Seat back assembly and seat assembly

Abstract

A seat back assembly including a pultruded reinforcement and a seat back frame formed of a resin material, the seat back frame being only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seat back frame.

Description

TECHNICAL FIELD

[0001] The present specification generally relates to a seat back frame assembly for a vehicle, and more particularly, to a seat back frame assembly having a seat back frame and a pultruded reinforcement. BACKGROUND

[0002] A vehicle can include a seat assembly having a stadium seat that is movable between a use position and a stowed position. Previously known seat assemblies can include a metal or resin frame. When a resin frame is incorporated into a seat assembly, the seat back frame of the seat assembly can include a reinforcement member to increase the strength of the seat back frame.

[0003] The resin frame of the seat assembly can be formed using an overmolding process. However, previous overmolding processes typically exert a large amount of pressure on the reinforcement member, thereby damaging the reinforcement member or misaligning the reinforcement member within the overmolded portion. Additionally, because the overmolded portion covers the reinforcement member in the overmolding process, it can be difficult to determine whether the reinforcement member is damaged or misaligned.

[0004] Accordingly, there is a need for an alternative seat back frame that reduces the amount of pressure exerted on the reinforcement member during an overmolding process and enables visual inspection of the reinforcement member after the overmolding process is complete. SUMMARY

[0005] In a first aspect, a seat back assembly includes a pultruded reinforcement and a seat back frame. The seat back frame is formed from a resin material. The seat back frame is only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seat back frame.

[0006] In a second aspect according to the first aspect, the pultruded reinforcement is formed from a continuous glass fiber reinforced resin material.

[0007] In a third aspect according to the first or second aspect, the plurality of openings includes a plurality of holes and a plurality of slots.

[0008] In a fourth aspect according to any of the first through third aspects, the pultruded reinforcement has a generally hat shape formed by a base wall, a pair of side walls extending from side edges of the base wall, and a pair of flanges extending from side edges of the pair of side walls.

[0009] In a fifth aspect according to any of the first through fourth aspects, the plurality of holes are formed in the seatback frame such that a portion of the base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of holes. The plurality of holes are formed in the seatback frame such that a portion of at least one of the pair of sidewalls is configured to be visually inspected through the plurality of holes.

[0010] In a sixth aspect according to any of the first through fifth aspects, the seatback frame includes a first surface and an opposing second surface, and the pultruded reinforcement is located between the first surface and the second surface of the seatback frame. The plurality of holes and the plurality of slots are formed in both the first surface and the second surface.

[0011] In a seventh aspect according to any of the first through sixth aspects, the second surface of the seatback frame includes a plurality of reinforcement ribs extending along a plurality of link portions formed in the second surface of the seatback frame, the plurality of link portions defining a plurality of holes formed in the second surface of the seatback frame.

[0012] In an eighth aspect according to any of the first through seventh aspects, the pultruded reinforcement has a generally double-hat shape formed by an upper flange, an upper base wall, a center wall, a first upper sidewall extending between the upper flange and the upper base wall, a second upper sidewall extending between the upper base wall and the center wall, a lower base wall, a lower flange, a first lower sidewall extending between the center wall and the lower base wall, and a second lower sidewall extending between the lower base wall and the lower flange.

[0013] In a ninth aspect according to any one of the first through eighth aspects, the plurality of openings includes a plurality of upper holes, a plurality of lower holes, a plurality of upper slots, a plurality of lower slots, and a plurality of middle slots. The plurality of upper holes are formed in the seatback frame such that a portion of the upper base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper holes. The plurality of lower holes are formed in the seatback frame such that a portion of the lower base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower holes. The plurality of upper slots are formed in the seatback frame such that at least a portion of the first upper sidewall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper slots. The plurality of lower slots are formed in the seatback frame such that at least a portion of the first lower sidewall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower slots. The plurality of middle slots are formed in the seatback frame such that at least a portion of the center wall of the pultruded reinforcement is configured to be visually inspected through the plurality of middle slots.

[0014] In a tenth aspect according to any one of the first through ninth aspects, the seatback frame includes a plurality of upper reinforcement ribs configured to be located between the first upper sidewall and the second upper sidewall of the pultruded reinforcement and a plurality of lower reinforcement ribs configured to be located between the first lower sidewall and the second lower sidewall of the pultruded reinforcement.

[0015] In an eleventh aspect, a seat assembly includes a seat cushion frame, a pultruded reinforcement, and a seatback frame. The seatback frame is formed of a resin material. The seatback frame is only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seatback frame.

[0016] In a twelfth aspect according to the eleventh aspect, the pultruded reinforcement is formed of a continuous glass fiber reinforced resin material.

[0017] In a thirteenth aspect according to any one of the eleventh through twelfth aspects, the plurality of openings includes a plurality of holes and a plurality of slots.

[0018] In a fourteenth aspect according to any one of the eleventh through thirteenth aspects, the pultruded reinforcement has a generally hat shape formed of a base wall, a pair of sidewalls extending from side edges of the base wall, and a pair of flanges extending from side edges of the pair of sidewalls.

[0019] In a fifteenth aspect according to any of the eleventh through fourteenth aspects, the plurality of holes are formed in the seatback frame such that a portion of a base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of holes. The plurality of holes are formed in the seatback frame such that a portion of at least one of the pair of side walls is configured to be visually inspected through the plurality of holes.

[0020] In a sixteenth aspect according to any of the eleventh through fifteenth aspects, the seatback frame includes a first surface and an opposing second surface, and the pultruded reinforcement is positioned between the first surface and the second surface of the seatback frame. The plurality of holes and the plurality of slots are formed in both the first surface and the second surface.

[0021] In a seventeenth aspect according to any of the eleventh through sixteenth aspects, the second surface of the seatback frame includes a plurality of reinforcement ribs extending along a plurality of link portions formed in the second surface of the seatback frame, the plurality of link portions defining a plurality of holes formed in the second surface of the seatback frame.

[0022] In an eighteenth aspect according to any of the eleventh through seventeenth aspects, the pultruded reinforcement has a generally double-hat shape formed by an upper flange, an upper base wall, a center wall, a first upper side wall extending between the upper flange and the upper base wall, a second upper side wall extending between the upper base wall and the center wall, a lower base wall, a lower flange, a first lower side wall extending between the center wall and the lower base wall, and a second lower side wall extending between the lower base wall and the lower flange.

[0023] In a nineteenth aspect according to any of the eleventh through eighteenth aspects, the plurality of openings includes a plurality of upper holes, a plurality of lower holes, a plurality of upper slots, a plurality of lower slots, and a plurality of intermediate slots. The plurality of upper holes are formed in the seatback frame such that a portion of an upper base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper holes. The plurality of lower holes are formed in the seatback frame such that a portion of the lower base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower holes. The plurality of upper slots are formed in the seatback frame such that at least a portion of a first upper side wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper slots. The plurality of lower slots are formed in the seatback frame such that at least a portion of a first lower side wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower slots. The plurality of intermediate slots are formed in the seatback frame such that at least a portion of a center wall of the pultruded reinforcement is configured to be visually inspected through the plurality of intermediate slots.

[0024] In a twentieth aspect according to any of the eleventh through nineteenth aspects, the seat back frame includes a plurality of upper stiffening ribs configured to be positioned between the first upper sidewall and the second upper sidewall of the pultruded stiffener and a plurality of lower stiffening ribs configured to be positioned between the first lower sidewall and the second lower sidewall of the pultruded stiffener.

[0025] These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, taken with the drawings, in which: BRIEF DESCRIPTION OF DRAWINGS

[0026] The embodiments set forth in the attached drawings are illustrative and exemplary in nature, not limiting, of the subject matter defined by the claims. Other embodiments can be understood and effected by those skilled in the art in practicing:

[0027] Figure 1 schematically depicts a perspective view of a vehicle including a seat assembly according to one or more embodiments shown and described herein;

[0028] Figure 2A schematically depicts a front view of a seat back frame of a seat assembly according to one or more embodiments shown and described herein; Figure 1

[0029] Figure 2B schematically depicts a rear view of a seat back frame of a seat assembly according to one or more embodiments shown and described herein; Figure 1

[0030] Figure 3A schematically depicts a partial cross-sectional view of a seat back frame of a seat assembly according to one or more embodiments shown and described herein taken along line A-A of Figure 2A

[0031] Figure 3B schematically depicts a partial cross-sectional view of a seat back frame of a seat assembly according to one or more embodiments shown and described herein taken along line A-A of Figure 3A

[0032] Figure 4 schematically depicts a partial cross-sectional view of a seat back frame of a seat assembly according to one or more embodiments shown and described herein taken along line A-A of Figure 1

[0033] Figure 5 schematically depicts a perspective view of a seat back assembly according to one or more embodiments shown and described herein; schematically depicts a perspective view of a seat back assembly according to one or more embodiments shown and described herein;​​​​

[0034] Figure 6A schematically depicts a front view of a seat back frame of a seat back assembly in accordance with one or more embodiments shown and described herein. Figure 5

[0035] Figure 6B schematically depicts a rear view of a seat back frame of a seat back assembly in accordance with one or more embodiments shown and described herein. Figure 5

[0036] Figure 7 schematically depicts a partial side view of a seat back frame of a seat back assembly in accordance with one or more embodiments shown and described herein. Figure 5

[0037] Figure 8 schematically depicts a partial cross-sectional view of a molding apparatus for a seat back frame in accordance with one or more embodiments shown and described herein. Figure 5 DETAILED DESCRIPTION

[0038] A seat back assembly in accordance with the present description includes a pultruded reinforcement and a seat back frame. The seat back frame is formed from a resin material. The seat back frame is only partially overmolded onto the pultruded reinforcement. The pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seat back frame. By only partially overmolding the seat back frame onto the pultruded reinforcement, the amount of pressure applied to the pultruded reinforcement during the overmolding process is reduced. Further, by configuring the pultruded reinforcement to be visually inspected through the plurality of openings formed in the seat back frame, an operator is allowed to verify that the pultruded reinforcement is properly positioned and not damaged upon completion of the overmolding process.

[0039] A seat assembly in accordance with the present description includes a seat back frame, a pultruded reinforcement, and a seat pan frame pivotally coupled to the seat back frame. The seat back frame is formed from a resin material. The seat back frame is only partially overmolded onto the pultruded reinforcement. The pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seat back frame. Various embodiments will be described in greater detail herein.

[0040] ​​​​As used herein, the term "vehicle longitudinal direction" refers to the fore-aft direction of the vehicle (i.e., the + / - vehicle X direction shown). The term "vehicle lateral direction" refers to the direction across the vehicle (i.e., the + / - vehicle Z direction shown) and is transverse to the vehicle longitudinal direction. The term "vehicle vertical direction" refers to the up-down direction of the vehicle (i.e., the + / - vehicle Y direction shown). Further, the terms "upwardly," "downwardly," "rearwardly," and "forwardly" are used to describe the relative positioning of various components of the vehicle with respect to one another. Because the vehicle structure can be generally symmetrical about a vehicle centerline, the terms "upwardly," "downwardly," "rearwardly," and "forwardly" can be switched when evaluating components positioned along opposite sides of the vehicle. Further, while certain components of the vehicle are described as extending in or being oriented toward one of the determined directions, it is to be understood that these components extend or are oriented at least in these recited directions.

[0041] Referring now to Figure 1 which generally depicts a seat assembly 10. In some embodiments, the seat assembly 10 is disposed within a vehicle 1, which in some embodiments can be an automobile. In other embodiments, the vehicle 1 can be a truck, sport utility vehicle, van, boat, airplane, or other vehicle type.

[0042] The vehicle 1 includes a passenger cabin in which the seat assembly 10 is positioned to seat a passenger within the vehicle 1. Although Figure 1 One seat assembly 10 is shown in the figures, it is to be understood that in other embodiments the vehicle 1 can include any number of seat assemblies 10.

[0043] In the illustrated embodiment, the seat assembly 10 is configured as a rear seat of the vehicle 1. As a non-limiting example, the rear seat of the vehicle 1 can be a rear 60 / 40 seat that includes the seat assembly 10 and a second seat assembly (not shown). Thus, the seat assembly 10 can be configured as a "60" seat to support an occupant on an outer portion of the seat assembly 10 and in an inner portion along the vehicle lateral direction (i.e., along the + / - Z direction of the coordinate axes shown in the figures). It is to be understood that in other embodiments the seat assembly 10 can be a "50 / 50" seat, a bench seat, a bucket seat, or other various seat assemblies.

[0044] Seat assembly 10 includes a seat back assembly 11 and a seat cushion frame 14. Seat back assembly 11 includes a seat back frame 12 and a pultruded reinforcement 70. As will be described in more detail below, the pultruded reinforcement 70 is only partially molded within the seat back frame 12, such that the pultruded reinforcement 70 is configured to be visually inspected through the seat back frame 12. The seat back frame 12 and the seat cushion frame 14 can be connected to each other via a pair of brackets 15. The brackets 15 can be used to connect the seat back frame 12 and the seat cushion frame 14 using fasteners.

[0045] In some embodiments, the seat cushion frame 14 is pivotally connected to the seat back frame 12 via a bracket 15 to move about a pivot axis P1. In some embodiments, the seat cushion frame 14 can pivot between a seated position and a flip-up position. In the seated position, the seat cushion frame 14 is positioned to support the occupant above the floor of the vehicle 1. In the flip-up position, the seat cushion frame 14 pivots about the pivot axis P1 toward the seat back frame 12 in the direction of arrow F1. In the flip-up position, the seat cushion frame 14 faces the seat back frame 12.

[0046] In some embodiments, the seat assembly 10 may include one or more attachment points (not shown) for securely fastening the seat assembly 10 to the floor of the vehicle 1. In some other embodiments, the seat assembly 10 may be slidably attached to the floor of the vehicle 1 via a pair of rails, such that the seat assembly 10 can slide along the longitudinal direction of the vehicle (i.e., along the ± vehicle X direction shown).

[0047] The seat cushion frame 14 may include a base wall 16, a pair of side walls 18, a front wall 20, and a rear wall 22. When in the seated position, such as Figure 1 As shown, the pair of sidewalls 18 may extend in the longitudinal direction of the vehicle (i.e., the + / -X direction), and the front wall 20 and rear wall 22 may extend in the transverse direction of the vehicle (i.e., the + / -Z direction). The pair of sidewalls 18, the front wall 20, and the rear wall 22 are formed to define the periphery of the seat cushion frame 14. The seat cushion frame 14 may also include a slot 23 that provides access for seat belt buckles or other seat accessories to an occupant supported by the seat cushion frame 14.

[0048] The seat cushion frame 14 is formed from a resin material. By way of non-limiting example, the seat cushion frame 14 can be formed from at least one of the following resins or combinations of resins, such as nylon, polyester, polyurethane, vinyl, vinyl ester, and / or epoxy. In some embodiments, the seat cushion frame 14 can be formed from a fiber-reinforced resin material, such as a glass-filled nylon resin material. In some embodiments, the base wall 16, the pair of side walls 18, the front wall 20, and the rear wall 22 of the seat cushion frame 14 are integrally formed as a single-piece monolithic structure. In particular, the seat cushion frame 14 can be integrally molded from a fiber-reinforced resin material as a single-piece monolithic structure.

[0049] Referring to Figure 1 and 2A -2B, the seat back frame 12 includes a base wall 24, an upper cross member 26, a lower cross member 28 spaced apart from the upper cross member 26, and a pair of side members 30. The upper cross member 26 and the lower cross member 28 can extend in the vehicle transverse direction (i.e., in the + / - Z direction). The pair of side members 30 extend between the ends of the upper cross member 26 and the lower cross member 28. The seat back frame 12 can include an intermediate cross member 32. The intermediate cross member 32 can extend in the vehicle vertical direction (i.e., in the + / - Y direction) from the upper cross member 26 toward the lower cross member 28. The intermediate cross member 32 can provide reinforcement between areas of the seat back frame 12 that can support an occupant in the case of a “60” seat. The base wall 24 of the seat back frame 12 includes a front surface (hereinafter referred to as a first surface) 34 and an opposite rear surface (hereinafter referred to as a second surface) 36.

[0050] The seat back frame 12 includes a reinforcement portion 105 that includes a pair of side walls 107A and an intermediate wall 107B. The side walls 107A and the intermediate wall 107C form a portion of the first surface 34 that at least partially covers the first surface 34 of the pultruded reinforcement 70.

[0051] The seat back frame 12 is formed from a resin material. By way of non-limiting example, the seat back frame 12 can be formed from at least one of the following resins or combinations of resins, such as nylon, polyester, polyurethane, vinyl, vinyl ester, and / or epoxy. In some embodiments, the seat back frame 12 can be formed from a fiber-reinforced resin material, such as a glass-filled nylon resin material. In some embodiments, the base wall 24, the upper cross member 26, the lower cross member 28, and the intermediate cross member 32 of the seat back frame 12 are integrally formed as a single-piece monolithic structure. In particular, the seat back frame 12 can be integrally molded from a fiber-reinforced resin material as a single-piece monolithic structure.

[0052] The seat back frame 12 can include a latch 38 integrally formed within the base wall 24. The latch 38 can be configured to secure an anchor of a child safety seat. In some embodiments, the seat back frame 12 can include a slot 42 that provides access to a passenger supported by the seat back frame 12 for a seat belt assembly or other seat accessory.

[0053] With reference to Figure 2B The overcross member 26 can be formed to have a generally U-shaped shape that defines a recess 48 on the second surface 36 of the seat back frame 12. The recess 48 can be defined by a pair of surfaces 44. A plurality of extension ribs 46 can extend within the recess 48, for example, between the pair of surfaces 44. In some embodiments, the plurality of extension ribs 46 extend in a first direction and a second direction that is generally perpendicular to the first direction, such that the plurality of extension ribs 46 are coupled to one another. The plurality of extension ribs 46 can be configured to reinforce the recess 48 of the overcross member 26.

[0054] The pair of side members 30 can be formed to have a generally U-shaped shape that defines a recess 50 in the second surface 36 of the seat back frame 12. The recess 50 can be defined by a pair of surfaces 52. A plurality of extension ribs 54 can extend within the recess 50 between the pair of surfaces 52. The plurality of extension ribs 54 can be configured to reinforce the recess 50 of the pair of side members 30.

[0055] The intermediate cross member 32 can be formed to have a generally U-shaped shape that defines a recess 56 on the second surface 36 of the seat back frame 12. The recess 56 can be defined by a pair of surfaces 58. A plurality of extension ribs 60 can extend within the recess 56 between the pair of surfaces 58. The plurality of extension ribs 60 can be configured to reinforce the recess 56 of the intermediate cross member 32.

[0056] As will be described in greater detail below, a reinforcement recess 62 can be formed in the seat back frame 12 at a location where the pultruded reinforcement 70 is located. The reinforcement recess 62 can be defined by a pair of side walls 64A and an intermediate wall 64B extending between the pair of side walls 64A. A plurality of reinforcement ribs 66 can extend within the reinforcement recess 62. The plurality of reinforcement ribs 66 can extend from the intermediate wall 64B and between the pair of side walls 64A.

[0057] Still referring to Figure 1 and 2A-2B, and 3A-3B, the seat back frame 12 includes a pultruded reinforcement 70. In some embodiments, the pultruded reinforcement 70 is an elongate reinforcing member that can extend within the seat back frame 12 in the vehicle transverse direction (i.e., + / - vehicle Z direction). In the illustrated embodiment, the pultruded reinforcement 70 is positioned between the lower cross member 28 and the upper cross member 26. It should be appreciated that in other embodiments, the pultruded reinforcement 70 can be positioned at other locations of the seat back frame 12 and can extend in other vehicle directions (e.g., the pultruded reinforcement 70 can be integrally provided within the upper cross member 26 and / or the lower cross member 28). The pultruded reinforcement 70 is configured to further stiffen the seat back frame 12.

[0058] As will be described in greater detail below, during the molding of the seat back frame 12, the pultruded reinforcement 70 is only partially overmolded into the seat back frame 12. In particular, the pultruded reinforcement 70 is overmolded by the seat back frame 12 such that the pultruded reinforcement 70 is positioned between the first surface 34 and the second surface 36 of the seat back frame 12. In some embodiments, the seat back frame 12 and the pultruded reinforcement 70 are integrally molded as a single-piece monolithic structure.

[0059] Referring to Figure 3A and 3B , the pultruded reinforcement 70 is formed to have a generally hat-shaped shape. The pultruded reinforcement 70 includes a base wall 90, a pair of side walls 92, a pair of flanges 94, and a pair of distal edges 96. In some embodiments, the pultruded reinforcement 70 can have other various geometric shapes, such as a planar shape, a regular shape, an irregular shape, or a complex shape.

[0060] The base wall 90 includes a first surface 90A, an opposite second surface 90B, and a pair of side edges 90C extending between the first surface 90A and the second surface 90B. The first surface 90A of the base wall 90 is positioned to face the inner side of the first surface 34 of the seat back frame 12. The second surface 90B of the base wall 90 is positioned within the seat back frame 12 to face the inner side of the second surface 36 of the seat back frame 12.

[0061] The pair of side walls 92 includes a first surface 92A, an opposite second surface 92B, and a pair of side edges 92C. Each of the pair of side walls 92 extends generally perpendicularly from the side edges 90C of the base wall 90. Each of the first surfaces 92A of the pair of side walls 92 is positioned within the seat back frame 12 to face the inner side of the first surface 34 of the seat back frame 12. Each of the second surfaces 92B of the pair of side walls 92 is positioned within the seat back frame 12 to face the inner side of the second surface 36 of the seat back frame 12.

[0062] The pair of flanges 94 includes a first surface 94A and an opposing second surface 94B. Each of the pair of flanges 94 extends generally perpendicularly from the side edge 92C of the pair of side walls 92. Each of the pair of flanges 94 extends between the side edge 92C and the pair of distal edges 96 of the pair of side walls 92. Each of the first surfaces 94A of the pair of flanges 94 is positioned within the seat back frame 12 to face an inside of the first surface 34 of the seat back frame 12. Each of the second surfaces 92B of the pair of flanges 94 is positioned within the seat back frame 12 to face an inside of the second surface 36 of the seat back frame 12.

[0063] Referring to Figure 1 , 2A and 2B, the pultruded reinforcement 70 can further include a pair of holes 98. Each of the pair of holes 98 is positioned proximate to an end portion of the pultruded reinforcement 70 in a longitudinal direction of the pultruded reinforcement 70. The pair of holes 98 is formed in the base wall 90. Each of the pair of holes 98 extends between the first surface 90A and the opposing second surface 90B of the base wall 90. As will be described in greater detail below, the pair of holes 98 facilitates maintaining the pultruded reinforcement 70 in a predetermined position when the seat back frame 12 is overmolded onto the pultruded reinforcement 70.

[0064] The pultruded reinforcement 70 can be formed from a continuous fiber-reinforced resin material. In some embodiments, the pultruded reinforcement 70 can include a resin composite material and one or more fibers extending in one direction. As a non-limiting example, the one or more fibers can be glass fibers, such as continuous glass fibers. As another non-limiting example, the one or more fibers can be glass fibers and nylon fibers (e.g., 95% of the one or more fibers are glass fibers and 5% of the one or more fibers are nylon fibers). The one or more fibers can be configured to reinforce the resin composite material (e.g., a resin such as epoxy, polyester, etc.) of the pultruded reinforcement 70. In this way, the glass fibers can increase the tensile strength, flexural modulus, impact resistance, and dimensional stability of the pultruded reinforcement 70. In some embodiments, the pultruded reinforcement 70 is formed from a continuous glass fiber-reinforced resin material.

[0065] In some embodiments, the pultruded reinforcement 70 is formed using a continuous molding pultrusion process in which reinforcing fibers (e.g., long strand glass fibers) are impregnated with a liquid resin material (e.g., a liquid polymeric resin) and then pulled through a heated forming die to form the general hat shape of the pultruded reinforcement 70. In some embodiments, a curing pigment and catalyst that reinforce the pultruded reinforcement 70 can be added while one or more of the continuous glass fibers are being impregnated with the liquid resin material. It should be appreciated that in other embodiments, the pultruded reinforcement 70 can be formed using any suitable pultrusion process or other suitable manufacturing process.

[0066] Referring to Figure 1 and 2A The first surface 34 of the seat back frame 12 is formed with a plurality of openings 100 positioned such that the pultruded reinforcement 70 is visible through the first surface 34 of the seat back frame 12. The plurality of openings 100 includes a plurality of shaped apertures 102 formed in the middle wall 107B and a plurality of slots 104 formed in the pair of side walls 107A and the middle wall 107B. The plurality of shaped apertures 102 and the plurality of slots 104 are separated by a plurality of link portions 106 and a parallel plurality of extension portions 108. The plurality of extension portions 108 extend from the top and bottom sides of the plurality of link portions 106.

[0067] The plurality of link portions 106 have a generally X-shape when viewed from the front of the seat back frame 12. The plurality of link portions 106 include inner sides 106A that define therebetween the plurality of shaped apertures 102 having a generally regular shape. The plurality of link portions 106 include outer sides 106B that define the plurality of slots 104 with the plurality of extension portions 108.

[0068] In some embodiments, the plurality of shaped apertures 102 are formed to have a generally diamond shape. It should be appreciated that the shape of the plurality of shaped apertures 102 is not limited to a generally diamond shape and can include other regular and irregular geometric shapes including, for example, triangles, circles, semi-circles, and rectangles.

[0069] The plurality of shaped apertures 102 are formed in the first surface 34 of the seat back frame 12 by the inner sides 106A of the plurality of link portions 106 so as to be positioned over at least a portion of the base wall 90 of the pultruded reinforcement 70. In this manner, at least a portion of the first surface 90A of the base wall 90 is configured to be visually inspected through the plurality of shaped apertures 102 formed in the seat back frame 12.

[0070] Referring to Figure 1 , 2AAs shown in FIGS. 3A and 3B, the plurality of slots 104 are formed with end portions having a generally triangular shape defined by the outer sides 106B of the plurality of link portions 106, and the remaining portions of the plurality of slots 104 are formed with a generally rectangular shape because each of the plurality of slots 104 is formed between adjacent extension portions 108. The plurality of slots 104 are formed in the first surface 34 of the seat back frame 12 by the outer sides 106B of the plurality of link portions 106 and the adjacent extension portions 108 so as to be positioned over at least a portion of the base wall 90, the pair of side walls 92, and the pair of flanges 94 of the pultruded reinforcement 70. As such, at least a portion of the first surface 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of each of the first surfaces 94A of the pair of flanges 94 are configured to be visually inspected through the plurality of slots 104. The plurality of link portions 106 of the seat back frame 12 include junctions 101. The junctions 101 are intersections of the plurality of link portions 106 of the first surface 34. The plurality of extension portions 108 are formed in the first surface 34 of the seat back frame 12 to extend upwardly and downwardly from the top and bottom portions, respectively, of the plurality of link portions 106. As such, the plurality of extension portions 108 are formed to extend over at least a portion of each of the first surfaces 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of the first surfaces 94A of the pair of flanges 94.

[0071] Referring to Figure 2B , 3A As shown in FIGS. 3A and 3B, the plurality of slots 104 are formed with end portions having a generally triangular shape defined by the outer sides 106B of the plurality of link portions 106, and the remaining portions of the plurality of slots 104 are formed with a generally rectangular shape because each of the plurality of slots 104 is formed between adjacent extension portions 108. The plurality of slots 104 are formed in the first surface 34 of the seat back frame 12 by the outer sides 106B of the plurality of link portions 106 and the adjacent extension portions 108 so as to be positioned over at least a portion of the base wall 90, the pair of side walls 92, and the pair of flanges 94 of the pultruded reinforcement 70. As such, at least a portion of the first surface 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of each of the first surfaces 94A of the pair of flanges 94 are configured to be visually inspected through the plurality of slots 104. The plurality of link portions 106 of the seat back frame 12 include junctions 101. The junctions 101 are intersections of the plurality of link portions 106 of the first surface 34. The plurality of extension portions 108 are formed in the first surface 34 of the seat back frame 12 to extend upwardly and downwardly from the top and bottom portions, respectively, of the plurality of link portions 106. As such, the plurality of extension portions 108 are formed to extend over at least a portion of each of the first surfaces 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of the first surfaces 94A of the pair of flanges 94.

[0072] As shown in FIGS. 3A and 3B, the plurality of slots 104 are formed with end portions having a generally triangular shape defined by the outer sides 106B of the plurality of link portions 106, and the remaining portions of the plurality of slots 104 are formed with a generally rectangular shape because each of the plurality of slots 104 is formed between adjacent extension portions 108. The plurality of slots 104 are formed in the first surface 34 of the seat back frame 12 by the outer sides 106B of the plurality of link portions 106 and the adjacent extension portions 108 so as to be positioned over at least a portion of the base wall 90, the pair of side walls 92, and the pair of flanges 94 of the pultruded reinforcement 70. As such, at least a portion of the first surface 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of each of the first surfaces 94A of the pair of flanges 94 are configured to be visually inspected through the plurality of slots 104. The plurality of link portions 106 of the seat back frame 12 include junctions 101. The junctions 101 are intersections of the plurality of link portions 106 of the first surface 34. The plurality of extension portions 108 are formed in the first surface 34 of the seat back frame 12 to extend upwardly and downwardly from the top and bottom portions, respectively, of the plurality of link portions 106. As such, the plurality of extension portions 108 are formed to extend over at least a portion of each of the first surfaces 90A of the base wall 90, a portion of each of the first surfaces 92A of the pair of side walls 92, and a portion of the first surfaces 94A of the pair of flanges 94.

[0073] In some embodiments, the plurality of shaped apertures 112 are formed to have a generally diamond shape. It should be appreciated that the shape of the plurality of shaped apertures 112 is not limited to a generally diamond shape and can include other regular and irregular geometric shapes including, for example, triangles, circles, semi-circles, and rectangles.

[0074] The plurality of shaped apertures 112 are formed in the second surface 36 of the seat back frame 12 by the inner sides 116A of the plurality of link portions 116 so as to be positioned over at least a portion of the base wall 90 of the pultruded reinforcement 70. As such, at least a portion of the second surface 90B of the base wall 90 is configured to be visually inspected through the plurality of shaped apertures 112 formed in the seat back frame 12.

[0075] Still referring to Figure 2B and 3B The plurality of slots 114 are formed to have end portions defined by the outer sides 116B of the plurality of link portions 116 that have a generally triangular shape and the remaining portions of the plurality of slots 114 are formed to have a generally rectangular shape as each of the plurality of slots 114 is formed between adjacent extension portions 118. The plurality of slots 114 are formed in the second surface 36 of the seat back frame 12 by the outer sides 116B of the plurality of link portions 116 and the adjacent extension portions 118 so as to be positioned over at least a portion of the base wall 90, the pair of side walls 92, and the pair of flanges 94 of the pultruded reinforcement 70. As such, at least a portion of the second surface 90B of the base wall 90, a portion of each of the second surfaces 92B of the pair of side walls 92, and a portion of each of the second surfaces 94B of the pair of flanges 94 are configured to be visually inspected through the plurality of slots 114. The plurality of link portions 116 of the seat back frame 12 include junctions 111. The junctions 111 are intersections of the plurality of link portions 116 of the second surface 36. The plurality of extension portions 118 are formed in the second surface 36 of the seat back frame 12 to extend upwardly and downwardly from the top and bottom portions, respectively, of the plurality of link portions 116. As such, the plurality of extension portions 118 are formed to extend over at least a portion of the second surface 90B of the base wall 90, a portion of each of the second surfaces 92B of the pair of side walls 92, and a portion of each of the second surfaces 94B of the pair of flanges 94.

[0076] Referring to Figure 2B and 3BThe generally hat-shaped form of the pultruded reinforcement 70 defines a reinforcement pocket 62. The plurality of reinforcement ribs 66 are positioned on and extend outwardly from the plurality of link portions 116. The plurality of reinforcement ribs 66 couple the plurality of link portions 116 to the sidewall 64A of the reinforcement pocket 62. In some embodiments, the plurality of reinforcement ribs 66 have a shape that corresponds to the shape of the plurality of link portions 116. In some embodiments, the plurality of reinforcement ribs 66 have a generally X-shaped form when viewed from the rear of the seat back frame 12 to accommodate the generally X-shaped form of the plurality of link portions 116. The plurality of reinforcement ribs 66 are configured to further reinforce the rigidity of the seat back frame 12.

[0077] In various embodiments, the plurality of link portions 106 can have a first thickness (T1) and the plurality of ribs 66 can have a second thickness (T2). In some embodiments, the second thickness (T2) is greater than or equal to the first thickness (T1). It should be appreciated that in other embodiments, the second thickness (T2) can be less than the first thickness (T1). As shown, the first thickness (T1) is taken at the junction 101 and the second thickness (T2) is taken at the junction 111 that extends through the reinforcement rib 66. In particular, the first thickness (T1) is the thickness of the intermediate wall 107B and the second thickness (T2) is the thickness of the rib 66. Figure 3A

[0078] While various embodiments show the plurality of link portions 106, the plurality of link portions 116, and the plurality of ribs 66 having a generally X-shaped form, it should be appreciated that in other embodiments, the plurality of link portions 106, the plurality of link portions 116, and the plurality of ribs 66 can have other geometric configurations that enable visual inspection of the pultruded reinforcement 70 through the seat back frame 12. As non-limiting examples, at least one of the plurality of link portions 106 and the plurality of link portions 116 have a generally circular or elliptical shape.

[0079] In various embodiments and as shown in Figure 3A The bracket 15 can be positioned adjacent to (i.e., proximate or close to) the pultruded reinforcement 70 and can be configured to pivotally couple the side member 30 to the seat pan frame 14 using a fastening member 99 (e.g., a rotatable fastening nut, a pivot bolt, a hinge, or similar other fastening element).

[0080] Referring to Figure 1 , 2A ​- 2B, 3A-3B, and 4, an exemplary process of forming the pultruded reinforcement 70 and the seat back frame 12 having the pultruded reinforcement 70 will now be described. As noted above, the pultruded reinforcement 70 can be formed during a pultrusion process. As a non-limiting example, the pultrusion process can include winding one or more continuous glass fibers using a tension roller. The one or more continuous glass fibers can then be placed in a resin bath (e.g., polyester, polyurethane, vinyl ester, epoxy, etc.), and the resin can infiltrate the one or more continuous glass fibers. In some embodiments, a curing pigment and catalyst that reinforce the pultruded reinforcement 70 can be added while the one or more continuous glass fibers are in the resin bath. Subsequently, the mixture of the one or more continuous glass fibers and resin can be provided to a heat source, such as a steel forming die, to polymerize the resin. The polymerized resin and one or more continuous glass fibers are removed from the heat source as a solid glass fiber reinforced polymer. It should be appreciated that in other embodiments, the pultruded reinforcement 70 can be formed using any suitable pultrusion process or other suitable manufacturing process.

[0081] During the pultrusion process, various geometric features of the pultruded reinforcement 70 can be defined. As a non-limiting example and as shown in the illustrated embodiment of Figure 3A and 3B The pultruded reinforcement 70 can be formed in a generally hat-shaped shape and include a base wall 90, a pair of side walls 92, a pair of flanges 94, and a pair of distal edges 96, as shown in the illustrated embodiment of

[0082] Once the pultruded reinforcement 70 is formed, the pultruded reinforcement 70 is only partially overmolded within the seat back frame 12 such that the pultruded reinforcement 70 is configured to be visually inspected through the seat back frame 12, through the plurality of openings 100 and the plurality of openings 110. In some embodiments, and with reference to Figure 4 , the pultruded reinforcement 70 is placed in the overmolding cavity 120. As a non-limiting example, the pultruded reinforcement 70 can be positioned between a first molding base 130 and a second molding base 140 of the overmolding cavity 120. In some embodiments, at least one of the first molding base 130 and the second molding base 140 can include at least two pin holes 181 for receiving positioning pins 180 (e.g., bi-directional positioning pins and quad-directional positioning pins), respectively, and the pair of holes 98 of the pultruded reinforcement 70 can be aligned with the positioning pins 180. As a non-limiting example, the positioning pins 180 can be used to position the pultruded reinforcement 70 within the overmolding cavity 120. Figure 4As shown, the positioning pin 180 is aligned with and extends into the hole 98 of the pultruded reinforcement 70 such that an end of the positioning pin 180 contacts a portion of the second molding base 140 when the overmolding cavity 120 is closed. The second molding base 140 can include a hole 182 configured to receive the positioning pin 180. In some embodiments, the hole 182 is a cavity with a bottom, and in some other embodiments, the hole 182 is a through-hole that extends through the second molding base 140.

[0083] Accordingly, when the seat back frame 12 is overmolded onto the pultruded reinforcement 70, the engagement between the pair of holes 98 and the positioning pin 180 holds the pultruded reinforcement 70 in a predetermined position relative to the overmolding cavity 120. Once the pultruded reinforcement 70 is positioned between the first and second molding bases 130, 140, the overmolding cavity 120 is sealed and isolated from the environment outside of the overmolding cavity 120.

[0084] Subsequently, an injection molding material can be provided within the overmolding cavity 120. As non-limiting examples, the injection molding material can be nylon, polyester, polyurethane, vinyl material, vinyl ester, and / or epoxy resin, or any other suitable injection molding material. In some embodiments, an additive material (e.g., plasticizer, fiber, flame retardant, colorant, etc.) can be heated and added to the overmolding cavity 120 with the injection molding material.

[0085] In some embodiments, the overmolding cavity 120 defines a cavity between the first and second molding bases 130, 140 in which the pultruded reinforcement 70 is positioned during the overmolding process. Each of the first and second molding bases 130, 140 can have a geometry such that, when the injection molding material in the overmolding cavity 120 is cured, the pultruded reinforcement 70 is positioned between the first and second surfaces 34, 36 of the seat back frame 12.

[0086] In some embodiments, the first molding base 130 can have a geometry such that, when the injection molding material in the overmolding cavity 120 is cured, the plurality of link portions 106 and the plurality of junctions 101 are formed in the first surface 34 of the seat back frame 12 to define the plurality of shaped holes 102 and the plurality of slots 104. The sides of the plurality of protrusions 150 form an inner side 106A and an outer side 106B of the plurality of link portions 106.

[0087] In some embodiments, the second molded substrate 140 can have a geometry such that, when the injection molded material in the overmolding cavity 120 solidifies, the plurality of reinforcing ribs 66 are formed in the reinforcing recesses 62 of the seat back frame 12. The second molded substrate 140 can have a geometry such that, when the injection molded material in the overmolding cavity 120 solidifies, the plurality of link portions 116 and the plurality of junctions 111 are formed in the second surface 36 of the seat back frame 12 to define the plurality of shaped holes 112, the plurality of slots 114, and the plurality of ribs 66. The sides of the plurality of protrusions 160 form the inner sides 116A and the outer sides 116B of the plurality of link portions 116.

[0088] Still referring to Figure 4 , the first molded substrate 130 can include a plurality of protrusions 150 (e.g., a plurality of hole protrusions and a plurality of slot protrusions) extending from the mold surface of the first molded substrate 130. The plurality of hole protrusions 150 can directly contact the first surface 90A of the base wall 90 of the pultruded reinforcement 70 during the overmolding process and can have a shape corresponding to the shape of the plurality of shaped holes 102. The plurality of slot protrusions 150 can directly contact the first surface 90A of the base wall 90, the first surface 92A of the pair of side walls 92, and the first surface 94A of the pair of flanges 94 during the overmolding process and can have a shape corresponding to the plurality of slots 104.

[0089] Accordingly, when the injection molded material is added to the overmolding cavity 120, the injection molded material is not located between the first surface 90A of the base wall 90 and the hole protrusions 150, thereby forming the plurality of shaped holes 102. Similarly, when the injection molded material is added to the overmolding cavity 120, the injection molded material is not located between the first surface 90A of the base wall 90, the first surface 92A of the pair of side walls 92, the first surface 94A of the pair of flanges 94, and the slot protrusions 150, thereby forming the plurality of slots 104.

[0090] Accordingly, when the injection molded material in the overmolding cavity 120 solidifies, the plurality of shaped holes 102 of the plurality of openings 100 and the plurality of slots 104 of the plurality of openings 100 are formed in the first surface 34 of the seat back frame 12 such that the pultruded reinforcement 70 is configured to be visually inspected through the seat back frame 12.

[0091] Still referring to Figure 4The second molding base 140 can include a plurality of protrusions 160 (e.g., a plurality of hole protrusions and a plurality of slot protrusions) extending from the molding surface of the second molding base 140. The plurality of hole protrusions 160 can directly contact the second surface 90B of the base wall 90 of the pultruded reinforcement 70 during the overmolding process and can have a shape that corresponds to the shape of the plurality of shaped holes 112. The plurality of slot protrusions 160 can directly contact the second surface 90B of the base wall 90, the second surface 92B of the pair of sidewalls 92, and the second surface 94B of the pair of flanges 94 during the overmolding process and can have a shape that corresponds to the shape of the plurality of slots 114 and the plurality of ribs 66.

[0092] Accordingly, when the injection molding material is added to the overmolding cavity 120, the injection molding material does not reside between the second surface 90B of the base wall 90 and the hole protrusions 160, thereby forming the plurality of shaped holes 112. Similarly, when the injection molding material is added to the overmolding cavity 120, the injection molding material does not reside between the second surface 90B of the base wall 90, the second surface 92B of the pair of sidewalls 92, the second surface 94B of the pair of flanges 94, and the slot protrusions, thereby forming the plurality of slots 114 and the plurality of ribs 66.

[0093] Accordingly, when the injection molding material in the overmolding cavity 120 solidifies, the plurality of shaped holes 112 of the plurality of openings 100, the plurality of slots 114 of the plurality of openings 100, and the plurality of ribs 66 are formed in the second surface 36 of the seat back frame 12 such that the pultruded reinforcement 70 is configured to be visually inspected through the seat back frame 12.

[0094] It can be appreciated that the first molding base 130 and the second molding base 140 can each have a shape that corresponds to the shape of the plurality of link portions 106 and the plurality of link portions 116. Accordingly, when the injection molding material in the overmolding cavity 120 solidifies, the plurality of link portions 106 and the plurality of link portions 116 of the plurality of openings 100 are formed in the first surface 34 and the second surface 36 of the seat back frame 12, respectively.

[0095] It should now be appreciated that the vehicle including the seat assembly 10 according to the present disclosure includes the seat back assembly 10 including the seat back frame 12 and the seat cushion frame 14. In various embodiments, the seat back frame 12 includes a plurality of openings 100 on the first surface 34 and the second surface 36 of the pultruded reinforcement 70 that are formed during the overmolding process. Accordingly, the seat back frame 12 is configured to enable visual inspection of the pultruded reinforcement 70 after the overmolding process is complete, thereby enabling an operator to verify that the pultruded reinforcement 70 is properly positioned and unharmed at the completion of the overmolding process. Further, the pultruded reinforcement 70 includes a plurality of reinforcement ribs 66 formed in the reinforcement recess 62 of the seat back frame 12 during the overmolding process. Accordingly, the plurality of reinforcement ribs 66 can provide rigidity against torsional forces applied to the seat back frame 12.

[0096] Accordingly, the method of forming the seat back assembly 10 includes providing the pultruded reinforcement 70, overmolding the seat back frame 12 onto the pultruded reinforcement 70, and forming the plurality of openings 100 and the plurality of openings 110 in the seat back frame 12 when overmolding the seat back frame 12 onto the pultruded reinforcement 70 such that the pultruded reinforcement 70 is configured to be visually inspected through the plurality of openings 100 and the plurality of openings 110.

[0097] The method further includes the step of forming the plurality of openings 100 on the first surface 34 of the seat back frame 12. The plurality of openings 100 includes a plurality of shaped holes 102 and a plurality of slots 104. The method further includes the step of forming the plurality of openings 110 on the second surface 36 of the seat back frame. The plurality of openings 110 includes a plurality of shaped holes 112 and a plurality of slots 114. The method further includes the step of forming the plurality of reinforcement ribs 66 in the second surface 36 of the seat back frame 12.

[0098] Referring to Figures 5-8 A seat assembly according to another embodiment is generally shown at 1010. The seat assembly 1010 is similar to the seat assembly 10 except that the seat assembly 1010 includes a seat back assembly 1011 having a seat back frame 1012 and a pultruded reinforcement 1070. As will be described in greater detail below, the pultruded reinforcement 1070 is only partially overmolded within the seat back frame 1012 such that the pultruded reinforcement 1070 is configured to be visually inspected through the seat back frame 1012. The seat assembly 1010 includes the seat cushion frame 14 of the seat assembly 10, which can be coupled to the seat back frame 1012 by a pair of brackets 15 that are coupled to the seat back frame 1012 by fasteners.

[0099] Referring to Figure 5 and 6A- 6B, the seat back frame 1012 is similar to the seat back frame 12, except that the seat back frame 1012 includes an upper reinforcement portion 1105A, a lower reinforcement portion 1105B, and an intermediate reinforcement recess 1105C located between the upper reinforcement portion 1105A and the lower reinforcement portion 1105B. The upper reinforcement portion 1105A includes a pair of upper side walls 1107A and an upper intermediate wall 1107B extending between the pair of upper side walls 1107A. The lower reinforcement portion 1105B includes a pair of lower side walls 1107C and a lower intermediate wall 1107D extending between the pair of lower side walls 1170C. The intermediate reinforcement recess 1105C includes an inner wall 1107E extending between an inner one of the pair of upper side walls 1107A and an inner one of the pair of lower side walls 1107C. The pair of upper side walls 1107A, the upper intermediate wall 1107B, the inner wall 1107E, the pair of lower side walls 1107C, and the lower intermediate wall 1107D are formed to at least partially cover a portion of the second surface 36 of the pultruded reinforcement 1070.

[0100] The seat back frame 1012 includes a base wall 24, an upper cross member 26, a lower cross member 28 spaced apart from the upper cross member 26, and a pair of side members 30. The upper cross member 26 and the lower cross member 28 can extend in the vehicle transverse direction (i.e., in the + / - Z direction). The pair of side members 30 extend between the ends of the upper cross member 26 and the lower cross member 28. The seat back frame 1012 can include an intermediate cross member 32. The intermediate cross member 32 can extend in the vehicle vertical direction (i.e., the + / - Y direction) from the upper cross member 26 toward the lower cross member 28. The intermediate cross member 32 can provide reinforcement to the seat back frame 1012 in the area between the positions at which a passenger can be supported in the case of the seat assembly 10 being a “60” seat. The base wall 24 of the seat back frame 1012 includes a front surface (hereinafter referred to as a first surface) 34 and an opposite rear surface (hereinafter referred to as a second surface) 36.

[0101] The seat back frame 1012 is formed from a resin material. By way of non-limiting example, the seat back frame 1012 can be formed from at least one of the following resins or combinations of resins, such as nylon, polyester, polyurethane, vinyl material, vinyl ester, and / or epoxy resin. In some embodiments, the seat back frame 1012 can be formed from a fiber-reinforced resin material, such as a glass-filled nylon resin material. In some embodiments, the base wall 24, the upper cross member 26, the lower cross member 28, and the intermediate cross member 32 of the seat back frame 1012 are integrally formed as a single one-piece monolithic structure. In particular, the seat back frame 1012 can be integrally molded as a single one-piece monolithic structure from a fiber-reinforced resin material.

[0102] The seat back frame 1012 can include a latch 38 integrally formed within the base wall 24. The latch 38 can be provided as an anchor to secure a child safety seat. In some embodiments, the seat back frame 1012 can include a notch 42 that provides access to a passenger supported by the seat back frame 12 for a seat belt assembly or other seat accessory.

[0103] Referring to Figure 5 and 6A , the first surface 34 can be formed with a plurality of first stiffeners 1035 and a plurality of second stiffeners 1037. The first stiffeners 1035 extend in a first direction, and the second stiffeners 1037 extend in a second direction that is generally perpendicular to the first direction. The first stiffeners 1035 extend continuously between one of the pair of side members 30 and the intermediate cross member 32. The second stiffeners 1037 extend discontinuously between the upper cross member 26 and the lower cross member 28. The second stiffeners 1037 extend between each of the plurality of first stiffeners 1035, such that the plurality of first stiffeners 1035 and the plurality of second stiffeners 1037 are discontinuous at intersections thereof. The plurality of first stiffeners 1035 and the plurality of second stiffeners 1037 are formed to have a generally U-shaped cross section and are raised relative to the first surface 34.

[0104] Referring to Figure 6B , the upper cross member 26 can be formed to have a generally U-shaped shape that defines a recess 48 on the second surface 36 of the seat back frame 1012. The recess 48 can be defined by a pair of surfaces 44. A plurality of extending ribs 46 can extend within the recess 48, for example, between the pair of surfaces 44. In some embodiments, the plurality of extending ribs 46 extend in a first direction and a second direction that is generally perpendicular to the first direction, such that the plurality of extending ribs 46 are coupled to one another. The plurality of extending ribs 46 can be provided to stiffen the recess 48 of the upper cross member 26.

[0105] The pair of side members 30 can be formed to have a generally U-shaped shape that defines a recess 50 in the second surface 36 of the seat back frame 12. The recess 50 can be defined by a pair of surfaces 52. A plurality of extending ribs 54 can extend within the recess 50 between the pair of surfaces 52. The plurality of extending ribs 54 can be provided to stiffen the recess 50 of the pair of side members 30.

[0106] The intermediate cross member 32 can be formed to have a generally U-shaped shape that defines a recess 56 on the second surface 36 of the seat back frame 1012. The recess 56 can be defined by a pair of surfaces 58. A plurality of extending ribs 60 can extend within the recess 56 between the pair of surfaces 58. The plurality of extending ribs 60 can be provided to stiffen the recess 56 of the intermediate cross member 32.

[0107] As will be described in greater detail below, the second surface 36 of the seat back frame 1012 can be formed with an upper reinforcement recess 1062A, a lower reinforcement recess 1062B, and an intermediate reinforcement portion 1062C at a location where the pultruded reinforcement 1070 is located. The intermediate reinforcement portion 1062C is positioned between the upper reinforcement recess 1062A and the lower reinforcement recess 1062B. The upper reinforcement recess 1062A can be defined by a pair of upper sidewalls 1064A and an upper intermediate wall 1064B extending between the pair of upper sidewalls 1064A. The lower reinforcement recess 1062B can be defined by a pair of lower sidewalls 1064C and a lower intermediate wall 1064D extending between the pair of lower sidewalls 1064C. The intermediate reinforcement portion 1062C includes an inner wall 1064E extending between a lower one of the pair of upper sidewalls 1064A and an upper one of the pair of lower sidewalls 1064C.

[0108] A plurality of upper reinforcement ribs 1066A can extend within the upper reinforcement recess 1062A. The plurality of upper reinforcement ribs 1066A can extend from the upper intermediate wall 1064B and between the pair of upper sidewalls 1064A. A plurality of lower reinforcement ribs 1066B can extend within the lower reinforcement recess 1062B. The plurality of lower reinforcement ribs 1066B can extend from the lower intermediate wall 1064D and between the pair of lower sidewalls 1064C.

[0109] In some embodiments, the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B have a generally X-shape when viewed from the rear of the seat back frame 1012. The plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B are configured to further reinforce the rigidity of the seat back frame 1012. The plurality of upper reinforcement ribs 1066A include junctions 1111A at locations where the plurality of upper reinforcement ribs 1066A intersect due to the generally X-shape. The plurality of lower reinforcement ribs 1066B include junctions 1111B at locations where the plurality of lower reinforcement ribs 1066B intersect due to the generally X-shape.

[0110] Still referring to Figure 5 and 6A-6B, the seat back frame 1012 includes a pultruded reinforcement 1070. In some embodiments, the pultruded reinforcement 70 is an elongated reinforcement member that can extend within the seat back frame 1012 in the vehicle transverse direction (i.e., + / - vehicle Z direction). In the illustrated embodiment, the pultruded reinforcement 1070 is positioned between the lower cross member 1028 and the upper cross member 1026. It should be appreciated that in other embodiments, the pultruded reinforcement 1070 can be positioned at other locations of the seat back frame 1012 and can extend in other vehicle directions (e.g., the pultruded reinforcement 1070 can be integrally provided within the upper cross member 26 and / or the lower cross member 1028). The pultruded reinforcement 1070 is configured to further stiffen the seat back frame 1012.

[0111] As will be described in greater detail below, the pultruded reinforcement 1070 is only partially overmolded into the seat back frame 1012 during a molding process of the seat back frame 1012. In particular, the pultruded reinforcement 1070 is overmolded by the seat back frame 1012 such that the pultruded reinforcement 1070 is positioned between the first surface 34 and the second surface 36 of the seat back frame 1012. In some embodiments, the seat back frame 1012 and the pultruded reinforcement 1070 are integrally molded as a single-piece monolithic structure.

[0112] Referring to Figure 7 and Figure 8 , the pultruded reinforcement 1070 is formed to have a generally double-hat shape. The pultruded reinforcement 1070 includes an upper base wall 1090A, a pair of upper sidewalls 1092A, an upper flange 1094A, a lower base wall 1090B, a pair of lower sidewalls 1092B, a lower flange 1094B, a center wall 1095, and an upper distal edge 1096A and a lower distal edge 1096B. In some embodiments, the pultruded reinforcement 1070 can have other various geometric shapes, such as a planar shape, a regular shape, an irregular shape, or a complex shape. The pair of upper sidewalls 1092A includes a first upper sidewall extending between the upper flange 1094A and the upper base wall 1090A and a second upper sidewall extending between the upper base wall 1090A and the center wall 1095. The pair of lower sidewalls 1092B includes a first lower sidewall extending between the center wall 1095 and the lower base wall 1090B and a second lower sidewall extending between the lower base wall 1090B and the lower flange 1094B.

[0113] The upper base wall 1090A includes a first upper surface 1090AA, an opposite second upper surface 1090AB, and a pair of upper side edges 1090AC extending between the first upper surface 1090AA and the second upper surface 1090AB. The first upper surface 1090AA of the upper base wall 1090A is positioned to face an inner side of the first surface 34 of the seat back frame 1012, in particular, an inner side of the upper middle wall 1107B of the first surface 34 of the seat back frame 1012. The second upper surface 1090AB of the upper base wall 1090A is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012, in particular, an inner side of the upper middle wall 1064B of the second surface 36 of the seat back frame 1012.

[0114] The pair of upper side walls 1092A includes a first upper surface 1092AA, an opposite second upper surface 1092AB, and a pair of upper side edges 1092AC. Each of the pair of upper side walls 1092A extends generally perpendicularly from an upper side edge 1090AC of the upper base wall 1090A. Each of the first upper surfaces 1092AA of the pair of upper side walls 1092A is positioned within the seat back frame 1012 to face an inner side of the first surface 34 of the seat back frame 1012, in particular, an inner side of the upper side wall 1107A of the first surface 34 of the seat back frame 1012. Each of the second upper surfaces 1092AB of the pair of upper side walls 1092A is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012, in particular, an inner side of the upper side wall 1064A of the second surface 36 of the seat back frame 1012.

[0115] The upper flange 1094A includes a first upper surface 1094AA and an opposite second upper surface 1094AB. The upper flange 1094A extends generally perpendicularly from one of the upper side edges 1092AC of the upper side wall 1092A to an upper distal edge 1096A. The first upper surface 1094AA of the upper flange 1094A is positioned within the seat back frame 1012 to face an inner side of the first surface 34 of the seat back frame 1012. The second upper surface 1092AB of the upper flange 1094A is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012.

[0116] The lower base wall 1090B includes a first lower surface 1090BA, an opposite second lower surface 1090BB, and a pair of lower side edges 1090BC extending between the first lower surface 1090BA and the second lower surface 1090BB. The first lower surface 1090BA of the lower base wall 1090B is positioned to face an inner side of the first surface 34 of the seat back frame 1012, particularly, an inner side of the lower middle wall 1107D of the first surface 34 of the seat back frame 1012. The second lower surface 1090BB of the lower base wall 1090B is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012, particularly, an inner side of the lower middle wall 1064D of the second surface 36 of the seat back frame 1012.

[0117] The pair of lower side walls 1092B includes a first lower surface 1092BA, an opposite second lower surface 1092BB, and a pair of lower side edges 1092BC. Each of the pair of lower side walls 1092B extends generally perpendicularly from a lower side edge 1090BC of the lower base wall 1090B. Each of the first lower surfaces 1092BA of the pair of lower side walls 1092B is positioned within the seat back frame 1012 to face an inner side of the first surface 34 of the seat back frame 1012, particularly, an inner side of the lower side wall 1107C of the first surface 34 of the seat back frame 1012. Each of the second lower surfaces 1092BB of the pair of lower side walls 1092B is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012, particularly, an inner side of the lower side wall 1064C of the second surface 36 of the seat back frame 1012.

[0118] The lower flange 1094B includes a first lower surface 1094BA and an opposite second lower surface 1094BB. The lower flange 1094B extends generally perpendicularly from one of the lower side edges 1092BC of the pair of lower side walls 1092B to a lower distal edge 1096B. The first lower surface 1094BA of the lower flange 1094B is positioned within the seat back frame 1012 to face an inner side of the first surface 34 of the seat back frame 1012. The second lower surface 1092BB of the lower flange 1094B is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012.

[0119] The center wall 1095 includes a first surface 1095A and an opposing second surface 1095B. The center wall 1095 extends between an upper side edge 1092AC of a lower one of the pair of upper side walls 1092A and a lower side edge 1092BC of an upper one of the pair of lower side walls 1092B. The first surface 1095A of the center wall 1095 is positioned within the seat back frame 1012 to face an inner side of the first surface 34 of the seat back frame 1012, particularly, an inner side of the inner wall 1107E of the first surface 34 of the seat back frame 1012. The second surface 1095B of the center wall 1095 is positioned within the seat back frame 1012 to face an inner side of the second surface 36 of the seat back frame 1012, particularly, an inner side of the inner wall 1064E of the second surface 36 of the seat back frame 1012.

[0120] Referring to Figure 5 , Figures 6A to 6B and Figure 7 , the pultruded reinforcement 1070 can also include a pair of upper holes 1098A and a pair of lower holes 1098B. Each of the pair of upper holes 1098A is positioned in the upper base wall 1090A adjacent to an end portion of the pultruded reinforcement 1070 in the longitudinal direction of the pultruded reinforcement 1070. Each of the pair of upper holes 1098A extends between a first upper surface 1090AA and an opposing second upper surface 1090AB of the upper base wall 1090A. Each of the pair of lower holes 1098B is positioned in the lower base wall 1090B adjacent to an end portion of the pultruded reinforcement 1070 in the longitudinal direction of the pultruded reinforcement 1070. Each of the pair of lower holes 1098B extends between a first lower surface 1090BA and an opposing second lower surface 1090BB of the lower base wall 1090B. As will be described in greater detail below, the pair of upper holes 1098A and the pair of lower holes 1098B help to hold the pultruded reinforcement 1070 in a predetermined position when the seat back frame 1012 is overmolded onto the pultruded reinforcement 1070.

[0121] The pultruded reinforcement 1070 can be formed from a continuous fiber-reinforced resin material. In some embodiments, the pultruded reinforcement 1070 can include a resin composite material and one or more fibers extending in one direction. As a non-limiting example, the one or more fibers can be glass fibers, such as continuous glass fibers. As another non-limiting example, the one or more fibers can be glass fibers and nylon fibers (e.g., 95% of the one or more fibers are glass fibers and 5% of the one or more fibers are nylon fibers). The one or more fibers can be configured to reinforce the resin composite material (e.g., a resin such as an epoxy resin, a polyester, etc.) of the pultruded reinforcement 1070. In this way, the glass fibers can increase the tensile strength, flexural modulus, impact resistance, and dimensional stability of the pultruded reinforcement 1070. In some embodiments, the pultruded reinforcement 1070 is formed from continuous glass fiber-reinforced resin material.

[0122] In some embodiments, the pultruded reinforcement 1070 is formed using a continuous molding pultrusion process in which reinforcing fibers (e.g., long strand glass fibers) are impregnated with a liquid resin material (e.g., a liquid polymer resin) and then pulled through a heated forming die to form the general hat shape of the pultruded reinforcement 1070. In some embodiments, a curing pigment and catalyst that enhance the pultruded reinforcement 1070 can be added while the one or more continuous glass fibers are being impregnated with the liquid resin material. It should be appreciated that in other embodiments, the pultruded reinforcement 1070 can be formed using any suitable pultrusion process or other suitable manufacturing process.

[0123] Referring to Figure 5 and 6A The first surface 34 of the seat back frame 1012 is formed with a plurality of openings 1100 positioned such that the pultruded reinforcement 1070 is visible through the first surface 34 of the seat back frame 1012. The plurality of openings 1100 includes a plurality of upper shaped apertures 1102A, a plurality of lower shaped apertures 1102B, a plurality of upper slots 1104A, a plurality of lower slots 1104B, and a plurality of middle slots 1104C. The plurality of upper shaped apertures 1102A are disposed on the upper middle wall 1107B to extend through the upper middle wall 1107B. The plurality of lower shaped apertures 1102B are disposed on the lower middle wall 1107D to extend through the lower middle wall 1107D.

[0124] Each of the pair of upper holes 1098A is disposed in the pultruded reinforcement 1070 to align with a respective upper shaped aperture 1102A. Each of the pair of lower holes 1098B is disposed in the pultruded reinforcement 1070 to align with a respective lower shaped aperture 1102B.

[0125] The plurality of upper slots 1104A are disposed to extend through a top one of the pair of upper sidewalls 1107A. The plurality of upper slots 1104A can also be disposed to extend through a portion of the upper intermediate wall 1107B. In some embodiments, the plurality of upper slots 1104A can extend through the upper intermediate wall 1107B, a top one of the pair of upper sidewalls 1107A, and into the first surface 34.

[0126] The plurality of lower slots 1104B are disposed to extend through a bottom one of the pair of lower sidewalls 1107C. The plurality of lower slots 1104B can also be disposed to extend through a portion of the lower intermediate wall 1107D. In some embodiments, the plurality of lower slots 1104B can extend through the lower intermediate wall 1170D, a bottom one of the pair of lower sidewalls 1107C, and into the first surface 34.

[0127] The plurality of intermediate slots 1104C are disposed to extend through the inner wall 1107E. The plurality of intermediate slots 1104C can also be disposed to extend through the upper intermediate wall 1107B, a bottom one of the pair of upper sidewalls 1107A, a top one of the pair of lower sidewalls 1107C, and at least one of the lower intermediate wall 1107D. In some embodiments, the plurality of intermediate slots 1104C can extend through the upper intermediate wall 1107B, a bottom one of the pair of upper sidewalls 1107A, the inner wall 1107E, a top one of the pair of lower sidewalls 1107C, and the lower intermediate wall 1107D.

[0128] In some embodiments, the plurality of upper shaped holes 1102A and the plurality of lower shaped holes 1102B are formed to have a generally circular shape. It can be appreciated that the shape of the plurality of upper shaped holes 1102A and the plurality of lower shaped holes 1102B is not limited to a generally circular shape and can include other regular and irregular geometric shapes, including for example, triangles, diamonds, semicircles, and rectangles. It can be appreciated that the plurality of upper shaped holes 1102A and the plurality of lower shaped holes 1102B can have the same or different shapes.

[0129] The plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C are disposed to have an elongated rectangular shape and have generally semicircular ends. The plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C are not limited to an elongated generally rectangular shape with generally semicircular ends and can include other regular and irregular geometric shapes, including for example, triangles, diamonds, semicircles, and rectangles. It can be appreciated that the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C can have the same or different shapes.

[0130] In some embodiments, the plurality of upper forming holes 1102A and the plurality of lower forming holes 1102B are aligned in the carrier vertical direction such that each of the plurality of upper forming holes 1102A is linearly aligned with a respective one of the plurality of lower forming holes 1102B. In some embodiments, the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of middle slots 1104C are aligned in the carrier vertical direction such that each of the plurality of upper slots 1104A is linearly aligned with a respective one of the plurality of lower slots 1104B and a respective one of the plurality of middle slots 1104C. In some embodiments, the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of middle slots 1104C are disposed between adjacent upper forming holes 1102A and adjacent lower forming holes 1102B.

[0131] As discussed above, the plurality of openings 1100 allows for visual inspection of the pultruded reinforcement 1070 after the seatback frame 1012 has been overmolded onto the pultruded reinforcement 1070. The plurality of upper forming holes 1102A allows the first upper surface 1090AA of the upper base wall 1090A to be visible through the seatback frame 1012, and in particular through the first surface 34 of the seatback frame 1012. The plurality of lower forming holes 1102B allows the first lower surface 1090BA of the lower base wall 1090B to be visible through the seatback frame 1012, and in particular through the first surface 34 of the seatback frame 1012. The plurality of upper slots 1104A allows the first upper surface 1090AA of the upper base wall 1090A, the first upper surface 1092AA of the top one of the pair of upper side walls 1092A, and the first upper surface 1094AA of the upper flange 1094A to be visible through the seatback frame 1012, and in particular through the first surface 34 of the seatback frame 1012. The plurality of lower slots 1104B allows the first lower surface 1090BA of the lower base wall 1090B, the first lower surface 1092BA of the bottom one of the pair of lower side walls 1092B, and the first lower surface 1094BA of the lower flange 1094B to be visible through the seatback frame 1012, and in particular through the first surface 34 of the seatback frame 1012.

[0132] The plurality of middle slots 1104C allows the first upper surface 1090AA of the upper base wall 1090A, the first upper surface 1092AA of the bottom one of the pair of upper side walls 1092A, the first surface 1095A of the center wall 1095, the first lower surface 1092BA of the top one of the pair of lower side walls 1092B, and the first lower surface 1092BA of the lower base wall 1090B to be visible through the seatback frame 1012, and in particular through the first surface 34 of the seatback frame 1012.

[0133] Referring to Figure 6BThe second surface 36 of the seat back frame 1012 is formed with a plurality of openings 1110 positioned so as to allow the pultruded reinforcement 1070 to be seen through the second surface 36 of the seat back frame 1012. The plurality of openings 1110 includes a plurality of upper shaped holes 1112A, a plurality of lower shaped holes 1112B, a plurality of upper slots 1114A, a plurality of lower slots 1114B, and a plurality of middle slots 1114C. The plurality of upper shaped holes 1112A are disposed on the upper middle wall 1064B so as to extend through the upper middle wall 1064B. The plurality of lower shaped holes 1112B are disposed on the lower middle wall 1064D so as to extend through the lower middle wall 1064D.

[0134] Each of the pair of upper holes 1098A is disposed in the pultruded reinforcement 1070 in alignment with a respective upper shaped hole 1112A. Each of the pair of lower holes 1098B is disposed in the pultruded reinforcement 1070 in alignment with a respective lower shaped hole 1112B. Thus, the alignment of the pair of upper holes 1098A with the upper shaped holes 1102A and the upper shaped holes 1112A allows a passageway to be formed through the seat back frame 1012 from the first surface 34 to the second surface 36. Similarly, the alignment of the pair of lower holes 1098B with the lower shaped holes 1102B and the lower shaped holes 1112B allows a passageway to be formed through the seat back frame 1012 from the first surface 34 to the second surface 36.

[0135] The plurality of upper slots 1114A are disposed so as to extend through a top one of the pair of upper side walls 1064A. The plurality of upper slots 1114A can also be disposed so as to extend through a portion of the upper middle wall 1064B. In some embodiments, the plurality of upper slots 1114A can extend through the upper middle wall 1064B, a top one of the pair of upper side walls 1064A, and into the second surface 36.

[0136] The plurality of lower slots 1114B are disposed so as to extend through a bottom one of the pair of lower side walls 1064C. The plurality of lower slots 1114B can also be disposed so as to extend through a portion of the lower middle wall 1064D. In some embodiments, the plurality of lower slots 1114B can extend through the lower middle wall 1064D, a bottom one of the pair of lower side walls 1064C, and into the second surface 36.

[0137] The plurality of intermediate slots 1114C are disposed to extend through the inner wall 1064E. The plurality of intermediate slots 1114C can also be disposed to extend through the upper intermediate wall 1064B, a bottom one of the pair of upper side walls 1064A, a top one of the pair of lower side walls 1064C, at least one of the lower intermediate wall 1064D. In some embodiments, the plurality of intermediate slots 1114C can extend through the upper intermediate wall 1064B, a bottom one of the pair of upper side walls 1064A, the inner wall 1064E, a top one of the pair of lower side walls 1064C, and the lower intermediate wall 1064D.

[0138] In some embodiments, the plurality of upper shaped holes 1112A and the plurality of lower shaped holes 1112B are formed to have a substantially circular shape. It can be appreciated that the shape of the plurality of upper shaped holes 1112A and the plurality of lower shaped holes 1112B is not limited to a substantially circular shape and can include other regular and irregular geometric shapes, including, for example, triangles, diamonds, semicircles, and rectangles. It can be appreciated that the plurality of upper shaped holes 1112A and the plurality of lower shaped holes 1112B can have the same or different shapes.

[0139] The plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C are disposed to have an elongated rectangular shape and have substantially semicircular ends. It can be appreciated that the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C can have the same or different shapes.

[0140] The plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C are not limited to an elongated substantially rectangular shape with substantially semicircular ends and can include other regular and irregular geometric shapes, including, for example, triangles, diamonds, semicircles, and rectangles. It can be appreciated that the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C can have the same or different shapes.

[0141] In some embodiments, the plurality of upper shaped holes 1112A and the plurality of lower shaped holes 1112B are aligned in the vertical direction of the carrier such that each of the plurality of upper shaped holes 1112A is linearly aligned with a respective one of the plurality of lower shaped holes 1112B. In some embodiments, the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C are aligned in the vertical direction of the carrier such that each of the plurality of upper slots 1114A is linearly aligned with a respective one of the plurality of lower slots 1114B and a respective one of the plurality of intermediate slots 1114C. In some embodiments, the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C are disposed between adjacent upper shaped holes 1112A and adjacent lower shaped holes 1112B.

[0142] In some embodiments, the plurality of openings 1100 and the plurality of openings 1110 are disposed on respective portions of the first surface 34 and the second surface 36, it being appreciated that the locations of the plurality of openings 1100 on the first surface 34 can not correspond to the locations of the plurality of openings 1110 on the second surface 36.

[0143] As discussed above, the plurality of openings 1110 allow for visual inspection of the pultruded reinforcement 1070 after the seat back frame 1012 has been overmolded onto the pultruded reinforcement 1070. The plurality of upper shaped holes 1112A allow the second upper surface 1090AB of the upper base wall 1090A to be visible through the seat back frame 1012, and in particular through the second surface 36 of the seat back frame 1012. The plurality of lower shaped holes 1112B allow the second lower surface 1090BB of the lower base wall 1090B to be visible through the seat back frame 1012, and in particular through the second surface 36 of the seat back frame 1012. The plurality of upper slots 1114A allow the second upper surface 1090AB of the upper base wall 1090A, the second upper surface 1092AB of the top one of the pair of upper sidewalls 1092A, and the second upper surface 1094AB of the upper flange 1094A to be visible through the seat back frame 1012, and in particular through the second surface 36 of the seat back frame 1012. The plurality of lower slots 1114B allow the second lower surface 1090BB of the lower base wall 1090B, the second lower surface 1092BB of the bottom one of the pair of lower sidewalls 1092B, and the second lower surface 1094BB of the lower flange 1094B to be visible through the seat back frame 1012, and in particular through the second surface 36 of the seat back frame 1012.

[0144] The plurality of middle slots 1114C allow the second upper surface 1090AB of the upper base wall 1090A, the second upper surface 1092AB of the bottom one of the pair of upper sidewalls 1092A, the second surface 1095B of the center wall 1095, the second lower surface 1092BB of the top one of the pair of lower sidewalls 1092B, and the second lower surface 1092BB of the lower base wall 1090B to be visible through the seat back frame 1012, and in particular through the second surface of the seat back frame 1012.

[0145] In various embodiments and as shown in FIGS. 1-3, the bracket 15 can be positioned adjacent to (i.e., proximate or near) the pultruded reinforcement 1070 and can be configured to pivotally couple the side member 30 to the seat cushion frame 14 using fastening members 99 (e.g., rotatable fastening nuts, pivot bolts, hinges, or similar other fastening elements). Figure 7

[0146] Referring to Figure 5 , Figures 6A to 6B ,​Figure 7 and Figure 8 An exemplary process of forming the pultruded reinforcement 1070 and the seat back frame 1012 having the pultruded reinforcement 1070 will now be described. As noted above, the pultruded reinforcement 1070 can be formed during a pultrusion process. As a non-limiting example, the pultrusion process can include winding one or more continuous glass fibers using a tension roller. The one or more continuous glass fibers can then be placed in a resin bath (e.g., polyester, polyurethane, vinyl ester, epoxy, etc.) and the resin can permeate the one or more continuous glass fibers. In some embodiments, a curing pigment and catalyst that reinforce the pultruded reinforcement 1070 can be added while the one or more continuous glass fibers are in the resin bath. Subsequently, the mixture of the one or more continuous glass fibers and resin can be provided to a heat source, such as a steel forming die, to polymerize the resin. The polymerized resin and one or more continuous glass fibers are removed from the heat source as a solid glass fiber reinforced polymer. It should be appreciated that in other embodiments, the pultruded reinforcement 1070 can be formed using any suitable pultrusion process or other suitable manufacturing process.

[0147] During the pultrusion process, various geometric features of the pultruded reinforcement 1070 can be defined. As a non-limiting example and as shown in the illustrated embodiment of FIGS. 10A-10B, the pultruded reinforcement 1070 can be formed as a substantially double-hat shape and include an upper base wall 1090, a pair of upper sidewalls 1092, an upper flange 1094A, a center wall 1095, a lower base wall 1090B, a pair of lower sidewalls 1092B, and a lower flange 1094B. Figure 7 and 8 During the pultrusion process, various geometric features of the pultruded reinforcement 1070 can be defined. As a non-limiting example and as shown in the illustrated embodiment of FIGS. 10A-10B, the pultruded reinforcement 1070 can be formed as a substantially double-hat shape and include an upper base wall 1090, a pair of upper sidewalls 1092, an upper flange 1094A, a center wall 1095, a lower base wall 1090B, a pair of lower sidewalls 1092B, and a lower flange 1094B.

[0148] Once the pultruded reinforcement 1070 is formed, the pultruded reinforcement 1070 is only partially overmolded within the seat back frame 1012 such that the pultruded reinforcement 1070 is configured to be visually inspected through the seat back frame 1012, through the plurality of openings 1100 and the plurality of openings 1110. In some embodiments, and with reference to FIGS. 11A-11B, the pultruded reinforcement 1070 is placed in an overmolding cavity 1120. As a non-limiting example, the pultruded reinforcement 1070 can be positioned between a first molding base 1130 and a second molding base 1140 of the overmolding cavity 1120. Figure 8

[0149] ​In some embodiments, at least one of the first molding substrate 1130 and the second molding substrate 1140 may each include a pair of upper pin holes 1181A and a pair of lower pin holes 1181B. The pair of upper pin holes 1181A are configured to receive a pair of upper locating pins 1180A (e.g., bidirectional and four-way locating pins), and the pair of upper pin holes 1098A of the pultruded reinforcement 1070 may be aligned with the pair of upper locating pins 1180A. The pair of lower pin holes 1181B are configured to receive a pair of lower locating pins 1180B (e.g., bidirectional and four-way locating pins), and the pair of lower pin holes 1098B of the pultruded reinforcement 1070 may be aligned with the pair of lower locating pins 1180B.

[0150] like Figure 8 As shown, the upper locating pin 1180A is aligned with and extends into the upper hole 1098A of the pultruded reinforcement 1070, such that when the encasing molded cavity 1120 is closed, the end of the upper locating pin 1180A contacts a portion of the second molding base 1140. Similarly, the lower locating pin 1180B is aligned with and extends into the lower hole 1098B of the pultruded reinforcement 1070, such that when the encasing molded cavity 1120 is closed, the end of the lower locating pin 1180B contacts a portion of the second molding base 1140. The second molding base 1140 may include an upper hole 1182A configured to receive the upper locating pin 1180A and a lower hole 1182B configured to receive the lower locating pin 1180B. In some embodiments, the upper hole 1182A and the lower hole 1182B are cavities with bottoms, and in some other embodiments, the upper hole 1182A and the lower hole 1182B are through holes extending through the second molded substrate 1140.

[0151] Therefore, when the seat back frame 1012 is overmolded onto the pultruded reinforcement 1070, the engagement between a pair of upper holes 1098A and upper locating pins 1180A, and the engagement between a pair of lower holes 1098B and lower locating pins 1180B, holds the pultruded reinforcement 1070 in a predetermined position relative to the overmolding cavity 1120. Once the pultruded reinforcement 1070 is positioned between the first molding base 1130 and the second molding base 1140 and held in place by a pair of upper locating pins 1180A and a pair of lower locating pins 1180B, the overmolding cavity 1120 is sealed and isolated from the environment outside the overmolding cavity 1120.

[0152] Subsequently, an injection molding material can be provided within the overmolding cavity 1120. As non-limiting examples, the injection molding material can be nylon, polyester, polyurethane, vinyl material, vinyl ester, and / or epoxy resin, or any other suitable injection molding material. In some embodiments, additive materials (e.g., plasticizers, fibers, flame retardants, colorants, etc.) can be heated and added to the overmolding cavity 120 along with the injection molding material.

[0153] In some embodiments, the overmolding cavity 1120 defines a cavity between the first molding base 1130 and the second molding base 1140, into which the pultruded reinforcement 1070 is positioned during the overmolding process. Each of the first molding base 1130 and the second molding base 1140 can have a geometry such that, when the injection molding material in the overmolding cavity 1120 is cured, the pultruded reinforcement 170 is positioned between the first surface 34 and the second surface 36 of the seat back frame 1012.

[0154] In some embodiments, the first molding base 1130 can have a geometry such that, when the injection molding material in the overmolding cavity 1120 is cured, the plurality of upper shaped apertures 1102A, the plurality of lower shaped apertures 1102B, the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C are formed in the first surface 34 of the seat back frame 1012.

[0155] In some embodiments, the second molding base 1140 can have a geometry such that, when the injection molding material in the overmolding cavity 1120 is cured, the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B are formed in the upper reinforcement recess 1062A and the lower reinforcement recess 1062B, respectively, of the seat back frame 1012. The second molding base 1140 can have a geometry such that, when the injection molding material in the overmolding cavity 1120 is cured, the plurality of upper shaped apertures 1112A, the plurality of lower shaped apertures 1112B, the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C are formed in the second surface 36 of the seat back frame 1012.

[0156] Still referring to Figure 8The first molding base 1130 can include a plurality of protrusions 1150 (e.g., a plurality of hole protrusions and a plurality of slot protrusions) extending from the mold surface of the first molding base 1130 to form the plurality of upper shaped holes 1102A, the plurality of lower shaped holes 1102B, the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C. The plurality of hole protrusions 1150 can directly contact the first upper surface 1090AA of the upper base wall 1090A and can directly contact the first lower surface 1090BA of the lower base wall 1090B of the pultruded reinforcement 1070 during the overmolding process and can have a shape corresponding to the shape of the plurality of upper shaped holes 1102A and the plurality of lower shaped holes 1102B. The plurality of slot protrusions 1150 can directly contact the first upper surface 1090AA of the upper base wall 1090A, the first upper surface 1092AA of the pair of upper sidewalls 1092A, the first upper surface 1094AA of the upper flange 1094A, the first surface 1095A of the center wall 1095, the first lower surface 1090BA of the lower base wall 1090B, the first lower surface 1092BA of the pair of lower sidewalls 1092B, the first lower surface 1094BA of the lower flange 1094B, and can have a shape corresponding to the shape of the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C.

[0157] Accordingly, when the injection molding material is added to the overmolding cavity 1120, the injection molding material is not located between the first upper surface 1090AA of the upper base wall 1090A, the first lower surface 1090BA of the lower base wall 1090B, and the hole protrusions 1150, thereby forming the plurality of upper shaped holes 1102A and the plurality of lower shaped holes 1102B. Similarly, when the injection molding material is added to the overmolding cavity 1120, the injection molding material is not located between the first upper surface 1090AA of the upper base wall 1090A, the first upper surface 1092AA of the pair of upper sidewalls 1092A, the first upper surface 1094AA of the upper flange 1094A, the first surface 1095A of the center wall 1095, the first lower surface 1090BA of the lower base wall 1090B, the first lower surface 1092BA of the pair of lower sidewalls 1092B, the first lower surface 1094BA of the lower flange 1094B, and the slot protrusions 1150, to form the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C.

[0158] Accordingly, as the injection molding material in the overmolding cavity 1120 solidifies, the plurality of upper forming holes 1102A, the plurality of lower forming holes 1102B, the plurality of upper slots 1104A, the plurality of lower slots 1104B, and the plurality of intermediate slots 1104C of the plurality of openings 1100 are formed in the first surface 34 of the seat back frame 1012 such that the pultruded reinforcement 1070 is configured to be visually inspected through the seat back frame 1012.

[0159] Still referring to Figure 8 , the second molding base 1140 can include a plurality of protrusions 1160 (e.g., a plurality of hole protrusions and a plurality of slot protrusions) extending from a mold surface of the second molding base 1140 to form the plurality of upper forming holes 1112A, the plurality of lower forming holes 1112B, the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C. The plurality of hole protrusions 1160 can directly contact the second upper surface 1090AB of the upper base wall 1090A and can directly contact the second lower surface 1090BB of the lower base wall 1090B of the pultruded reinforcement 1070 during the overmolding process and can have a shape corresponding to the shape of the plurality of upper forming holes 1112A and the plurality of lower forming holes 1112B. The plurality of slot protrusions 1160 can directly contact the second upper surface 1090AB of the upper base wall 1090A, the second upper surface 1092AB of the pair of upper side walls 1092A, the second upper surface 1094AB of the upper flange 1094A, the second surface 1095B of the center wall 1095, the second lower surface 1090BB of the lower base wall 1090B, the second lower surface 1092BB of the pair of lower side walls 1092B, the second lower surface 1094BB of the lower flange 1094B, and can have a shape corresponding to the shape of the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C.

[0160] Accordingly, when the injection molding material is added to the overmolding cavity 1120, the injection molding material does not lie between the second upper surface 1090AB of the upper base wall 1090A, the second lower surface 1090BB of the lower base wall 1090B, and the hole protrusion 1160, thereby forming a plurality of upper shaped holes 1112A and a plurality of lower shaped holes 1112B. Similarly, when the injection molding material is added to the overmolding cavity 1120, the injection molding material does not lie between the second upper surface 1090AB of the upper base wall 1090A, the second upper surfaces 1092AB of the pair of upper side walls 1092A, the second upper surface 1094AB of the upper flange 1094A, the second surface 1095B of the center wall 1095, the second lower surface 1090BB of the lower base wall 1090B, the second lower surfaces 1092BB of the pair of lower side walls 1092B, the second lower surface 1094BB of the lower flange 1094B, and the slot protrusion 1160, thereby forming a plurality of upper slots 1114A, a plurality of lower slots 1114B, and a plurality of intermediate slots 1114C.

[0161] Accordingly, when the injection molding material in the overmolding cavity 1120 solidifies, the plurality of upper shaped holes 1112A, the plurality of lower shaped holes 1112B, the plurality of upper slots 1114A, the plurality of lower slots 1114B, and the plurality of intermediate slots 1114C of the plurality of openings 1110 are formed in the second surface 36 of the seat back frame 1012 such that the pultruded reinforcement 1070 is configured to be visually inspected through the seat back frame 1012.

[0162] It is to be understood that the second molded base 1140 can have a shape that corresponds to the shape of the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B, respectively. Accordingly, when the injection molding material in the overmolding cavity 1120 solidifies, the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B are formed in the second surface 36 of the seat back frame 1012.

[0163] It should now be appreciated that the vehicle according to the present disclosure includes a seat assembly 1010 that includes a seat back frame 1012 and a seat cushion frame 14. In various embodiments, the seat back frame 1012 includes a plurality of openings 1100 on a first surface 34 of the pultruded reinforcement 1070 and a plurality of openings 1110 on a second surface 36 formed during the overmolding process. Accordingly, the seat back frame 1012 is configured to enable visual inspection of the pultruded reinforcement 1070 after the overmolding process is complete, thereby enabling an operator to verify that the pultruded reinforcement 1070 is properly positioned and unharmed at the completion of the overmolding process. Further, the pultruded reinforcement 1070 includes a plurality of upper reinforcement ribs 1066A and a plurality of lower reinforcement ribs 1066B formed in an upper reinforcement recess 1062A and a lower reinforcement recess 1062B, respectively, of the seat back frame 1012 during the overmolding process. Accordingly, the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B can provide stiffness against torsional forces applied to the seat back frame 1012.

[0164] Accordingly, the method of forming the seat back assembly 1010 includes providing a pultruded reinforcement 1070, overmolding a seat back frame 1012 onto the pultruded reinforcement 1070, and forming a plurality of openings 1100 and a plurality of openings 1110 in the seat back frame 1012 when overmolding the seat back frame 1012 onto the pultruded reinforcement 1070 such that the pultruded reinforcement 1070 is configured to be visually inspected through the plurality of openings 1100 and the plurality of openings 1110.

[0165] The method further includes the step of forming the plurality of openings 1100 on the first surface 34 of the seat back frame 1012. The plurality of openings 1100 includes a plurality of upper shaped holes 1102A, a plurality of lower shaped holes 1102B, a plurality of upper slots 1104A, a plurality of lower slots 1104B, and a plurality of middle slots 1104C. The method further includes the step of forming the plurality of openings 1110 on the second surface 36 of the seat back frame 1012. The plurality of openings 1110 includes a plurality of upper shaped holes 1112A, a plurality of lower shaped holes 1112B, a plurality of upper slots 1114A, a plurality of lower slots 1114B, and a plurality of middle slots 1114C. The method further includes the step of forming the plurality of upper reinforcement ribs 1066A and the plurality of lower reinforcement ribs 1066B in the second surface 36 of the seat back frame 1012.

[0166] In another embodiment, a method includes providing a pultruded reinforcement, overmolding a seat back frame onto the pultruded reinforcement, and forming a plurality of openings in the seat back frame. The plurality of openings is formed when overmolding the seat back frame onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through the plurality of openings.

[0167] Note that the terms "substantially" and "about" can be utilized herein to represent the inherent degree of uncertainty that can be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation can vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

[0168] Various terms are used herein to describe spatial and functional relationships between components. As used in this document, the terminology "connected" or "coupled" or "linked" or "attached" or "adjacent" or "near" or "immediately adjacent" or "on top of" or "above" or "below" or "positioned" or "disposed" refers to an indirect or direct electrical or physical connection or relationship between the components, unless expressly described as "direct". When a relationship between components is described in the above disclosure, unless expressly described as "direct", the relationship can be a direct relationship in which no other intermediate components are present between the first and second components, but can also be an indirect relationship in which one or more intermediate components (spatially or functionally) are present between the first and second components.

[0169] Although specific embodiments have been shown and described herein, it is understood that various other changes and modifications can be made therein without departing from the scope of the claimed subject matter. Furthermore, while various aspects of the claimed subject matter have been described herein, these aspects need not be utilized in combination. Accordingly, the appended claims are intended to cover all such changes and modifications that are within the scope of the claimed subject matter.

Claims

1. A seat back assembly comprising: a pultruded reinforcement extending along a vehicle lateral direction, the vehicle including the seat back assembly, the vehicle lateral direction referring to a direction across the vehicle as viewed along a direction perpendicular to the vehicle lateral direction, the pultruded reinforcement having a generally hat shape formed by a base wall, a pair of side walls extending from side edges of the base wall, and a pair of flanges extending from side edges of the pair of side walls; and a seat back frame formed of a resin material, the seat back frame being only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of holes and a plurality of slots formed in the seat back frame. The pultruded reinforcement is formed of a continuous glass fiber reinforced resin material.

2. The seat back assembly of claim 1, wherein, The plurality of holes are formed in the seat back frame such that a portion of the base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of holes, 3. The seat back assembly of claim 1, wherein, wherein the plurality of holes are formed in the seat back frame such that a portion of at least one of the pair of side walls is configured to be visually inspected through the plurality of holes. The seat back frame includes a first surface and an opposing second surface, and the pultruded reinforcement is located between the first surface and the second surface of the seat back frame, and 4. The seat back assembly of claim 3, wherein, wherein the plurality of holes and the plurality of slots are formed in both the first surface and the second surface. The second surface of the seat back frame includes a plurality of reinforcing ribs extending along a plurality of linkages formed in the second surface of the seat back frame, the plurality of linkages defining a plurality of holes formed in the second surface of the seat back frame.

5. The seat back assembly of claim 4, wherein, 6. A seat back assembly comprising: a pultruded reinforcement extending along a vehicle lateral direction, the vehicle including the seat back assembly, the vehicle lateral direction referring to a direction across the vehicle as viewed along a direction perpendicular to the vehicle lateral direction, the pultruded reinforcement having a generally double hat shape formed by an upper flange, an upper base wall, a center wall, a first upper side wall extending between the upper flange and the upper base wall, a second upper side wall extending between the upper base wall and the center wall, a lower base wall, a lower flange, a first lower side wall extending between the center wall and the lower base wall, and a second lower side wall extending between the lower base wall and the lower flange; and a seat back frame formed of a resin material, the seat back frame being only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of openings formed in the seat back frame. The plurality of openings includes a plurality of upper holes, a plurality of lower holes, a plurality of upper slots, a plurality of lower slots, and a plurality of middle slots, 7. The seat back assembly of claim 6, wherein, wherein the plurality of upper holes are formed in the seat back frame such that a portion of the upper base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper holes, ​ wherein the plurality of lower holes are formed in the seatback frame such that a portion of the lower base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower holes, wherein the plurality of upper slots are formed in the seatback frame such that at least a portion of the first upper side wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper slots, wherein the plurality of lower slots are formed in the seatback frame such that at least a portion of the first lower side wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower slots, and wherein the plurality of intermediate slots are formed in the seatback frame such that at least a portion of the center wall of the pultruded reinforcement is configured to be visually inspected through the plurality of intermediate slots.

8. The seat back assembly of claim 7, wherein, The seatback frame includes a plurality of upper reinforcement ribs configured to be positioned between the first upper side wall and the second upper side wall of the pultruded reinforcement and a plurality of lower reinforcement ribs configured to be positioned between the first lower side wall and the second lower side wall of the pultruded reinforcement.

9. A seat assembly comprising: a seat cushion frame; a pultruded reinforcement extending along a vehicle transverse direction, the vehicle including the seat assembly, the vehicle transverse direction referring to a direction of the vehicle that is traversed when viewed along a direction that is perpendicular to the vehicle transverse direction, the pultruded reinforcement having at least one generally hat shape formed by a base wall, a pair of side walls extending from side edges of the base wall, and a pair of flanges extending from side edges of the pair of side walls; and a seatback frame formed of a resin material, the seatback frame being only partially overmolded onto the pultruded reinforcement such that the pultruded reinforcement is configured to be visually inspected through a plurality of holes and a plurality of slots formed in the seatback frame. The pultruded reinforcement is formed of a continuous glass fiber reinforced resin material.

10. The seat assembly of claim 9, wherein, The plurality of holes are formed in the seatback frame such that a portion of the base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of holes, 11. The seat assembly of claim 9, wherein, wherein the plurality of holes are formed in the seatback frame such that a portion of at least one of the pair of side walls is configured to be visually inspected through the plurality of holes. The seatback frame includes a first surface and an opposing second surface, and the pultruded reinforcement is positioned between the first surface and the second surface of the seatback frame, and 12. The seat assembly of claim 11, wherein, wherein the plurality of holes and the plurality of slots are formed in both the first surface and the second surface. The second surface of the seatback frame includes a plurality of reinforcement ribs extending along a plurality of link portions formed in the second surface of the seatback frame, the plurality of link portions defining the plurality of holes formed in the second surface of the seatback frame.

13. The seat assembly of claim 12, wherein, ​ 14. The seat assembly of claim 9, wherein, The at least one generally hat shape of the pultruded reinforcement is a generally double hat shape, the pair of flanges includes an upper flange and a center wall, and the pair of sidewalls includes a first upper sidewall and a second upper sidewall, wherein the generally double hat shape is formed by the base wall, the center wall, a first upper sidewall extending between the upper flange and the base wall, a second upper sidewall extending between the base wall and the center wall, a lower base wall, a lower flange, a first lower sidewall extending between the center wall and the lower base wall, and a second lower sidewall extending between the lower base wall and the lower flange.

15. The seat assembly of claim 14, wherein, The plurality of holes includes a plurality of upper holes, a plurality of lower holes, the plurality of slots includes a plurality of upper slots, a plurality of lower slots, and a plurality of intermediate slots, wherein the plurality of upper holes are formed in the seat back frame such that a portion of the base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper holes, wherein the plurality of lower holes are formed in the seat back frame such that a portion of the lower base wall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower holes, wherein the plurality of upper slots are formed in the seat back frame such that at least a portion of the first upper sidewall of the pultruded reinforcement is configured to be visually inspected through the plurality of upper slots, wherein the plurality of lower slots are formed in the seat back frame such that at least a portion of the first lower sidewall of the pultruded reinforcement is configured to be visually inspected through the plurality of lower slots, and wherein the plurality of intermediate slots are formed in the seat back frame such that at least a portion of the center wall of the pultruded reinforcement is configured to be visually inspected through the plurality of intermediate slots.

16. The seat assembly of claim 15, wherein, The seat back frame includes a plurality of upper reinforcement ribs and a plurality of lower reinforcement ribs, the plurality of upper reinforcement ribs are configured to be located between the first upper sidewall and the second upper sidewall of the pultruded reinforcement, and the plurality of lower reinforcement ribs are configured to be located between the first lower sidewall and the second lower sidewall of the pultruded reinforcement.

Images