other. At least one of the multiple stacked layers has a substantially uniform thickness.

[0053] According to a further embodiment, the plurality of layers is further provided with a base layer for mounting to the seat frame. The second layer is mounted to the base layer. The second layer has a substantially uniform thickness.

[0054] According to a further embodiment, the base layer has a first firmness. The second layer has a second firmness, the second firmness being less firm than the first firmness.

[0055] According to another further embodiment, the base layer has a first thickness. The second layer has a second thickness that is less than the first thickness.

[0056] According to another further embodiment, the base layer is formed from a monofilament textile material.

[0057] According to another further embodiment, the second layer is formed from a monofilament textile material.

[0058] According to another further embodiment, the second layer is formed from polyester.

[0059] According to another further embodiment, the second layer is welded, stitched or bonded to the base layer.

[0060] According to another further embodiment, a plurality of zones is provided, wherein at least two zones differ in thickness or solidity.

[0061] According to still further embodiments, the plurality of zones are further provided with bosses, inserts, and pairs of bolsters on laterally opposite sides of the bosses and inserts to support the seat bottom.

[0062] According to another further embodiment, the plurality of zones are further provided with an insert, a pair of bolsters on laterally opposite sides of the insert, and a pair of shoulders on laterally opposite sides of the insert to support the seat back.

[0063] According to another embodiment, a seat assembly is provided with a substrate. A seat support is provided with multiple layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The seat support is attached to the substrate. The multiple layers are stacked on top of each other. At least one of the multiple stacked layers has a substantially uniform thickness. The multiple layers are also provided with a base layer for mounting to the seat frame. A second layer is mounted to the base layer. The second layer has a substantially uniform thickness.

[0064] According to a further embodiment, a seat frame is provided, and a substrate is attached to the seat frame.

[0065] According to another embodiment, a seat assembly is provided with a seat support having a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame. The plurality of layers are stacked on top of each other. At least one of the plurality of stacked layers has a substantially uniform thickness. The plurality of layers are also provided with a base layer for mounting to the seat frame. A second layer is mounted to the base layer. The second layer has a substantially uniform thickness. A trim cover is sized to receive the seat support, wherein the second layer is positioned between the trim cover and the base layer.

[0066] According to another embodiment, a method for manufacturing a seat assembly forms a base seat support portion. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is mounted on the base seat support portion.

[0067] According to a further embodiment, the trim cover is mounted over the base seat support portion and the second seat support portion such that the second seat support portion is positioned between the base seat support portion and the trim cover.

[0068] According to another further embodiment, the second seat support portion is fastened to the base seat support portion.

[0069] According to yet another further embodiment, the base seat support portion is formed from a non-foam material.

[0070] According to another embodiment, a seat assembly is manufactured by forming a base seat support portion. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is mounted on the base seat support portion.

[0071] According to yet another embodiment, a method for manufacturing a seat assembly forms a base seat support portion from a non-foam material. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is mounted on the base seat support portion. The second seat support portion is fastened to the base seat support portion. A trim cover is mounted over the base seat support portion and the second seat support portion such that the second seat support portion is positioned between the base seat support portion and the trim cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Figure 1 is a partial perspective cross-sectional view of a seat assembly according to one embodiment;

[0073] Figure 2 According to another embodiment Figure 1 A perspective cross-sectional view of a portion of a seat assembly;

[0074] Figure 3 According to another embodiment Figure 1 a perspective view of a portion of a seat assembly;

[0075] Figure 4 is a perspective view of a portion of a seat assembly according to one embodiment;

[0076] Figure 5 is an exploded cross-sectional view of a fastener assembly of a seat assembly according to another embodiment;

[0077] Figure 6 is a perspective view of a trim clip of a seat assembly according to one embodiment;

[0078] Figure 7 is a perspective view of a seat assembly according to another embodiment;

[0079] Figure 8 yes Figure 7 A front view of a seat assembly;

[0080] Fig. 9 is a partial perspective cross-sectional view of a seat assembly according to another embodiment;

[0081] Fig.10 yes Fig. 9 a cross-sectional view of a portion of a seat assembly;

[0082] Fig.11 yes Fig. 9 a cross-sectional view of another portion of the seat assembly;

[0083] Fig.12 is a partial perspective cross-sectional view of a seat assembly according to another embodiment;

[0084] Fig.13 yes Fig.12 An exploded view of the various parts of the seat assembly;

[0085] Fig.14 yes Fig.12 a front perspective view of the center seat assembly showing the trim cover removed;

[0086] Fig.15 is a front perspective view of a seat assembly according to another embodiment; and

[0087] Fig.16 yes Fig.15 Another front perspective view of the seat assembly of . Detailed Description

[0088] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the present invention, and these embodiments may be implemented in various forms and alternative forms. The drawings are not necessarily to scale; some features may be enlarged or minimized to show the details of a particular component. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to implement the present invention in different ways.

[0089] Seat assemblies and vehicle seat assemblies are designed and manufactured to various specifications including support, comfort, performance, heating, ventilation, cooling, adjustability, etc. Seat assemblies are typically provided with a frame and various foam layers having varying densities to accommodate proper load distribution throughout the seat assembly.

[0090] Figure 1 A seat assembly 20 according to one embodiment is shown. The seat assembly 20 is depicted as a vehicle seat that can be used as a seat assembly in vehicles such as land vehicles, aircraft, ships, etc. The seat assembly 20 can be used in any row within a vehicle. Alternatively, the seat assembly 20 can also be used as an office chair or any individual chair. The seat assembly 20 omits traditional foam to improve support and comfort while reducing cost, material, and size. The seat assembly 20 also uses recycled materials that are manufactured for further recycling at the end of the use of the seat assembly 20.

[0091] The seat assembly 20 includes a seat bottom 22, which is sized to receive a seated occupant to support the pelvis and thighs of the occupant. The seat assembly 20 also includes a seat back 24, which is sized to extend upright from the seat bottom 22 to support the back of the occupant. A head restraint 26 is supported on and above the seat back 24 to support the head of the occupant. The seat bottom 22 is adapted to be supported by a support surface below. For the described embodiment, the seat assembly 20 includes a pair of tracks 28 for mounting the seat bottom 22 to the vehicle floor so as to be adjusted forward and backward relative to the vehicle floor. The seat back 24 can also be adjustable to tilt relative to the seat bottom 22. The head restraint 26 can also be adjustable in height, tilt and front / rear direction. As known in the art, other adjustments can be provided.

[0092] The seat bottom 22 includes a frame 30 for providing rigid structural support to the seat bottom 22. The seat back 24 also includes a frame 32. The seat back frame 32 can be connected to the seat bottom frame 30 to extend vertically from the seat bottom 222. The seat back frame 32 provides rigid structural support to the seat back 24. The frames 30, 32 can be formed of stamped steel alloy, fiber reinforced polymer, or any suitable structural material. A pair of head protection posts 34 are connected to the upper region of the seat back frame 32 to support the head restraint 26 above the seat back 24.

[0093] Conventional seat assemblies include multiple foam layers to collectively provide cushioning on the head restraint 26 on the frames 30, 32 and posts 34. The multiple foam layers are of varying densities to provide compliant support to the occupant while distributing forces from the occupant to the frames 30, 32 and posts 34. The foam layers also provide comfort to the occupant. The foam layers are typically molded, so each foam layer of each seat assembly requires a dedicated tooling.

[0094] The seat assembly 20 is formed without foam to improve comfort, performance, compactness, and recyclability while reducing manufacturing tooling costs. For example, the seat assembly 20 includes a seat bottom support 36 that provides a seat bottom cushion for the seat bottom 22. The seat bottom support 36 is formed from a plurality of stacked layers of non-foam material. The seat back 24 includes a seat back support 38 that is also formed from a non-foam stacked layer. Likewise, the head restraint 26 may also be provided with a head restraint support 40 formed from a non-foam stacked layer.

[0095] Figure 2 A plurality of stacked layers 42, 44, 46 are illustrated for constructing the seat bottom support 36, the seat back support 38, and the head restraint support 40. Each of the depicted layers 42, 44, 46 is formed of a knitted monofilament textile material. An example of such a material is polyester, such as polyethylene terephthalate. The material may also be formed of recycled material to reduce material costs and waste. The material of each layer 42, 44, 46 is a similar polyester, so the entire seat support 36, 38, 40 can be recycled without disassembling the individual layers 42, 44, 46.

[0096] The material is knitted or woven to provide structure while also leaving space to provide porosity, ventilation, and compliance. Each layer 42, 44, 46 can have a uniform thickness and can be formed from a sheet or roll. Each of the layers 42, 44, 46 can be different in firmness or thickness. An example of a knitted non-foam material is disclosed in U.S. Patent No. 10,736,435 B2 to Duncan et al., which was issued to Lear Corporation on August 11, 2020, and the entire contents of which are incorporated herein by reference.

[0097] Layers 42, 44, 46 can be customizable. Layers 42, 44, 46 can each be formed with a specific firmness and thickness so that different combinations of layers 42, 44, 46 can be used to optimize the specific support and comfort curve profiles of various seats. The firmness of layers 42, 44, 46 can be modified by modifying the density of the layers, the density of the threads in the layers, the thickness of the threads in the layers, the spacing of the threads in the layers, etc. The comfort curve profile is formed by the pressure distribution of the entire seat assembly 20 estimated based on the set design characteristics of the occupant, the expected height, weight and other data of the occupant in the target range. Compared with the same seat assembly 20 made of foam, the weight of the former can be reduced by up to two pounds when it is designed to provide the same static comfort. In addition, stacking layers 42, 44, 46 allows greater design flexibility to reduce the pressure in the peak area of ​​the seat assembly 20.

[0098] A range of thickness variations may be provided by the layers 42, 44, 46, 48, which may be combined for a target thickness of the seat supports 36, 38, 40. According to one example, each layer may have a thickness in the range of 6 to 15 millimeters.

[0099] Figure 3 Another non-foamed monofilament textile is shown providing one of the layers 48. The textile is formed into a roll. Each of the layers 42, 44, 46, 48 may be different in terms of knit pattern. For example, the layers 42, 44, 46, 48 may be formed with a hidden surface, referred to in the art as a B surface. Some layers may be formed with a surface designed to be exposed, referred to as a face cloth, or A surface, such as Figure 3 The face cloth surface 50 of the layer 48 in the embodiment of the present invention is provided. By providing the face cloth surface 50 on one of the layers, the external decorative cover can be minimized or eliminated.

[0100] Each seat support 36, 38, 40 is formed of a plurality of stacked layers 42, 44, 46, 48. The layers 42, 44, 46, 48 can be individually unfolded and then cut into a specific decorative pattern. According to one embodiment, the layers 42, 44, 46, 48 are cut by laser. According to another embodiment, the layers are cut by automation, such as a robotic tool. By cutting the layers 42, 44, 46, 48, the decorative die and foam molding tool are eliminated, thereby reducing the tooling cost of manufacturing the seat assembly 20.

[0101] The layers 42, 44, 46, 48 are then stacked together to form the seat supports 36, 38, 40. Referring again to Figure 1 , the seat bottom frame 30 can be formed as a disk. Each of the layers 42, 44, 46, 48 can be stacked and nested into the disk-shaped frame 30. Alternatively, a substrate, such as a carrier or disk 52, can be provided in the seat bottom 22 to receive the layers 42, 44, 46, 48 and connect the layers to the frame 30. Likewise, the seat back frame 32 can also be formed as a disk. The seat back carrier 54 can be separately provided to support the layers 42, 44, 46, 48 and attach the layers 42, 44, 46, 48 to the frame 30. The head restraint carrier 56 can also be provided to support the layers 42, 44, 46, 48 and attach the layers 42, 44, 46, 48 to the post 34.

[0102] Figure 4 A seat back carrier 54 is shown according to one embodiment. The seat back carrier 54 has the general overall shape and contour of the seat back 24. The seat back carrier 54 may also be provided with other functional components placed under the cushion of the seat back support 38. For example, a plurality of air bags 58 are attached to the carrier 54. The air bags 58 may be used for support, posture and comfort adjustment of the seat back 24.

[0103] Each of the layers 42, 44, 46, 48 may be stacked and nested into each carrier 52, 54, 56 to construct a respective seat support 36, 38, 40. Each carrier 52, 54, 56 may also be formed from the same polyester material as the layers 42, 44, 46, 48. Thus, the seat supports 36, 38, 40 may be recycled at the end of use without removing the layers 42, 44, 46, 48 from the carriers 52, 54, 56.

[0104] Each of the layers 42, 44, 46, 48 can be fastened together to form each seat support 36, 38, 40. According to one embodiment, a polyester adhesive is provided between adjacent layers 42, 44, 46, 48 to bond the layers 42, 44, 46, 48 together. The polyester adhesive can be recycled with the layers 42, 44, 46, 48 without being removed prior to recycling. The polyester adhesive can be heat activated, wherein the assembled layers 42, 44, 46, 48 are heated to bond together. The polyester adhesive is not susceptible to degradation over time and is also not susceptible to changes in temperature and humidity. According to one example, the polyester adhesive can be knitted into the outer threads of the layers 42, 44, 46, 48.

[0105] Alternatively, the layers 42, 44, 46, 48 may be welded together, for example by radio frequency welding. The fastening of the layers 42, 44, 46, 48 by welding may also be automated. Other mechanisms for fastening adjacent layers include stitching, embroidery, quilting, etc. Successive layers 42, 44, 46, 48 may be provided with one of a hook fastener and a loop fastener to connect to each other.

[0106] Figure 5 Two layers 72 are shown, each formed with a loop fastener 74 formed around the layer 72. An intermediate hook layer 76 is provided with an array of outer hooks 78 for fastening to the loops 74 of the successively adjacent layer 72. Each of the layers 72, 76 and fasteners 74, 78 are formed of polyester for recyclable use with the seat supports 36, 38, 40.

[0107] Reference again Figure 1 Once the stacked layers 42, 44, 46, 48 are assembled, the seat supports 36, 38, 40 are disposed on the carriers 52, 54, 56. A trim cover 60, 62, 64 is disposed on each seat support 36, 38, 40. The seat bottom trim cover 60, the seat back trim cover 62, and the head restraint trim cover 64 can each be formed of a polyester material. Therefore, the trim covers 60, 62, 64 can be recycled with the seat supports 36, 38, 40 without being removed from the seat supports 36, 38, 40. The trim covers 60, 62, 64 can be formed of sustainable materials, such as reprieve yarn, polyester-based textiles, or leather substitutes.

[0108] Alternatively, the trim covers 60, 62, 64 may be formed of leather. The leather trim covers 60, 62, 64 may each be formed of a single material substrate without a coating to allow for recycling at the end of use. The leather trim covers 60, 62, 64 may be removed from the seat supports 36, 38, 40 to be recycled separately from the seat supports 36, 38, 40.

[0109] Figure 6 A trim clip 66 is shown according to one embodiment. The trim clip 66 can function as known in the art, having a base 68 that is sized to be received in a groove within one of the seat supports 36, 38, 40. The trim clip 66 also includes a pair of retainers 70 extending from the base 68. The retainers 70 receive a portion of the trim cover 60, 62, 64 to attach the trim cover 60, 62, 64 to the seat support 36, 38, 40. Although one trim clip 66 example is shown and described, any suitable trim clip can be used. Multiple trim clips 66 can be used, and multiple trim clips 66 can be interconnected or tethered in an array or strip arrangement of known groups of clips 66. The trim clip 66 can also be formed of a similar recyclable material (polyester). If tethered, the tether can also be formed of polyester. Due to the similar materials, the trim clip 66 can be recycled with the seat support 36, 38, 40 without being removed from the seat support 36, 38, 40.

[0110] Various components for the seat assembly 20 can be formed from recycled materials to reduce the carbon footprint. In addition, at the end of their life, the seat supports 36, 38, 40 can be disassembled from the frames 30, 32 and the posts 34 for recycling. For recycling, the polyester components can be ground together without disassembly. The recycled materials can be reused. The recycled materials can also be made into monofilament textile material rolls for making new seat assemblies 20.

[0111] By eliminating the foam in the seat assembly 20, molding tools and molds can be eliminated, thereby reducing tooling costs. The flexibility of laser cutting reduces maintenance costs and improves part quality. The recyclability of the material reduces waste. In addition, the use of chemicals is reduced during the manufacturing process.

[0112] The seat assembly 20 is lighter than similar seats made with foam padding. The seat assembly 20 is also more compact in size. Layers of targeted comfort are provided and can be easily redesigned for future models or options without additional tooling costs.

[0113] Figure 7 and Figure 8A seat assembly 80 according to another embodiment is illustrated. Similar to the previous embodiment, the seat assembly 80 includes a seat bottom 82, a seat back 84, and a head restraint 86. The seat bottom 82 includes a seat bottom support 88 formed by a plurality of zones. For example, the seat bottom 82 may include an insert 90 centrally located at the rear of the seat bottom 82, and the insert 90 is sized to receive the pelvis of the occupant. A boss 92 is located forward of the insert 90, and the boss 92 is sized to support the thighs of the occupant. A pair of bolsters 94 are each located laterally outboard of the insert 90 and the boss 92 to provide lateral support and comfort to the pelvis and thighs.

[0114] Each zone 90, 92, 94 of the seat bottom support 88 is formed by multiple stacked layers, so that the thickness and firmness of these zones are different. According to one embodiment, the seat bottom support 88 is formed by four independent pieces of material, and the firmness of these pieces of material varies from firm, semi-firm, semi-soft and soft. Each of these zones can be composed of multiple layers of material. For example, the insert 90 can be formed from the bottom to the top in five layers: firm, firm, semi-soft, semi-soft and soft. The boss 92 supports less weight and provides five layers in order: semi-firm, semi-soft, soft, soft, and soft. The bolster 94 is a little more firm and is stacked from the bottom in order: firm, firm, semi-firm, semi-soft, and semi-soft. Each zone 90, 92, 94 is somewhat firm at the base to provide support and softens near the surface to provide comfort. The zones 90, 92, 94 are different in structure to provide a target comfort profile based on the estimated pressure distribution. The configuration of zones 90, 92, 94 is by way of example to illustrate how a target comfort profile can be provided by four types of material layers stacked up to five layers. Any number of layers may be used within any zone to achieve a target support and comfort profile.

[0115] The seat back 84 includes a seat back support 96. The seat back frame 96 includes a plurality of regions. For example, a seat back insert 98 supports the rear lumbar and thoracic regions of the occupant's back. A pair of seat back bolsters 100 are laterally spaced about the insert 98 to provide lateral support to the occupant's back. A pair of shoulder regions 102 are disposed above the bolsters 100 and extend from lateral sides of the insert 98 to the head restraint 86.

[0116] The seat back 84 supports lighter loads than the seat bottom 82. According to one embodiment, the seat back support 96 is formed from various combinations of the four material layers used for the seat bottom support 88. The insert 98 provides five layers from back to front: semi-firm, semi-firm, semi-firm, semi-firm, and semi-soft. The bolster 100 is thinner and provides four layers from back to front: semi-firm, semi-firm, semi-firm, and semi-soft. The shoulder 102 is provided with one layer, semi-soft. The comfort profile can also be varied depending on the number of material layers, as shown for the seat back support 96.

[0117] Fig. 9 A seat assembly 110 according to another embodiment is depicted. The seat assembly 110 includes a seat bottom 112, a seat back 114, and a head restraint 116. The seat assembly 110 includes a track 118 for connecting to the vehicle floor. The seat bottom 112 includes a seat bottom support 120 formed of multiple layers of monofilament textile (as described above in the previous embodiment). Similarly, the seat back 114 includes a seat back support 122 also formed of multiple non-foam layers. A decorative cover 124 is disposed on the seat bottom 112. A seat back decorative cover 126 is disposed on the seat back 114. A heater 128 is disposed between the layers in the seat bottom support 120. A cooling layer 130 is also disposed with the seat bottom support 120.

[0118] Fig.10 1 is a partial cross-sectional view of the seat bottom support 120 through the heater 128. The seat bottom 112 includes a seat bottom carrier 132. The seat bottom carrier 132 may be provided with ventilation holes to allow ventilation through and under the seat bottom 112. A plurality of layers 134 of monofilament material are provided on the carrier 132. The heater 128 is provided on the layers 134. The porosity of the monofilament textile material 134 allows ventilation through the layers 134. Thus, additional ducting or ventilation distribution bags are omitted compared to the prior art.

[0119] Another monofilament textile layer 136 is disposed on top of layer 134, with the heater 128 between the monofilament textile layer 136 and layer 134. The upper layer 136 can allow heat to pass therethrough so that the heat is conducted and transported through the upper layer 136 to the decorative cover 124. The upper layer 136 can be formed with thermally conductive yarns to conduct heat from the heater 128 to the decorative cover 124. The conductive yarns may include thermally conductive carbon fibers. One of the layers 134, 136 below or above the heater 128 may be formed with a conductive wire to transport electricity to the heater 128. U.S. Patent No. 10,882,444B2 to Townley et al., issued to Lear Corporation on January 5, 2021, discloses a textile having a conductive element, which U.S. Patent No. is incorporated herein by reference in its entirety.

[0120] Fig.11 A partial cross-sectional view through a cooling layer 130 of a seat bottom support 120 according to one embodiment is illustrated. A cooling assembly 138 is attached to the carrier 132. The cooling assembly 138 includes a blower fan as known in the art. The cooling assembly 138 may also include a thermoelectric device including a module for cooling a pressurized airflow. A plurality of layers 140 are disposed on the substrate 132, between the substrate 132 and the cooling layer 130. Ports 142 are formed through the layers 140 to direct the pressurized airflow through the layers 140. The ports 142 are sealed to prevent the pressurized airflow from indirectly passing through the intermediate layer 140.

[0121] The pressurized air flow is delivered to the cooling layer 130. Due to the porosity of the monofilament layer 130, the pressurized air flow is dispersed through the monofilament layer 130 to cool the trim cover 124. A seal 144 is also provided between the cooling layer 130 and the adjacent middle layer 140 to prevent the cooling air from penetrating the middle layer 140. The seal 144 guides the air and mitigates air flow losses. The seal 144 can also be formed of a polyester material for recycling with the seat bottom 112. The monofilament layer allows for improved thermal comfort and energy efficiency in the seat assembly 110.

[0122] Fig.12 and Fig.13 A seat assembly 150 according to another embodiment is illustrated. The seat assembly 150 may employ any of the features set forth in the previous embodiments. The seat assembly 150 includes a seat bottom 152, a seat back 154, and / or a head restraint 156. For the depicted embodiment, the seat assembly 150 includes a pair of tracks 158 for mounting the seat bottom 152 to the vehicle floor for fore-and-aft adjustment relative to the vehicle floor. The seat bottom 152 includes a frame 160; and the seat back 154 includes a frame 162.

[0123] The seat assembly 150 is formed without foam to improve comfort, performance, compactness, and recyclability while reducing manufacturing tooling costs. For example, the seat assembly 150 includes a seat bottom support 166 that provides a seat bottom padding for the seat bottom 152. The seat bottom support 166 is formed from multiple stacked layers of non-foam material. The seat back 154 includes a seat back support 168 that is also formed from non-foam stacked layers.

[0124] Fig.12 and Fig.13 The seat bottom support 166 is illustrated as including a seat bottom base layer 172 and a seat bottom comfort layer 174. The seat back support 168 also includes a seat back base layer 176 and a seat back comfort layer 178. The seat bottom base layer 172 and the seat back base layer 176 are formed of a knitted monofilament textile material. The base layers 172, 176 are knitted or woven to provide structure, while the material also leaves space to provide porosity, ventilation and flexibility. The base layers 172, 176 can each be different in firmness or thickness, and the contours can be shaped to form the shape of the seat bottom support 166 and the seat back support 168, respectively. The base layers 172, 176 can be formed of an extruded plastic mesh material. Alternatively, U.S. Patent No. 10,736,435B2 issued to Lear Corporation on August 11, 2020 by Duncan et al. discloses another example of a knitted non-foam material for the base layer 172, 176, which is incorporated herein by reference in its entirety. According to another example, the base layers 172, 176 can each be formed from a sheet or roll.

[0125] The seat bottom comfort layer 174 and the seat back comfort layer 178 are also formed of a knitted monofilament textile material, as disclosed in U.S. Patent No. 10,736,435B2 to Duncan et al., which was issued to Lear Corporation on August 11, 2020 and is incorporated herein by reference in its entirety. The material is knitted or woven to provide structure while also leaving space to provide porosity, ventilation, and flexibility. Alternatively, each of the layers 174, 178 can have a uniform thickness and can be formed from a sheet or roll. Each of the layers 174, 178 can be different in firmness or thickness.

[0126] Each of the base layers 172, 176 can be formed to have a different firmness while being firm enough to support the comfort layers 174, 178 and the occupant. The comfort layers 174, 178 can be formed to have a second firmness that is less than the firmness of the base layers 172, 176 to provide more compliance and comfort between the occupant and the base layers 172, 176. Each of the comfort layers 174, 178 can have a uniform thickness that is less than the total thickness of the base layers 172, 176 to provide sufficient compliance and luxurious contact with the occupant. The combination of one of the base layers 172, 176 and one of the comfort layers 174, 178 allows for the formation of a multi-layer, non-foam, monofilament textile seat support 166, 168 with minimal gaps (5 mm or less) between transitions from one layer to another.

[0127] The comfort layers 174, 178 may be fastened to the support layers 172, 176 by welding, sewing, adhesives, or the like. Fig.12 1 and 2 illustrate a decorative cover 180 disposed on the seat bottom support 166 and the seat back support 168 to conceal the frames 160, 162, the seat bottom support 166, the seat back support 168, and any other components supported on the frames 160, 162. The comfort layers 174, 178 are positioned between the support layers 172, 176 and the decorative cover 180 to provide direct comfort to the seated occupant. An intermediate cushion 182 may be disposed below the decorative cover 180 for additional transition from contact to comfort and to provide support. The comfort layers 174 and 176 may be attached to the decorative cover 180 by sewing or the like. The decorative cover 180 may be attached to the support layers 172, 176 by clips, hook and loop fasteners, loops, or the like.

[0128] Fig.14 A seat assembly 210 according to another embodiment is shown. The seat assembly 210 can employ any of the features set forth in the previous embodiments. The seat assembly 210 includes a seat bottom 212 and a seat back 214. The seat assembly 210 can be formed without foam to improve comfort, performance, compactness, and recyclability while reducing manufacturing tooling costs. For example, the seat assembly 210 includes a seat bottom support 216 that provides a seat bottom pad for the seat bottom 212. The seat bottom support 216 is formed by a plurality of stacked layers of non-foam material. The seat back 214 includes a seat back support 218 that is also formed by stacked layers of non-foam.

[0129] The seat bottom support 216 includes a seat bottom base layer 222 and a seat bottom comfort layer 224. The seat back support 218 also includes a seat back base layer 226 and a seat back comfort layer 228. The seat bottom base layer 222 and the seat back base layer 226 are formed of a knitted monofilament textile material. The base layers 222, 226 are knitted or woven to provide structure, while the material also leaves space to provide porosity, ventilation and flexibility. The base layers 222, 226 can each be different in firmness or thickness and can be contoured to form the shape of the seat bottom support 216 and the seat back support 218, respectively. The base layers 222, 226 can be formed of an extruded plastic mesh material.

[0130] The seat bottom comfort layer 224 and the seat back comfort layer 228 are also formed of a knitted monofilament textile material, as disclosed in U.S. Patent No. 10,736,435B2 to Duncan et al., which was issued to Lear Corporation on August 11, 2020 and is incorporated herein by reference in its entirety. The material is knitted or woven to provide structure while also leaving space to provide porosity, ventilation, and flexibility. Alternatively, each of the layers 224, 228 can have a uniform thickness and can be formed from a sheet or roll. Each of the layers 224, 228 can be different in firmness or thickness.

[0131] Fig.15 and Fig.16 A seat assembly 190 according to another embodiment is illustrated. The seat assembly 190 may employ any of the features set forth in the previous embodiments. According to one embodiment, the seat assembly 190 is illustrated as a rear vehicle bench seat 190. The seat assembly 190 is illustrated with the trim cover removed. The seat assembly 190 includes a seat bottom 192 and a seat back 194.

[0132] The seat assembly 190 is formed without foam to improve comfort, performance, compactness, and recyclability while reducing manufacturing tooling costs. For example, the seat assembly 190 includes a seat bottom support 196 that provides a seat bottom padding for the seat bottom 192. The seat bottom support 196 is formed from multiple stacked layers of non-foam material. The seat back 194 includes a seat back support 198 that is also formed from non-foam stacked layers.

[0133] The seat bottom support 196 and the seat back support 198 are formed of a knitted monofilament textile material. The seat bottom support 196 and the seat back support 198 can be formed of multiple layers, each layer being formed of a knitted monofilament textile material. The seat bottom support 196 and the seat back support 198 are knitted or woven to provide structure, while the material also leaves space to provide porosity, ventilation, and flexibility. The seat bottom support 196 and the seat back support 198 can each be different in firmness or thickness, and can be contoured to form the shape of the seat bottom support 196 and the seat back support 198, respectively. An example of a knitted non-foam material for a base layer is disclosed in U.S. Patent No. 10,736,435B2 to Duncan et al., which was issued to Lear Corporation on August 11, 2020 and is incorporated herein by reference in its entirety.

[0134] The seat bottom support 196 and the seat back support 198 may be manufactured from a resin material such as linear low density polyethylene (LLDPE), thermoplastic elastomer (TPE), high density polyethylene (HDPE), etc. The seat bottom support 196 and the seat back support 198 may each be manufactured by a forming operation such as knitting, weaving, printing, etc. The seat bottom support 196 and the seat back support 198 may each be formed by extrusion, cutting, etc.

[0135] Although various embodiments are described above, it is not intended that these embodiments describe all possible forms of the present invention. On the contrary, the words used in this specification are descriptive and non-restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present invention. In addition, the features of various embodiments can be combined to form other embodiments of the present invention.

Claims

1. A seat support comprising a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame, wherein: The seat assembly including the seat support and the seat frame is formed of a non-foam material, and wherein the multiple layers are stacked on each other and each of the multiple stacked layers has a substantially uniform thickness, and wherein a sealed ventilation port is formed through at least one of the layers, and wherein at least the area between consecutive pairs of layers is sealed so that ventilation is directed through one of the consecutive pairs of layers.

2. The seat support according to claim 1, wherein: One of the plurality of layers has a first solidity; and Another one of the plurality of layers has a second firmness different from the first firmness.

3. The seat support according to claim 1, wherein: One of the plurality of layers has a first thickness; and Another one of the plurality of layers has a second thickness different from the first thickness.

4. The seat support of claim 1 further comprising a plurality of zones, wherein at least two of the zones differ in thickness, firmness, or number of stacked layers.

5. The seat support according to claim 4, wherein: The plurality of zones also include a boss, an insert, and a pair of bolsters on laterally opposing sides of the boss and the insert to support a seat bottom.

6. The seat support according to claim 4, wherein: The plurality of zones also include an insert, a pair of bolsters on laterally opposing sides of the insert, and a pair of shoulders on laterally opposing sides of the insert to support a seat back.

7. The seat support according to claim 1, wherein: Each of the plurality of layers is formed from a monofilament textile material.

8. The seat support according to claim 7, wherein: At least one of the plurality of layers is formed from a recycled material.

9. The seat support according to claim 7, wherein: At least one of the plurality of layers is formed from polyester.

10. The seat support of claim 7, further comprising a heating pad or a blower.

11. The seat support according to claim 10, wherein: A sealed vent port is formed through at least one of the layers.

12. The seat support according to claim 10, wherein: The areas between consecutive pairs of layers are sealed so that ventilation is directed through one of the consecutive pairs of layers.

13. The seat support of claim 7 further comprising a conductive yarn within one of the monofilament textile material layers.

14. The seat support of claim 13, further comprising a heating pad positioned between two of the plurality of layers, wherein the heating pad is in electrical communication with the conductive yarn.

15. The seat support according to claim 7, wherein: Each successive pair of layers is welded or sewn together.

16. The seat support of claim 7, wherein: Each layer further includes one of a hook fastener and a loop fastener to fasten to a consecutive layer of the plurality of layers.

17. The seat support according to claim 7, wherein: Each of the plurality of layers is formed from a similar recyclable material.

18. The seat support of claim 17, further comprising an adhesive disposed between each successive pair of the plurality of layers to bond the successive layers together, wherein the adhesive is formed from the like recyclable material.

19. A seat assembly comprising: substrate; as well as The seat support of claim 7 attached to said substrate.

20. The seat assembly of claim 19 further comprising a seat frame, wherein the substrate is attached to the seat frame.

21. The seat assembly of claim 19, wherein: Each of the plurality of layers is formed of a similar recyclable material; and wherein said substrate is formed from said similar recyclable material.

22. A seat assembly comprising: The seat support according to claim 17; and A trim cover is sized to receive the seat support.

23. The seat assembly of claim 22, wherein: The trim cover is formed from a recyclable material similar to the recyclable material of the plurality of layers.

24. The seat assembly of claim 22, wherein: The trim cover is formed from a single leather layer without coating.

25. The seat assembly of claim 22, further comprising a trim clip connecting the trim cover to the seat support, wherein the trim clip is formed of a recyclable material similar to the recyclable material of the plurality of layers.

26. A method for manufacturing a seat assembly, comprising: cutting a plurality of seat support portions from the first sheet of monofilament material; stacking the plurality of seat support sections to form a seat support; mounting the seat support on a substrate formed of a non-foam material, the substrate being mounted to a seat frame; and Installing the decorative cover on the seat support, Wherein the seat support is configured to be mounted to the substrate and to support an occupant on the seat frame such that the seat assembly is formed from a non-foam material.

27. The method of claim 26, further comprising unrolling the sheet of monofilament material prior to cutting the plurality of seat support portions.

28. The method of claim 26, further comprising laser cutting the plurality of seat support portions.

29. The method of claim 26, further comprising installing a heating pad or a blower.

30. The method of claim 26, further comprising sealing one of the plurality of seat support portions to direct ventilation through the seat assembly.

31. The method of claim 26, further comprising forming a duct through one of the plurality of seat support portions to direct ventilation through the seat assembly.

32. The method of claim 26, further comprising fastening the plurality of seat support sections together.

33. The method of claim 26, further comprising: Recycling of polymer materials; and The first sheet of monofilament material is manufactured from recycled polymeric material.

34. The method of claim 33, further comprising fabricating the substrate from the recycled polymeric material.

35. The method of claim 33, further comprising manufacturing the trim cover from the recycled polymeric material.

36. The method of claim 33, further comprising bonding a plurality of seat support sections together using an adhesive of the recycled polymeric material.

37. A method for manufacturing a seat assembly, comprising: cutting a first seat support portion from the first sheet of monofilament material; cutting a second seat support portion from a second sheet of monofilament material having a different firmness or thickness than the first sheet of monofilament material; and stacking the first seat support portion and the second seat support portion to form a seat support; mounting the seat support on a substrate formed of a non-foam material, the substrate being mounted to a seat frame; and Installing the decorative cover on the seat support, Wherein the seat support is configured to be mounted to the substrate and to support an occupant on the seat frame such that the seat assembly is formed from a non-foam material.

38. A method for manufacturing a seat assembly, comprising: cutting a first plurality of seat support portions from the first sheet of monofilament material; cutting a second plurality of seat support portions from the second sheet of monofilament material; and stacking the first plurality of seat support sections and the second plurality of seat support sections into sections to form a seat support; mounting the seat support on a substrate formed of a non-foam material, the substrate being mounted to a seat frame; and Installing the decorative cover on the seat support, Wherein the seat support is configured to be mounted to the substrate and to support an occupant on the seat frame such that the seat assembly is formed from a non-foam material.

39. A seat support assembly comprising: The seat support as claimed in claim 7; and A heating pad or blower wherein the monofilament textile material allows ventilation without an air distribution bag.

40. The seat support assembly of claim 39, wherein: Sealed ventilation ports are formed through the monofilament textile material.

41. The seat support assembly of claim 39, wherein: The area through the monofilament textile material is sealed so that ventilation is directed through the monofilament textile material.

42. A method for recycling the seat assembly of claim 22, comprising: grinding of seat supports made of polymeric materials; and The trim clip or the trim cover is ground without being removed from the seat support, the trim clip or the trim cover being made of a polymer material similar to that of the seat support.

43. The method of claim 42, further comprising grinding the trim clip and the trim cover without removing the trim clip or the trim cover from the seat support, the trim clip and the trim cover being made of a polymeric material similar to a polymeric material of the seat support.

44. The method of claim 42, further comprising grinding the substrate without removing the substrate from the seat support, the substrate being made of a polymeric material similar to a polymeric material of the seat support.

45. The method of claim 42, further comprising grinding the adhesive without removing the adhesive from the seat support, the adhesive being made of a polymeric material similar to a polymeric material of the seat support.

46. ​​The method of claim 42, further comprising making a roll of monofilament material, the roll of monofilament material being made from the ground polymeric material.

47. A seat support comprising a plurality of layers of non-foam material for mounting to a seat frame and supporting an occupant on the seat frame, such that a seat assembly comprising the seat support and the seat frame is formed of the non-foam material, wherein the plurality of layers are stacked upon one another and at least one of the plurality of stacked layers has a substantially uniform thickness, and wherein, The plurality of layers includes a base layer and a second layer mounted to the base layer.

48. A seat support according to claim 47, wherein: The base layer is mounted to the seat frame; and wherein the second layer has a generally uniform thickness.

49. A seat support according to claim 48, wherein: The base layer has a first firmness; and The second layer has a second firmness, and the second firmness is less firm than the first firmness.

50. The seat support of claim 48, wherein: The base layer has a first thickness; and The second layer has a second thickness that is less than the first thickness.

51. The seat support of claim 48, wherein: The base layer is formed from a monofilament textile material.

52. The seat support of claim 48, wherein: The second layer is formed from a monofilament textile material.

53. The seat support of claim 48, wherein: The second layer is formed from polyester.

54. The seat support of claim 48, wherein: The second layer is welded, stitched or bonded to the base layer.

55. The seat support of claim 47 further comprising a plurality of zones wherein at least two of the zones differ in thickness or firmness.

56. A seat support according to claim 55, wherein: The plurality of zones also include a boss, an insert, and a pair of bolsters on laterally opposing sides of the boss and the insert to support a seat bottom.

57. A seat support according to claim 55, wherein: The plurality of zones also include an insert, a pair of bolsters on laterally opposing sides of the insert, and a pair of shoulders on laterally opposing sides of the insert to support a seat back.

58. A seat assembly comprising: substrate; as well as The seat support of claim 48 attached to said substrate.

59. The seat assembly of claim 58 further comprising the seat frame, wherein the substrate is attached to the seat frame.

60. A seat assembly comprising: A seat support according to claim 48; and A trim cover is sized to receive the seat support, wherein the second layer is positioned between the trim cover and the base layer.

61. A method for manufacturing a seat assembly, comprising: forming a base seat support portion; cutting a second seat support portion from the sheet of monofilament material; and mounting the second seat support portion on the base seat support portion to form a seat support, Wherein the seat support is configured to be mounted to a seat frame and to support an occupant on the seat frame such that the seat assembly is formed of a non-foam material.

62. The method of claim 61 further comprising mounting a trim cover over the base seat support portion and the second seat support portion such that the second seat support portion is positioned between the base seat support portion and the trim cover.

63. The method of claim 61 further comprising securing the second seat support portion to the base seat support portion.

64. The method of claim 61 further comprising forming the base seat support portion from a non-foam material.

65. A seat assembly manufactured according to the method of claim 61.

66. A method for manufacturing a seat assembly, comprising: forming a base seat support portion from a non-foam material; cutting a second seat support portion from the sheet of monofilament material; mounting the second seat support portion on the base seat support portion; securing the second seat support portion to the base seat support portion to form a seat support; installing a trim cover over the base seat support portion and the second seat support portion such that the second seat support portion is positioned between the base seat support portion and the trim cover; and The seat support is mounted to a seat frame for supporting an occupant on the seat frame such that the seat assembly is formed from a non-foam material.

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