Vehicle seat assembly with inner side support cushion portions of different stiffness

Abstract

The present invention provides a "Vehicle Seat Assembly with Inner Side Support Cushion Portions of Different Stiffness." A foam assembly of a vehicle seat assembly can be configured to cradle a user in the event of a force being applied against the vehicle seat assembly. The foam assembly can be configured to cradle the user according to a spatial relationship between the foam assembly and a seat back frame. Additionally, the foam assembly can be configured to cradle the user according to an outer side wing and an inner side wing disposed within the foam assembly and a first set of ribs and a second set of ribs interposed between the foam assembly and the seat back frame. Furthermore, the ability of the foam assembly to cradle the user can vary according to the positioning of structural wires of the foam assembly relative to a headrest aperture formed in an upper portion of the foam assembly.

Description

Technical Field

[0001] This disclosure generally relates to a vehicle seat assembly. More specifically, this disclosure generally relates to a design modification of the foam assembly of a vehicle seat assembly, wherein the modified foam assembly facilitates translation of the foam assembly to support the user of the vehicle seat assembly when force is applied against the seat foam assembly. Background Technology

[0002] Motor vehicles are typically equipped with a vehicle seat assembly, which generally includes a seat back frame and a foam assembly with support padding. It is desirable to provide a seat assembly that allows for enhanced performance characteristics while allowing the vehicle seat assembly to respond in a desired manner to forces applied against it. Summary of the Invention

[0003] According to a first aspect of this disclosure, a vehicle seat assembly includes a seat back frame and a foam assembly connected to the seat back frame, wherein the foam assembly includes an outer support pad portion, an inner support pad portion, an upper portion extending between the outer support pad portion and the inner support pad portion, and a torso portion, wherein the inner support pad portion includes a first inner portion and a second inner portion, wherein the first inner portion has a first rigidity and the second inner portion has a second rigidity, wherein the second rigidity is greater than the first rigidity.

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

[0005] - The inner support pad portion forms an inner fracture portion that is inserted between the first inner portion and the second inner portion;

[0006] - The vehicle seat assembly also includes an inner flap, wherein the inner flap is inserted between a first inner portion and a second inner portion;

[0007] - The inner surface of the first inner portion forms a first chamfered surface;

[0008] - The vehicle seat assembly also includes multiple ribs inserted between the foam assembly and the seat back frame;

[0009] - The vehicle seat assembly also includes a first set of ribs disposed in the first front portion of a seat back frame clearance groove formed between the inner side of the torso portion and the first arm of the seat back frame.

[0010] - The vehicle seat assembly also includes an upper crossbeam clearance groove formed between the inner side of the upper portion and the seat back frame;

[0011] - The inner support pad portion also includes a lateral portion and a rear portion, wherein the lateral portion extends from the second inner portion and connects to the rear portion;

[0012] - The inner support pad portion also includes a lateral portion and a rear portion, wherein the lateral portion extends from the second inner portion and connects to the rear portion, wherein the rear portion, the lateral portion, the first inner portion and the second inner portion cooperate to define an inner recess clearance groove.

[0013] - The vehicle seat assembly also includes structural wires embedded within the foam assembly, wherein the structural wires extend through a section of the upper portion relative to the headrest opening formed by the upper portion in the rear proximal side of the vehicle.

[0014] - The vehicle seat assembly also includes a lumbar support groove formed between the inner surface of the torso and the lower crossbeam between the seat back frame; and

[0015] - The seat back frame is essentially confined within the foam assembly.

[0016] According to a second aspect of this disclosure, a vehicle seat assembly includes a seat back frame and a foam assembly connected to the seat back frame. The foam assembly includes an outer support pad portion, an inner support pad portion, an upper portion extending between the outer support pad portion and the inner support pad portion, and a torso portion partially surrounded by the outer support pad portion, the inner support pad portion, and the upper portion. The foam assembly is configured to elastically deform under an applied force, wherein the outer support pad portion translates toward the inner support pad portion, the inner support pad portion translates toward the outer support pad portion, and the torso portion translates toward a gap formed by the seat back frame.

[0017] Embodiments of the second aspect of this disclosure may include any one or a combination of the following features:

[0018] - The vehicle seat assembly also includes multiple ribs inserted between the foam assembly and the seat back frame, wherein the multiple ribs are configured to collapse when the torso portion translates toward the gap formed by the seat back frame under an applied force.

[0019] - The inner support pad portion forms a first inner portion and a second inner portion, wherein the first inner portion is configured to translate toward the seat back frame and the second inner portion is configured to translate toward the outer support pad portion, wherein the first inner portion is configured to translate before the second inner portion when force is applied against the vehicle seat assembly;

[0020] - The foam assembly is configured to elastically deform from a first configuration to a second configuration, wherein in the second configuration, the foam assembly is adapted to support the occupants of the vehicle seat assembly; and

[0021] - The vehicle seat assembly is configured to deform under applied force so that the occupant of the vehicle seat assembly translates toward the gap formed by the seat back frame.

[0022] According to a third aspect of this disclosure, a vehicle seat assembly includes a seat back frame and a foam assembly connected to the seat back frame. The foam assembly includes an inner support pad portion formed by a first inner portion and a second inner portion, an outer support pad portion formed by a first outer portion and a second outer portion, an upper portion extending between the outer support pad portion and the inner support pad portion, and a torso portion partially surrounded by the outer support pad portion, the inner support pad portion, and the upper portion. The foam assembly is configured to elastically deform from a first configuration to a second configuration, wherein in the second configuration, the foam assembly is adapted to support an occupant of the vehicle seat assembly.

[0023] Embodiments of the third aspect of this disclosure may include any one or a combination of the following features:

[0024] - A first inner portion is configured to translate toward the seat back frame, and a second inner portion is configured to translate toward the outer support pad portion, wherein the first inner portion is configured to translate before the second inner portion when force is applied against the vehicle seat assembly; and

[0025] - The vehicle seat assembly also includes structural wiring embedded within the foam assembly, wherein the structural wiring extends through a section of the upper portion relative to the headrest opening on the rear side of the vehicle.

[0026] These and other features, advantages and objectives of this disclosure will be further understood and appreciated by those skilled in the art upon reference to the following specification, claims and drawings. Attached Figure Description

[0027] In the attached diagram:

[0028] Figure 1 This is a side perspective view of the seat assembly inside the passenger compartment of the vehicle.

[0029] Figure 2 This is a top-down perspective view of the seat back frame of the seat assembly.

[0030] Figure 3 This is a top-down perspective view of the front of the foam assembly of the seat assembly.

[0031] Figure 4 This is a top-down perspective view of the rear of the foam assembly of the seat assembly.

[0032] Figure 5 Is Figure 3 A cross-sectional view of the foam assembly taken at line V in the figure shows the inner recessed clearance groove.

[0033] Figure 6 This is a rear view elevation of the foam assembly.

[0034] Figure 7 Is Figure 6 The cross-sectional view of the foam assembly taken at line VII shows the upper beam clearance groove.

[0035] Figure 8 This is a rear view elevation of the foam assembly.

[0036] Figure 9 Is Figure 8 The cross-sectional view of the foam assembly taken at line IX shows the first front portion of the seat back relief groove.

[0037] Figure 10 This is a rear view elevation of the foam assembly.

[0038] Figure 11 Is Figure 10 The cross-sectional view of the foam assembly taken at line XI shows the second front portion of the seat back relief groove.

[0039] Figure 12 This is a rear view elevation of the foam assembly.

[0040] Figure 13 Is Figure 12 A cross-sectional view of the foam assembly taken at line XIII shows the waist clearance groove.

[0041] Figure 14 This is a rear view elevation of the foam assembly.

[0042] Figure 15 Is Figure 14 A cross-sectional view of the foam assembly taken at line XV shows the first chamfered recess formed by the first chamfered surface of the foam assembly.

[0043] Figure 16 This is a rear view elevation of the foam assembly.

[0044] Figure 17 Is Figure 16 A cross-sectional view of the foam assembly taken at line XVII shows the second chamfered recess formed by the second chamfered surface of the foam assembly.

[0045] Figure 18 This is a top-down perspective view of the foam assembly, showing the structural wires embedded within it. Detailed Implementation

[0046] Reference will now be made in detail to the preferred embodiments of this disclosure, examples of which are illustrated in the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. In the drawings, structural elements are depicted not to scale, and some parts are enlarged relative to others for emphasis and understanding purposes.

[0047] Detailed embodiments of this disclosure are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely examples of this disclosure and may be implemented in various and alternative forms. The accompanying drawings are not necessarily detailed designs; some schematic diagrams may be enlarged or minimized to show a functional overview. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but rather serve only as a representative basis for teaching those skilled in the art to employ this disclosure in different ways.

[0048] For descriptive purposes, the terms "up," "down," "right," "left," "back," "front," "vertical," "horizontal," and their derivatives should be used in this document. Figure 1 The concept of orientation is used. However, it should be understood that the concept may present various alternative orientations unless explicitly stated otherwise. It should also be understood that the specific apparatus and processes shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concept defined in the appended claims. Therefore, unless otherwise expressly stated in the claims, the specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered limiting.

[0049] The embodiments shown in this invention primarily relate to combinations of method steps and apparatus components related to vehicle seat assemblies, specifically, to foam assemblies of vehicle seat assemblies, wherein the foam assembly is modified to facilitate translation of the foam assembly to support a user of the vehicle seat assembly when force is applied against it. Therefore, apparatus components and method steps have been indicated by conventional symbols in the accompanying drawings where appropriate, showing only those specific details relevant to understanding embodiments of this disclosure, so as not to obscure the disclosure in ways obvious to those skilled in the art who benefit from the description herein. Furthermore, the same reference numerals denote the same elements in the specification and drawings.

[0050] As used herein, the term "and / or" when used with two or more listed items means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition is described as containing components A, B, and / or C, the composition may contain: A only; B only; C only; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0051] In this document, relational terms such as first and second, top and bottom are used individually to distinguish one entity or action from another, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprising,” “including,” or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article of manufacture, or apparatus that comprises a list of elements includes not only those elements but may also include other elements not expressly listed or inherent to such process, method, article of manufacture, or apparatus. Without further constraints, an element preceded by “comprising…” does not exclude the presence of additional identical elements in the process, method, article of manufacture, or apparatus that includes said element.

[0052] As used herein, the term "about" means that a quantity, dimension, formulation, parameter, and other quantity and characteristic is not precise, nor is it required to be precise, but may be approximate and / or larger or smaller as needed to reflect tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term "about" is used to describe an endpoint of a value or range, this disclosure should be understood to include the specific value or the mentioned endpoint. Whether or not the endpoints of numerical values ​​or ranges in this specification are referred to as "about," the endpoints are intended to include two embodiments: one modified by "about" and one not modified by "about." It should also be understood that each endpoint of a range is significant both in relation to and independent of another endpoint.

[0053] As used herein, the terms “substantially,” “basically,” and variations thereof are intended to indicate that the described feature is equal to or approximately equal to a value or description. For example, a “substantially planar” surface is intended to indicate a planar or approximately planar surface. Additionally, “substantially” is intended to mean that two values ​​are equal or approximately equal. In some embodiments, “substantially” may indicate that the values ​​are within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0054] Unless explicitly indicated otherwise, as used herein, the terms “the,” “an,” or “a” mean “at least one” and should not be limited to “only one.” Thus, for example, unless the context clearly indicates otherwise, references to “component” include embodiments having two or more such components.

[0055] refer to Figures 1 to 18Reference numeral 20 generally designates the vehicle seat assembly 20 of vehicle 22. The vehicle seat assembly 20 is configured to be coupled to the floor 24 of vehicle 22. The vehicle seat assembly 20 includes a support frame and a seat back frame 28 rotatably coupled to the support frame. Additionally, the vehicle seat assembly 20 may include a headrest coupled to the seat back frame 28. Both the support frame and the seat back frame 28 provide support for a user accommodation space 30 configured to support a user of vehicle 22. The user accommodation space 30 includes a foam assembly 32 coupled to the seat back frame 28. The foam assembly 32 can be configured to support the user when force is applied against the vehicle seat assembly 20. The foam assembly 32 can be configured to support the user according to the spatial relationship between the foam assembly 32 and the seat back frame 28. Additionally, the foam assembly 32 can be configured to support the user based on outer and inner flaps disposed within the foam assembly 32, and a first set of ribs 36 and a second set of ribs 37 inserted between the foam assembly 32 and the seat back frame 28. Furthermore, the ability of the foam assembly 32 to support the user can vary depending on the positioning of the structural wires 38 of the foam assembly 32 relative to the headrest openings 40 formed in the upper portion 68 of the foam assembly 32.

[0056] refer to Figure 1 The vehicle seat assembly 20 may be positioned within the vehicle 22. For example, the vehicle seat assembly 20 may be positioned within the passenger compartment of the vehicle 22. The vehicle 22 may be a motor vehicle. For example, the vehicle 22 may be a land-based vehicle (e.g., a car, motorcycle, train, etc.) or an air-based vehicle (e.g., an airplane or other aircraft). While the vehicle 22 may be a motor vehicle, this disclosure is not limited to an internal combustion engine as the power source for the operation of the vehicle 22. For example, the vehicle 22 may be powered by an electric motor, a fuel cell, and / or a petroleum-based fuel engine. According to various examples, semi-autonomous examples of the vehicle 22 may perform many or all commuter functions (e.g., braking, turning, signaling, etc.) independently of user interaction while the user maintains overriding control of the vehicle 22.

[0057] refer to Figure 2The seat back frame 28 is formed by an upper crossbeam 42, a lower crossbeam 44, a first arm 46, and a second arm 48. The upper crossbeam 42 and the lower crossbeam 44 are connected via the first arm 46, which extends vertically from a first end 50 of the upper crossbeam 42 to a first end 52 of the lower crossbeam 44. Additionally, the upper crossbeam 42 and the lower crossbeam 44 are connected via the second arm 48, which extends vertically from a second end 54 of the upper crossbeam 42 to a second end 56 of the lower crossbeam 44. Thus, the upper crossbeam 42, the lower crossbeam 44, the first arm 46, and the second arm 48 cooperate to define a gap 58 in the seat back frame 28. The seat back frame 28 provides an outer surface 60 and an inner surface 62, wherein the outer surface 60 of the seat back frame 28 abuts against and supports the foam assembly 32.

[0058] refer to Figure 3 The foam assembly 32 is formed by an outer support pad portion 64, an inner support pad portion 66, an upper portion 68, and a body portion 70. The outer support pad portion 64 and the inner support pad portion 66 are connected via the upper portion 68, which extends laterally between a first end 72 of the outer support pad portion 64 and a first end 74 of the inner support pad portion 66. Furthermore, the outer support pad portion 64, the inner support pad portion 66, and the upper portion 68 are interconnected via the body portion 70, which is attached to an inner periphery 76 defined by the outer support pad portion 64, the inner support pad portion 66, and the upper portion 68. Together, the outer support pad portion 64, the inner support pad portion 66, the upper portion 68, and the body portion 70 provide an outer surface 78 and an inner surface 80 referred to as the B side. Each of the aforementioned components of the foam assembly 32 may be a separate component joined together to form the foam assembly 32, or alternatively, some or all of the aforementioned components may be integrally formed such that the foam assembly 32 is a single monolithic body.

[0059] Continue to refer to Figure 3 Each component of the foam assembly 32 provides a degree of elasticity, allowing each component to deform under applied force and then return to its pre-deformation configuration when the applied force is removed. Therefore, the foam assembly 32 is elastically deformable.

[0060] Now for reference Figure 4The outer support pad portion 64, the inner support pad portion 66, the upper portion 68, and the torso portion 70 can define the B-side cavity 82. Specifically, the B-side cavity 82 can be defined by the inner surfaces 80 of the outer support pad portion 64, the inner support pad portion 66, and the torso portion 70. The foam assembly 32 is connected to the seat back frame 28 such that the inner surface 80 of the foam assembly 32 abuts against and is adjacent to the outer surface 60 of the seat back frame 28. Specifically, the seat back frame 28 can be disposed within the B-side cavity 82. Therefore, the upper crossbeam 42 of the seat back frame 28 can be disposed within the portion of the B-side cavity 82 formed by the upper portion 68 of the foam assembly 32. Furthermore, the first arm 46 of the seat back frame 28 can be disposed within the portion of the B-side cavity 82 formed by the outer support pad portion 64, and the second arm 48 can be disposed within the portion of the B-side cavity 82 formed by the inner support pad portion 66. Therefore, the entire seat back frame 28 can be set within the cavity 82 on side B and surrounded by the foam assembly 32.

[0061] Now for reference Figures 4 to 18 The foam assembly 32 can be configured to translate relative to the seat back frame 28 to allow the foam assembly 32 to support the user when an applied force is applied against it. Specifically, the foam assembly 32 may form a plurality of clearance slots located within and / or adjacent to the seat back frame 28, which allow the foam assembly 32 to translate relative to the seat back frame 28, thus supporting the user. Furthermore, a plurality of structural components may be disposed within and / or inserted between the foam assembly 32 and the seat back frame 28 to further allow the foam assembly 32 to support the user when an applied force is applied. Additionally, structural wires 38 inserted within the foam assembly 32 may be positioned relative to a plurality of headrest openings 40 formed by the upper portion 68, allowing the foam assembly 32 to support the user when an applied force is applied.

[0062] Now for reference Figure 4 and Figure 5The inner support pad portion 66 can form an inner recess avoidance groove 84. As shown in the illustrated embodiment, the inner support pad portion 66 is formed by a first inner portion 158, a second inner portion 160, a rear portion 88, and a lateral portion 90, which together cooperate to define the inner recess avoidance groove 84. The first inner portion 158 extends from the torso portion 70, and the second inner portion 160 extends from the first inner portion 158, such that the first inner portion 158 is inserted between the torso portion 70 and the second inner portion 160. The lateral portion 90 connects to the second inner portion 160 and the rear portion 88 and extends laterally between them. The first inner portion 158, the second inner portion 160, the rear portion 88, and the lateral portion 90 together cooperate to define the inner recess avoidance groove 84, thereby providing a hollow interior to the inner support pad 66. In addition, the inner recess avoidance groove 84 can have a substantially elliptical shape, such as... Figure 5 As shown in the example, in this configuration, the long axis of the inner recess avoidance groove 84 can extend substantially vertically toward the upper portion 68 and substantially toward the floor 24 of the vehicle 22. The short axis of the inner recess avoidance groove 84 can extend substantially toward the lateral portion 90 and substantially toward the torso portion 70.

[0063] Still referencing Figure 4 and Figure 5 The first inner portion 158, the second inner portion 160, the rear portion 88, and the lateral portion 90 may each be a component connected together to form the inner support pad portion 66 and define the inner recess relief groove 84. Alternatively, two or more of the above components may be integrally formed, such that the inner support pad portion 66 is a single integral body, or formed by components integrally formed and defining a single integral body.

[0064] Now for reference Figures 6 to 7 The foam assembly 32 can define an upper crossbeam clearance groove 98. The upper crossbeam clearance groove 98 can be formed by the foam assembly 32 at a portion of the foam assembly 32 adjacent to the upper crossbeam 42. Therefore, the upper crossbeam clearance groove 98 is positioned adjacent to the outer surface 60 of the upper crossbeam 42 of the seat back frame 28. The upper crossbeam clearance groove 98 can be formed by the upper portion 68 of the foam assembly 32, specifically via the inner surface 80 of the upper portion 68 of the foam assembly 32. Furthermore, the upper crossbeam clearance groove 98 can be defined between the inner surface 80 of the upper portion 68 of the foam assembly 32 and the outer surface 60 of the upper crossbeam 42 of the seat back frame 28. Therefore, the upper crossbeam clearance groove 98 provides a gap between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the upper crossbeam 42.

[0065] Continue to refer to Figures 6 to 7 The upper crossbeam 42 can be formed by the top panel 100 and the bottom panel 102, such as Figures 6 to 7 As shown in the example, the bottom panel 102 can be positioned below the top panel 100, and the bottom panel 102 can be formed relative to the top panel 100 on the rear proximal side of the vehicle 22. Therefore, the bottom panel 102 can be closer to the floor 24 and the rear of the vehicle 22 than the top panel 100. An upper crossbeam clearance groove 98 can specifically be formed between the inner surface 80 of the upper portion 68 of the foam assembly 32 and the outer surface 60 of the bottom panel 102. Therefore, the upper crossbeam clearance groove 98 can have a substantially rectangular shape that is substantially proportional to the dimensions of the bottom panel 102.

[0066] refer to Figure 7 The inner surface 80 of the upper portion 68, which partially defines the upper crossbeam clearance groove 98, can form a first surface 104, a cantilever 106, and a second surface 108. The first surface 104 can extend at an angle relative to the bottom panel 102 and define a substantially flat surface. Similarly, the second surface 108 can extend at an angle relative to the bottom panel 102 and define a substantially flat surface. The second surface 108 can be positioned below the first surface 104. Alternatively, the second surface 108 can be offset from the first surface 104 such that the first surface 104 is positioned near the bottom panel 102 relative to the second surface 108. Therefore, the first surface 104 is positioned above the second surface 108 and is positioned closer to the bottom panel 102 than the second surface 108. The cantilever 106 extends substantially perpendicularly relative to the first surface 104 and the second surface 108 and connects the first surface 104 and the second surface 108.

[0067] Now for reference Figure 8 and Figure 9 The foam assembly 32 can define a first front portion of the seat backrest clearance groove 112. The first front portion of the seat backrest clearance groove 112 can be formed by the foam assembly 32 adjacent to the outer surface 60 of the first arm 46 of the seat backrest frame 28. Therefore, the first front portion of the seat backrest clearance groove 112 is positioned adjacent to the outer surface 60 of the first arm 46 of the seat backrest frame 28. The first front portion of the seat backrest clearance groove 112 can be formed by the torso portion 70, specifically, via the portion of the inner surface 80 of the torso portion 70 adjacent to the outer surface 60 of the first arm 46. Additionally, the first front portion of the seat backrest clearance groove 112 can be formed by the outer support pad portion 64, specifically, via the portion of the inner surface 80 of the outer support pad portion 64 adjacent to the outer surface 60 of the first arm 46. Furthermore, the first front portion of the seat back relief groove 112 can be formed by both the torso portion 70 and the outer support pad portion 64, specifically, via the inner surface 80 of the torso portion 70 and the outer support pad portion 64.

[0068] Still referencing Figure 8 and Figure 9The first front portion of the seat backrest clearance groove 112 may provide a gap between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the first arm 46 of the seat backrest. The gap may define a distance, for example, from about 8 mm to about 12 mm, extending between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the first arm 46. The first front portion of the seat backrest clearance groove 112 may extend substantially the length of the inner surface 80 of the foam assembly 32 adjacent to the outer surface 60 of the first arm 46. Alternatively, the first front portion of the seat backrest clearance groove 112 may extend only a portion of the length of the inner surface 80 of the foam assembly 32 adjacent to the outer surface 60 of the first arm 46. Thus, according to this example, at least a portion of the inner surface 80 of the foam assembly 32 is spaced from the outer surface 60 of the first arm 46 by about 8 mm to about 12 mm.

[0069] Still referencing Figure 8 and Figure 9 The first set of ribs 36 can be inserted between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the first arm 46. Specifically, the first set of ribs 36 can be positioned within the first front portion of the seat back relief groove 112. The first set of ribs 36 may include multiple ribs. Alternatively, the first set of ribs 36 may include a single rib. Each rib in the first set of ribs 36 can serve as a structural support, thereby providing support for the foam assembly 32 against the first arm 46 of the seat back frame 28. Furthermore, each rib may be formed by a base 116, a first leg 118, and a second leg 120. The base 116 of each rib forms a substantially flat rib surface 122 that extends laterally and longitudinally across the outer surface 60 of the first arm 46 and forms a substantially rectangular shape. Thus, the long axis of each rib extends substantially toward the outer support pad portion 64 and substantially toward the inner support pad portion 66, and the long axis of each rib extends substantially toward the upper crossbeam 42 and substantially toward the lower crossbeam 44. The first leg 118 may extend vertically toward the inner surface 80 of the foam assembly 32, substantially perpendicular to the rib surface 122. The first leg 118 may be positioned adjacent to a first edge 124 of the rib surface 122 and extend substantially along the entire first edge. The second leg 120 may be positioned adjacent to a second edge 126 of the rib surface 122 and extend substantially along the entire second edge, wherein the second edge 126 is disposed opposite to the first edge 124. Furthermore, the first edge 124 may be disposed above the second edge 126, such that the first edge 124 is closer to the upper portion 68 of the foam assembly 32 than the second edge 126. Additionally, the first edge 124 and the second edge 126 may extend substantially parallel to the long axis of each rib.

[0070] Continue to refer to Figure 8 and Figure 9In one example, the first leg 118 and the second leg 120 of each rib may be defined with a distance of about 12 mm to about 18 mm between them. In addition, when the first group of ribs 36 includes more than one rib, each rib may be longitudinally spaced, wherein the distance between each rib in the first group of ribs 36 may be about 20 mm to about 30 mm.

[0071] Now for reference Figure 10 and Figure 11 The foam assembly 32 can define a second front portion of the seat backrest clearance groove 128. The second front portion of the seat backrest clearance groove 128 can be formed by the foam assembly 32 adjacent to the outer surface 60 of the second arm 48 of the seat backrest frame 28. Therefore, the second front portion of the seat backrest clearance groove 128 is positioned adjacent to the outer surface 60 of the second arm 48 of the seat backrest frame 28. The second front portion of the seat backrest clearance groove 128 can be formed by the torso portion 70, specifically, via the portion of the torso portion 70 adjacent to the outer surface 60 of the second arm 48. Additionally, the second front portion of the seat backrest clearance groove 128 can be formed by the inner support pad portion 66, specifically, via the portion of the inner surface 80 of the inner support pad portion 66 adjacent to the outer surface 60 of the second arm 48. Furthermore, the second front portion of the seat back relief groove 128 can be formed by both the torso portion 70 and the inner support pad portion 66, specifically, via the inner surfaces 80 of both the torso portion 70 and the inner support pad portion 66.

[0072] Continue to refer to Figure 10 and Figure 11 The second front portion of the seat backrest clearance groove 128 may provide a gap between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the second arm 48 of the seat backrest frame 28. This gap may define a distance, for example, from about 8 mm to about 12 mm, extending between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the second arm 48. The second front portion of the seat backrest clearance groove 128 may extend substantially the length of the inner surface 80 of the foam assembly 32 adjacent to the outer surface 60 of the second arm 48. Alternatively, the second front portion of the seat backrest clearance groove 128 may extend only a portion of the length of the inner surface 80 of the foam assembly 32 adjacent to the outer surface 60 of the second arm 48. Thus, in this example, at least a portion of the inner surface 80 of the foam assembly 32 is spaced from the outer surface 60 of the second arm 48 by about 8 mm to about 12 mm.

[0073] Still referencing Figure 10 and Figure 11The second set of ribs 37 can be inserted between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the second arm 48. Specifically, the second set of ribs 37 can be positioned within the second front portion of the seat back relief groove 128. The second set of ribs 37 may include multiple ribs. Alternatively, the second set of ribs 37 may include a single rib. Each rib in the second set of ribs 37 can serve as a structural support, thereby providing support for the foam assembly 32 against the second arm 48 of the seat back frame 28. Furthermore, each rib may be formed by a base 132, a first leg 134, and a second leg 136. The base 132 of each rib forms a substantially flat rib surface 138 that extends laterally and longitudinally across the outer surface 60 of the second arm 48 and forms a substantially rectangular shape. Thus, the long axis of each rib extends substantially toward the outer support pad portion 64 and substantially toward the inner support pad portion 66, and the long axis of each rib extends substantially toward the upper crossbeam 42 and substantially toward the lower crossbeam 44. The first leg 134 may extend vertically toward the inner surface 80 of the foam assembly 32, substantially perpendicular to the rib surface 138. The first leg 134 may be positioned adjacent to a first edge 140 of the rib surface 138 and extend substantially along the entire first edge. The second leg 136 may be positioned adjacent to a second edge 142 of the rib surface 138 and extend substantially along the entire second edge, wherein the second edge 142 is disposed opposite to the first edge 140. Furthermore, the first edge 140 may be disposed above the second edge 142, such that the first edge 140 is closer to the upper portion 68 of the foam assembly 32 than the second edge 142. Additionally, the first edge 140 and the second edge 142 may extend substantially parallel to the long axis of each rib.

[0074] Continue to refer to Figure 10 and Figure 11 For example, the first leg 134 and the second leg 136 of each rib in the second group of ribs 37 may be defined with a distance of about 12 mm to about 18 mm therebetween. In addition, when the second group of ribs 37 includes more than one rib, each rib may be longitudinally spaced apart, wherein the distance between each rib in the second group of ribs 37 may be about 20 mm to about 30 mm.

[0075] Now for reference Figure 12 and Figure 13The foam assembly 32 may define a waist clearance groove 144. The waist clearance groove 144 may be formed by the outer surface 60 of the foam assembly 32 adjacent to the lower crossbeam 44. Therefore, the waist clearance groove 144 is positioned adjacent to the outer surface 60 of the lower crossbeam 44. The waist clearance groove 144 may be formed by the torso portion 70, specifically via a portion of the inner surface 80 of the torso portion 70 adjacent to the outer surface 60 of the lower crossbeam 44. The waist clearance groove 144 may provide a gap between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the lower crossbeam 44. The gap may define a distance of approximately 12 mm to approximately 18 mm extending between the inner surface 80 of the foam assembly 32 and the outer surface 60 of the lower crossbeam 44.

[0076] Now for reference Figure 14 and Figure 15 The outer support pad portion 64 can be formed by a first outer portion 146 and a second outer portion 148. The first outer portion 146 can be adjacent to and extend from the body portion 70 of the foam assembly 32. The second outer portion 148 can be adjacent to and extend from the first outer portion 146. Thus, the first outer portion 146 can be inserted between the body portion 70 and the second outer portion 148. The first outer portion 146 and the second outer portion 148 can be separate components joined together to form the outer portion. Alternatively, the first outer portion 146 and the second outer portion 148 can be integrally formed, such that the outer support pad portion 64 is formed from a single integral body.

[0077] Continue to refer to Figure 14 and Figure 15The first outer portion 146 may have a first rigidity, and the second outer portion 148 may have a second rigidity. The second rigidity provided by the second outer portion 148 may be greater than the first rigidity provided by the first outer portion 146. Therefore, the first outer portion 146 provides less resistance to the force applied against the outer support pad portion 64 relative to the second outer portion 148. Moreover, the first outer portion 146 is configured to elastically deform relative to the second outer portion 148 in time as the force is incrementally applied against the outer support pad portion 64. Therefore, when a force is applied against the outer support pad portion 64, the outer support pad portion 64 deforms at the first outer portion 146 and then at the second outer portion 148. In addition, the outer support pad portion 64 may deform about an outer deformation axis extending longitudinally between the first outer portion 146 and the second outer portion 148, thereby causing the second outer portion 148 to translate laterally substantially toward the centerline of the foam assembly 32 when the outer support pad portion 64 deforms or bends at said outer deformation axis. Therefore, when force is applied against the outer support pad portion 64, the outer support pad portion 64 deforms at the outer deformation axis, and the second outer portion 148 moves toward the user to achieve support for the user through the foam assembly 32.

[0078] Still referencing Figure 14 and Figure 15 An outer fracture portion 150 may be formed between the first outer portion 146 and the second outer portion 148 of the outer support pad portion 64. The outer fracture portion 150 may extend from the outer surface 78 of the outer support pad portion 64 into the interior of the outer support pad portion 64, thereby forming a gap that substantially extends the entire height of the outer support pad portion 64. Furthermore, the outer fracture portion 150 may extend substantially perpendicular to the outer surface 78 of the outer support pad portion 64. The outer fracture portion 150 may additionally form a substantially triangular cross-section. The outer fracture portion 150 may be configured to facilitate translation of the second outer portion 148 toward the user, generally facilitating the foam assembly 32 to support the user under applied force. Therefore, the outer fracture portion 150 may be aligned with the outer deformation axis, such that the outer support pad portion 64 may deform around the outer fracture portion 150 under applied force.

[0079] Continue to refer to Figure 14 and Figure 15The outer flap can be inserted between the first outer portion 146 and the second outer portion 148 of the outer support pad portion 64. The outer flap can form a substantially flat body and extend from the outer surface 78 of the outer support pad portion 64 into the interior of the outer support pad portion 64. Furthermore, the outer flap can extend longitudinally for at least a portion of the height of the outer support pad portion 64. Additionally, the outer flap can be disposed within the outer fracture portion 150. The outer flap serves to further separate the first outer portion 146 and the second outer portion 148, thereby promoting deformation of the first outer portion 146 and the resulting translation of the second outer portion 148 toward the user when force is applied to the foam assembly 32.

[0080] Continue to refer to Figure 14 and Figure 15 The inner surface 80 of the first outer portion 146 may form a first chamfered surface 154. Alternatively, the first chamfered surface 154 may be formed together by the inner surface 80 of the torso portion 70 and the inner surface 80 of the first outer portion 146. When the first chamfered surface 154 is partially formed by the torso portion 70, the first chamfered surface 154 may extend substantially the entire height of the first outer portion 146, or alternatively, substantially the entire height of the torso portion 70. Furthermore, the first chamfered surface 154 may be positioned adjacent to and spaced apart from the first arm 46 of the seat back frame 28. Thus, a first chamfered recess 156 may be defined between the first chamfered surface 154 and the outer surface 60 of the first arm 46. The first chamfered surface 154 is configured to facilitate translation of the first outer portion 146 across the first chamfered recess 156 toward the outer surface 60 of the first arm 46 when the outer support pad portion 64 deforms. Therefore, the first chamfered surface 154 facilitates the translation of the second outer portion 148 toward the user under the applied force.

[0081] Now for reference Figure 16 and Figure 17 The outer support pad portion 66 may be formed by a first outer portion 158 and a second inner portion 160. The first inner portion 158 may be adjacent to and extend from the body portion 70 of the foam assembly 32. The second inner portion 160 may be adjacent to and extend from the first inner portion 158. Thus, the first inner portion 158 may be inserted between the body portion 70 and the second inner portion 160. The first inner portion 158 and the second inner portion 160 may be separate components joined together to form the inner support pad portion 66. Alternatively, the first inner portion 158 and the second inner portion 160 may be integrally formed, such that the inner support pad portion 66 is formed from a single integral body.

[0082] Continue to refer to Figure 16 and Figure 17The first inner portion 158 may have a first rigidity, and the second inner portion 160 may have a second rigidity. The second rigidity provided by the second inner portion 160 may be greater than the first rigidity provided by the first inner portion 158. Therefore, the first inner portion 158 provides less resistance to the force applied against the inner support pad portion 66 relative to the second inner portion 160. Moreover, the first inner portion 158 is configured to elastically deform in time relative to the second inner portion 160 when the force is applied incrementally against the inner support pad portion 66. Therefore, when a force is applied against the inner support pad portion 66, the inner support pad portion 66 deforms at the first inner portion 158 and then at the second inner portion 160. Additionally, the inner support pad portion 66 can deform about an inner deformation axis extending longitudinally between the first inner portion 158 and the second inner portion 160, thereby causing the second inner portion 160 to translate laterally substantially toward the centerline of the foam assembly 32 when the inner support pad portion 66 deforms or bends at the inner deformation axis. Therefore, when a force is applied against the inner support pad portion 66, the inner support pad portion 66 deforms at the inner deformation axis, and the second inner portion 160 moves toward the user to provide support for the user via the foam assembly 32.

[0083] Still referencing Figure 16 and Figure 17 An inner fracture portion 162 may be formed between the first inner portion 158 and the second inner portion 160. The inner fracture portion 162 may extend from the outer surface 78 of the inner support pad portion 66 into the interior of the inner support pad portion 66, thereby forming a gap that substantially extends the entire height of the inner support pad portion 66. Furthermore, the inner fracture portion 162 may extend substantially perpendicular to the outer surface 78 of the inner support pad portion 66. The inner fracture portion 162 may additionally form a substantially triangular cross-section. The inner fracture portion 162 may be configured to facilitate translation of the second inner portion 160 toward the user, generally facilitating the foam assembly 32 to support the user under applied force. Therefore, the inner fracture portion 162 may be aligned with the inner deformation axis, such that the inner support pad portion 66 may deform around the inner fracture portion 162 under applied force.

[0084] Still referencing Figure 16 and Figure 17The inner flap can be inserted between the first inner portion 158 and the second inner portion 160. The inner flap can form a substantially flat body and extend from the outer surface 78 of the inner support pad portion 66 into the interior of the inner support pad portion 66. Furthermore, the inner flap can extend longitudinally for at least a portion of the height of the inner support pad portion 66. Additionally, the inner flap can be disposed within the inner fracture portion 162. The inner flap serves to further separate the first inner portion 158 and the second inner portion 160, thereby facilitating the translation of the second inner portion 160 toward the user when force is applied to the foam assembly 32.

[0085] Continue to refer to Figure 16 and Figure 17 The inner surface 80 of the first inner portion 158 may form a second chamfered surface 166. Alternatively, the second chamfered surface 166 may be formed together by the inner surface 80 of the torso portion 70 and the inner surface 80 of the first inner portion 158. When the second chamfered surface 166 is partially formed by the torso portion 70, the second chamfered surface 166 may extend substantially the entire height of the first inner portion 158, or alternatively, substantially the entire height of the torso portion 70. Furthermore, the second chamfered surface 166 may be positioned adjacent to and spaced apart from the second arm 48 of the seat back frame 28. Thus, the second chamfered recess 168 may be defined between the second chamfered surface 166 and the outer surface 60 of the second arm 48. The second chamfered surface 166 is configured to facilitate translation of the first inner portion 158 toward the outer surface 60 of the second arm 48 when the inner support pad portion 66 deforms. Thus, the second chamfered surface 166 facilitates translation of the second inner portion 160 toward the user under applied force.

[0086] Now for reference Figure 18 The structural wire 38 can be embedded within the interior of the foam assembly 32. The structural wire 38 can extend throughout the entire interior of the foam assembly 32 and substantially conform to the shape formed by the foam assembly 32. Specifically, the structural wire 38 can extend through a section of the upper portion 68 near the rear of the vehicle 22 relative to each of the plurality of headrest openings 40 formed by the outer surface 78 of the upper portion 68. Therefore, the headrest of the vehicle seat assembly 20, installed to the upper portion 68 via the plurality of headrest openings 40, will be positioned closer to the user of the seat assembly than the structural wire 38.

[0087] In operation, each of the features of the foam assembly 32 described in detail above mates to facilitate translation of the foam assembly 32 from a first configuration to a second configuration. In the first configuration, the foam assembly 32 is undeformed and positioned to receive the user. In the second configuration, the foam assembly 32 deforms such that it substantially supports the user. Specifically, under applied force, both the outer support pad portion 64 and the inner support pad portion 66 deform about their respective deformation axes, causing the second outer portion 148 and the second inner portion 160 to translate toward the user. As the inner support pad portion 66 and the outer support pad portion 64 deform, the first inner portion 158 and the first outer portion 146 translate toward the seat back frame 28, and the second outer portion 148 and the second inner portion 160 thus translate toward the user. Therefore, each of the support pad portions 64, 66 curls inward substantially toward the centerline of the foam assembly and, under applied force, curls approximately toward the user. Furthermore, when the support pad portion curls toward the user, the torso portion 70 translates toward the gap 58 formed by the seat back frame 28. As a result, both sets of ribs 36 and 37 are flattened, and when the torso portion 70 translates toward the gap 58 formed by the seat back frame 28, the inner surface 80 of the foam assembly 32 traverses each of the aforementioned clearance grooves.

[0088] It should be understood that changes and modifications may be made to the foregoing structures without departing from the concept of this disclosure, and it should also be understood that such concepts are intended to be covered by the appended claims unless otherwise expressly stated in their language.

[0089] According to the present invention, a vehicle seat assembly is provided, the vehicle seat assembly having: a seat back frame; and a foam assembly connected to the seat back frame, the foam assembly including: an outer support pad portion; an inner support pad portion, the inner support pad portion including a first inner portion and a second inner portion, wherein the first inner portion has a first rigidity and the second inner portion has a second rigidity, wherein the second rigidity is greater than the first rigidity; an upper portion extending between the outer support pad portion and the inner support pad portion; and a torso portion.

[0090] According to an embodiment, the inner support pad portion forms an inner fracture portion inserted between the first inner portion and the second inner portion.

[0091] According to an embodiment, the invention is further characterized by an inner wing, wherein the inner wing is inserted between a first inner portion and a second inner portion.

[0092] According to an embodiment, the inner surface of the first inner portion forms a first chamfered surface.

[0093] According to an embodiment, the invention is further characterized by a plurality of ribs inserted between the foam assembly and the seat back frame.

[0094] According to an embodiment, the first group of ribs among the plurality of ribs is disposed in the first front part of the seat back frame clearance groove formed between the inner side of the torso portion and the first arm of the seat back frame.

[0095] According to an embodiment, the upper crossbeam clearance groove is formed between the inner side of the upper portion and the seat back frame.

[0096] According to an embodiment, the inner support pad portion further includes a lateral portion and a rear portion, wherein the lateral portion extends laterally from the second inner portion and connects to the rear portion.

[0097] According to an embodiment, the rear portion, the lateral portion, the first inner portion, and the second inner portion cooperate to define an inner recess clearance groove.

[0098] According to an embodiment, the invention is further characterized by structural wires embedded within the foam assembly, wherein the structural wires extend through a section of the upper portion relative to the headrest opening formed by the upper portion on the rear proximal side of the vehicle.

[0099] According to an embodiment, a lumbar relief groove is formed between the inner surface of the torso portion and the lower crossbeam of the seat back frame.

[0100] According to an embodiment, the seat back frame is substantially confined within the foam assembly.

[0101] According to the present invention, a vehicle seat assembly is provided, the vehicle seat assembly having: a seat back frame; and a foam assembly connected to the seat back frame, the foam assembly including: an outer support pad portion; an inner support pad portion; an upper portion extending between the outer support pad portion and the inner support pad portion; and a torso portion partially surrounded by the outer support pad portion, the inner support pad portion and the upper support pad portion, wherein the foam assembly is configured to elastically deform under an applied force, wherein: the outer support pad portion translates toward the inner support pad portion; the inner support pad portion translates toward the outer support pad portion; and the torso portion translates toward the gap formed by the seat back frame.

[0102] According to an embodiment, the invention is further characterized by a plurality of ribs inserted between the foam assembly and the seat back frame, wherein the plurality of ribs are configured to collapse when the torso portion translates toward the gap formed by the seat back frame under an applied force.

[0103] According to an embodiment, the inner support pad portion forms a first inner portion and a second inner portion, wherein the first inner portion is configured to translate toward the seat back frame, and the second inner portion is configured to translate toward the outer support pad portion, wherein the first inner portion is configured to translate before the second inner portion when force is applied against the vehicle seat assembly.

[0104] According to an embodiment, the foam assembly is configured to elastically deform from a first configuration to a second configuration, wherein in the second configuration, the foam assembly is adapted to support the occupants of the vehicle seat assembly.

[0105] According to an embodiment, the vehicle seat assembly is configured to deform under an applied force so that the occupant of the vehicle seat assembly translates toward the gap formed by the seat back frame.

[0106] According to the present invention, a vehicle seat assembly is provided having a seat back frame; and a foam assembly connected to the seat back frame, the foam assembly including: an inner support pad portion formed by a first inner portion and a second inner portion; an outer support pad portion formed by a first outer portion and a second outer portion; an upper portion extending between the outer support pad portion and the inner support pad portion; and a torso portion partially surrounded by the outer support pad portion, the inner support pad portion and the upper portion, wherein the foam assembly is configured to elastically deform from a first configuration to a second configuration, wherein in the second configuration, the foam assembly is adapted to support an occupant of the vehicle seat assembly.

[0107] According to an embodiment, the first inner portion is configured to translate toward the seat back frame, and the second inner portion is configured to translate toward the outer support pad portion, wherein the first inner portion is configured to translate before the second outer portion when force is applied against the vehicle seat assembly.

[0108] According to an embodiment, the invention is further characterized by structural wires embedded within the foam assembly, wherein the structural wires extend through a section of the upper portion relative to the headrest opening formed by the upper portion on the rear proximal side of the vehicle.

Claims

1. A vehicle seat assembly comprising: Seat back frame; as well as A foam assembly, connected to the seat back frame, the foam assembly comprising: Outer support pad portion; The inner support pad portion includes a first inner portion and a second inner portion, wherein the first inner portion has a first robustness and the second inner portion has a second robustness, wherein the second robustness is greater than the first robustness. The upper portion extends between the outer support pad portion and the inner support pad portion; and The torso.

2. The vehicle seat assembly of claim 1, wherein the inner support pad portion forms an inner fracture portion inserted between the first inner portion and the second inner portion.

3. The vehicle seat assembly of claim 1, further comprising an inner flap, wherein the inner flap is inserted between the first inner portion and the second inner portion.

4. The vehicle seat assembly of claim 1, wherein the inner surface of the first inner portion forms a first chamfered surface.

5. The vehicle seat assembly of claim 1, further comprising a plurality of ribs inserted between the foam assembly and the seat back frame.

6. The vehicle seat assembly of claim 5, wherein a first group of ribs of the plurality of ribs is disposed within a first front portion of a seat back frame clearance groove formed between the inner side of the torso portion and a first arm of the seat back frame.

7. The vehicle seat assembly of claim 1, wherein the upper crossbeam clearance groove is formed between the inner side of the upper portion and the seat back frame.

8. The vehicle seat assembly of claim 1, wherein the inner support pad portion further includes a lateral portion and a rear portion, wherein the lateral portion extends laterally from the second inner portion and is connected to the rear portion.

9. The vehicle seat assembly of claim 8, wherein the rear portion, the lateral portion, the first inner portion, and the second inner portion cooperate to define an inner recess clearance groove.

10. The vehicle seat assembly of claim 1, further comprising structural wiring embedded within the foam assembly, wherein the structural wiring extends through a portion of the upper portion relative to a headrest opening formed by the upper portion on the rear proximal side of the vehicle.

11. The vehicle seat assembly of claim 1, wherein a lumbar relief groove is formed between the inner surface of the torso portion and the lower crossbeam of the seat back frame.

12. The vehicle seat assembly as claimed in any one of claims 1 to 11, wherein the seat back frame is substantially confined within the foam assembly.

13. A vehicle seat assembly comprising: Seat back frame; as well as A foam assembly, connected to the seat back frame, the foam assembly comprising: Outer support pad portion; Inner support pad section; The upper portion extends between the outer support pad portion and the inner support pad portion; and The torso portion, which is partially surrounded by the outer support pad portion, the inner support pad portion, and the upper support pad portion, wherein the foam assembly is configured to elastically deform under applied force, wherein: The outer support pad portion is translated toward the inner support pad portion; The inner support pad portion is translated toward the outer support pad portion; and The torso portion translates toward the gap formed by the seat back frame.

14. The vehicle seat assembly of claim 13, further comprising a plurality of ribs inserted between the foam assembly and the seat back frame, wherein the plurality of ribs are configured to collapse when the torso portion translates toward the gap formed by the seat back frame under an applied force.

15. The vehicle seat assembly of claim 13 or claim 14, wherein the inner support pad portion forms a first inner portion and a second inner portion, wherein the first inner portion is configured to translate toward the seat back frame, and the second inner portion is configured to translate toward the outer support pad portion, wherein the first inner portion is configured to translate before the second inner portion when a force is applied against the vehicle seat assembly.

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