Vehicle seating arrangement

Abstract

Vehicle seating arrangement (10, 108, 210, 310), comprising: a backrest (12, 212, 312) with a polymer body section (14) defining a support frame (16, 216, 316) with a plurality of forward-extending connecting pins (18) arranged around a circumference of a front face of the support frame (16, 216, 316); a flexible comfort support (22) arranged over a front of the polymer body section (14) and having a plurality of openings (24) defining a support matrix (26) that bears the weight of a passenger, wherein the flexible comfort support (22) also has a plurality of slots (28) designed to receive and engage with the plurality of forward-extending connecting pins (18); a cushioning layer (30) extending over the flexible comfort support (22); and a headrest (32) extending upwards from the front support frame (16, 216, 316).

Description

[0001] The present invention relates generally to a vehicle seat assembly and, more particularly, to a seat cushion shell assembly for a vehicle seat assembly.

[0002] Vehicle seat arrangements are generally known, for example, from US 7 891 740 B2, US 8 590 978 B2, DE 10 2011 055 286 A1 and US 7 290 836 B2.

[0003] The overall construction of the vehicle seat assembly according to the invention is lightweight and thin, yet rigid to support a passenger during regular use and in the event of an impact. The lightweight material also provides a flexible, resilient layer for the vehicle seat assembly to increase overall passenger comfort.

[0004] One aspect of the present invention includes a vehicle seat assembly having a backrest with a polymeric body portion defining a support frame with a plurality of forwardly extending connecting pins disposed about a perimeter of a front surface of the support frame. A flexible comfort support is disposed over a front surface of the polymeric body portion and has a plurality of openings defining a support matrix that supports the weight of a passenger. The flexible comfort support also has a plurality of slots adapted to receive and engage the plurality of forwardly extending connecting pins. A cushion layer extends over the flexible comfort support. A headrest extends upwardly from the front support frame.

[0005] Another aspect of the present invention includes a vehicle seat assembly having a backrest with a polymeric body portion having cup holders and a storage compartment on a rear side thereof and defining a support frame with substantially linearly vertically extending side portions and a plurality of forwardly extending connecting pins disposed about a perimeter of a front side of the support frame. A flexible comfort support is disposed over a front side of the polymeric body portion and has a plurality of openings defining a support matrix that supports the weight of a passenger. The flexible comfort support also has a plurality of slots configured to receive and engage the plurality of forwardly extending connecting pins.

[0006] Another aspect of the present invention includes a vehicle seat assembly having a backrest with a polymer body portion defining a front support frame with a plurality of forwardly extending connecting pins. A flexible comfort support is disposed over a front surface of the polymer body portion and has a plurality of openings defining a support matrix. The flexible comfort support has a plurality of keyhole slots configured to receive the plurality of forwardly extending connecting pins.

[0007] These and other aspects, objects and features of the present invention will become apparent and understandable to those skilled in the art upon reading the following specification, claims and appended drawings.

[0008] The drawings show: Fig. 1 is a perspective top view of a vehicle having an embodiment of a vehicle seat assembly according to the invention; Fig. 2 is a perspective top view of an embodiment of a part of a plurality of backrests according to the invention; Fig. 3A is a perspective bottom view of an embodiment of a vehicle backrest according to the invention; Fig. 3B is an enlarged bottom perspective view of a connecting pin engaging an engagement slot; Fig. 3C is an enlarged side cross-sectional view taken along line 3C-3C Fig. 3B; Fig. 4 is a perspective side view of an embodiment of a backrest for a vehicle with a static headrest; Fig. 5 is a perspective bottom view of an embodiment of a backrest for a vehicle with a movable headrest; Fig. 6 is a perspective top view of an embodiment of a backrest for a vehicle having a comfort support and a cushioning material extending over the vehicle backrest; Fig. 7 is a perspective side view of an embodiment of a flexible comfort support according to the invention; Fig. 8 is a perspective side view of an embodiment of a cushioning layer according to the invention; Fig. 9 is a perspective bottom view of an embodiment of a movable headrest; Fig. 10 is a perspective cross-sectional view from below of a movable headrest installed in a support frame and in a position of use; Fig. 11 is a side perspective view of a vehicle seat assembly according to the present invention with the headrest moved forward to a stowed position; Fig. 12 is a top perspective view of another embodiment of a vehicle seat assembly with a fixed headrest; Fig. 13 is a top perspective view of a fixed headrest for use with a vehicle seat assembly according to the invention; Fig. 14 is a top perspective view of one embodiment of a vehicle seat assembly with a cup holder assembly; Fig. 15 a front elevation of the vehicle seating arrangement from Fig. 14; Fig. 16 a front elevation of the vehicle seating arrangement of Fig. 14, with the cup holder assembly removed; Fig. 17 a front elevation of the vehicle seating arrangement from Fig. 14, with the cup holder assembly and flexible comfort support removed; Fig. 18 is a perspective side view of a cup holder assembly according to the invention; Fig. 19 is an enlarged perspective side view of the cup holder assembly of Fig. 18 with a locking device attached thereto; Fig. 20 is a perspective top view of another embodiment of a vehicle seat assembly according to the invention; Fig. 21 a rear elevation of the vehicle seating arrangement from Fig. 20; Fig. 22 is a perspective top view of an embodiment of a seat of the vehicle seat assembly of Fig. 20; Fig. 23 a perspective top view of the seat from Fig. 22 with the seat shell in an open position; Fig. 24 is a front perspective view of another embodiment of a vehicle seat assembly according to the present invention; Fig. 25 a perspective rear view of the vehicle seat assembly from Fig. 24; Fig. 26 a perspective rear view of the vehicle seat assembly from Fig. 24, with the backrest plate removed; Fig. 27 a perspective top view of a vehicle backrest panel from Fig. 25; Fig. 28A is a top perspective view of another embodiment of a seat and seat pan for use with the vehicle seat assembly of the present invention; Fig. 28B is a side elevation of the seat Fig. 28A is shown; Fig. 29 a plan view of the seat shell used in the seat of Fig. 28A is shown; Fig. 30 a bottom view of the seat shell Fig. 29; Fig. 31 a bottom view of the seat shell from Fig. 30 with an added reinforcing support; Fig. 32 a perspective top view of the reinforcement support from Fig. 31; Fig. 33 is a top perspective view of another embodiment of a vehicle seat pan for use with the vehicle seat assembly of the present invention; Fig. 34 a perspective bottom view of the seat shell from Fig. 33; and Fig. 35 a lower view of the seat shell from Fig. 33.

[0009] For the purposes of the description herein, the terms “upper”, “lower”, “right”, “left”, “rear”, “front”, “vertical”, “horizontal” and their derivatives refer to the orientation of the invention as described in Fig. 1. It is to be understood, however, that the invention may assume various alternative orientations unless expressly stated to the contrary. It is also to be understood that the specific devices and methods shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered limiting unless expressly stated otherwise in the claims.

[0010] Referring to Fig. 1, Fig. 2 and Fig. 6, reference numeral 8 generally designates a vehicle having a vehicle seating assembly 10 including a seat 11 and a backrest 12 having a polymeric body portion 14 defining a support frame 16 having a plurality of forwardly extending connecting pins 18 disposed about a perimeter of a front surface 20 of the support frame 16. A flexible comfort support 22 is disposed over the front surface 20 of the support frame 16. The flexible comfort support 22 has a plurality of openings 24 defining a support matrix 26 for supporting the weight of a passenger. The flexible comfort support 22 has a plurality of slots 28 for receiving and engaging the plurality of forwardly extending connecting pins 18. A cushioning layer 30 extends over the flexible comfort support 22. A headrest 32 extends upwardly from the support frame 16.

[0011] Now referring to Fig. 2 and Fig. 3A, the vehicle seat assembly 10 shown has substantially linear, vertically extending side portions 40 for engagement with an adjacent vehicle seat assembly 10 ( Fig. 2). It should be noted that the plurality of slots 28 are generally linearly aligned on each of the side portions 40 and an upper portion of the backrest 12. The backrest 12 has cutouts 41 at a lower portion for connection to a hinge assembly extending upwardly from the seat 11 of the vehicle seat assembly 10. As shown in Fig. 3A, there are pivot pin openings 44 in the cutouts 41 for engagement with rotary knobs 46, as shown in Fig. 14, whereby the backrest 12 can rotate relative to the seat 11. The backrest 12 is also adapted to receive various headrests 32, such as a fixed headrest 48 ( Fig. 12 and Fig. 13), or a movable headrest 50 as shown in Fig. 3A. The versatility of the movable headrest 50 is discussed in more detail below.

[0012] Now referring to Fig. 3B and Fig. 3C, the plurality of slots 28 generally define keyhole slots having a flared portion 49 and a narrowed portion 52. The forwardly extending connecting pins 18 are adapted to engage the flared portion 49 of the slots 28 and slide into the narrowed portion 52 of the slots 28, where the forwardly extending connecting pins 18 are retained. The engagement of the forwardly extending connecting pins 18 with the keyhole slots 28 holds the flexible comfort support 22 in position on the support frame 16. The forwardly extending connecting pins 18 include a neck 60 with a head 62 extending therefrom. An angled wall 64 transitions from the neck 60 to the head 62.During assembly, a manufacturer would position the flexible comfort support 22 adjacent the seatback 12 and align the flared portion 49 of the keyhole slots 28 with the forwardly extending connecting pins 18. The manufacturer would insert the forwardly extending connecting pins 18 into the flared portion 49 and press the flexible comfort support 22 downward, forcing the forwardly extending connecting pins 18 into secure engagement with the narrowed portion 52 of the keyhole slots 28. The flexible comfort support 22 would then be installed. Devices such as those disclosed in US 2014 / 0203618 A1, which is hereby incorporated by reference in its entirety, may also be implemented.

[0013] Now referring to Fig. 4 and Fig. 5, the support frame 16 includes a series of forwardly extending support flanges 70 that extend both vertically and horizontally and provide structural rigidity and overall strength to the support frame 16. An outer periphery of the support frame 16 includes a series of planar portions 72 from which the forwardly extending connecting pins 18 extend. The forwardly extending connecting pins 18 and the planar portions 72 are equidistantly spaced around the periphery in the embodiment shown. An upper portion of the seat 11 includes a headrest receiving assembly 74 adapted to receive a support post 76 of the movable headrest 50 ( Fig. 5) or for receiving first and second cylindrical support posts 77, 78 of the fixed head restraint 48. The general construction of the support frame 16, and in particular the polymer body portion 14 of the support frame 16, is designed to be light and thin, yet exceptionally strong to support a passenger during regular use and in the event of an impact. An intermediate portion of the support frame 16 includes a depressed area contoured to the shape of a passenger's back. A lower portion of the intermediate portion may bulge outward to support the lower lumbar region of a passenger's back.

[0014] Now referring to Fig. 6-9, the general construction of the vehicle seat assembly 10 includes the seat back 12 connected to the flexible comfort support 22 via the interface of the keyhole slots 28 and the forwardly extending connecting pins 18. The cushioning layer 30 extends over the flexible comfort support 22 and may include an open- or closed-cell foam material 84 secured over the flexible comfort support 22. The foam material 84 is lightweight and provides another flexibly resilient layer to the seat 11 to increase the overall comfort of the vehicle seat assembly 10. After the foam material 84 is attached, a cover fabric is secured over the foam material 84 to generally protect the foam material 84 and the seat back 12.

[0015] The flexible comfort support 22, as in Fig. 8, is generally constructed of a flexible polymer. In the embodiment shown, the plurality of openings 24 defining the support matrix 26 are provided in various rows of vertical and horizontal rings 90 having a generally linear configuration. The horizontal rings 90 may extend in a vertical direction or in a horizontal direction. The design of the flexible comfort support 22 allows the rings 90 to expand and contract depending on the shape and size of a passenger, and a dynamic load can be applied to the flexible comfort support 22 during regular use and in the event of an impact. In addition, reinforcing rings 93 are provided surrounding each slot 28 to reinforce and support the flexible comfort support 22.A periphery 95 of the flexible comfort support 22 has a reinforced portion 92 having a plurality of cover fabric engagement holes 97 for receiving and securing engagement elements on the cover fabric.

[0016] Now referring to Fig. 9-11, the movable headrest 50 is generally configured to extend into the headrest receiving assembly 74 and the support frame 16. The support post 76 of the movable headrest 50 is of generally planar construction and has a blade configuration with a planar intermediate portion 94 and side portions 96 defining the trim material engagement holes 97 that connect to the headrest receiving assembly 74 of the support frame 16. The trim material engagement holes 97 help guide the support posts 76 between the use positions ( Fig. 2 and Fig. 10) and the stowed positions ( Fig. 11). A stop may be provided at a lower portion 93 of the support post 76. The movable headrest 50 includes a headrest 98 supported on the post 76. The attachment of the post 76 to the headrest 98 is reinforced by flanges 101. The flanges 101 taper from the movable headrest 50 to the support post 76. The headrest 98 includes planar side members 102. The interior of the headrest 98 includes a plurality of vertical and horizontal reinforcement members 103. An upper portion of the headrest 98 may taper such that a lower portion of the headrest 98 is wider than an upper portion. The planar intermediate portion 94 includes an opening 99 for receiving a retaining hook 100 ( Fig. 10). The movable headrest 50 can thus be inserted into the support frame 16 until the retaining hook 100 engages the opening 99. When the retaining hook 100 engages the opening 99, the movable headrest 50 is held in a secure relationship with the support frame 16. To remove the movable headrest 50, the movable headrest 50 is pushed downward, forcing the retaining hook 100 out of engagement with the opening 99. The movable headrest 50 can then be pulled out and rotated forward, as shown in Fig. 11. It is generally contemplated that a push-push mechanism, as known to one of ordinary skill in the art, could be used to both engage and disengage the movable head restraint 50 from the seatback 12. Alternatively, the retaining hook 100 may be permanently fixed to the opening 99 and released only with a special tool. In the illustrated embodiment, the movable head restraint 50 can be tilted forward to 94 degrees relative to the seatback 12. With the head restraint 32 in the forward stowed position, the seatback 12 can be rotated forward to a lower position without interfering with the seatback 12 from a front seat in the passenger compartment. In one embodiment, the movable head restraint 50 is raised until a lower portion of the post 76 is adjacent a stop member 105 ( Fig. 10). The movable headrest 50 can then be rotated approximately 94 degrees until the post 76 abuts the stop member 105. Alternatively, the seatback 12 can be maintained in the upright position, providing better rearward visibility for passengers and the driver in the front seat of the passenger compartment. The support post 76 is designed to be substantially retracted from the seatback 12 before being moved from the in-use position to the stowed position.

[0017] Now referring to Fig. 12 and Fig. 13, the fixed headrest 48 is designed to engage the support frame 16 and maintain a fixed position relative to the support frame 16 during use. However, it is contemplated that the fixed headrest 48 could be removed if the fixed headrest 48 needs to be repaired or replaced. To receive the first and second cylindrical posts 77, 78 extending downwardly from the fixed headrest 48, the seatback 12 additionally includes another headrest receiving assembly 74 adapted to receive the first and second cylindrical support posts 77, 78. The vehicle seat assembly 10 is otherwise similar to the embodiment described with reference to Fig. 2-5 and 7-9. The headrest receiving assembly 74 includes two post receivers configured for locking engagement with latches 79 on the posts 77, 78, thereby holding the fixed headrest 48 in fixed relationship to the vehicle seat assembly 10.

[0018] Now referring to Fig. 14-19, the illustrated vehicle seat assembly 108 includes a cup holder assembly 110 having a generally T-shaped configuration. A base portion 112 of the cup holder assembly 110 is pivotally connected to the seatback 12. Accordingly, the cup holder assembly 110 can be rotated vertically about a horizontal axis between deployed and undeployed positions. In the undeployed position, the cup holder assembly 110 is generally aligned with a front side of a trim panel of the seatback 12. In the deployed position, the cup holder assembly 110 extends forward relative to the seatback 12, and the first and second cup holders 114, 115 are deployable and available for use by a passenger.

[0019] Referring to Fig. 16, when the cup holder assembly 110 is not attached, the flexible comfort support 22 may simply comprise a solid polymer portion 117. It should be noted that the vehicle seat assembly 108 with the cup holder assembly 110 includes a small headrest 118. It is contemplated that the small headrest 118 may be movable or fixed, depending on the desired use of the vehicle seat assembly 108. The small headrest 118 provides a lower height to the vehicle seat assembly 108, thereby generally improving the rearward visibility of a passenger in a forward portion of the passenger compartment. As shown in Fig. 17, the backrests 12 may have common planar portions 72. Other features of the vehicle seat assembly 108 are similar to features previously disclosed with respect to other embodiments.

[0020] Now referring to Fig. 18 and Fig. 19, the cup holder assembly 110 may have various configurations. As shown in Fig. 18 and Fig. 19, the base portion 112 of the cup holder assembly 110 includes openings configured to engage knobs 46 in the seatback 12. The cup holder assembly 110 can be rotated forward as mentioned above, and the cup holders 114, 115 can be deployed so that containers containing a beverage can be inserted into the openings defined by the cup holders 114, 115. The cup holder assembly 110 includes an interior support 116 that supports the cup holder assembly 110. The cup holder assembly 110 can be rotated between the deployed position and the undeployed position by rotating the cup holder assembly 110 about the pivot openings 120.

[0021] Now referring to Fig. 20-23, another embodiment of the present invention includes a narrow vehicle seat assembly 210. In the embodiment shown, the narrow vehicle seat assembly 10 is a 20 percent seat, meaning the vehicle seat assembly 10 is not a full-size seat and is generally configured to be disposed between two 40 percent seats in the passenger compartment. The vehicle seat assembly 210 includes a backrest 212 having upper and lower portions 213, 215 supported on a frame 216, and a headrest 214. The vehicle seat assembly 210 also includes a seat 220 having a seat pan 222 extending over the seat 220. The seat 220 is supported on a frame assembly 223. An upwardly facing portion 224 of the frame assembly 223 is pivotally connected to the backrest 212. A front portion 226 of the frame assembly 223 supports a base portion 225 which engages the seat pan 222.

[0022] The seat shell 222 can be adjusted between a closed position ( Fig. 22) and an open position ( Fig. 23). The seat pan 222 has a flexible intermediate section 230 that flexes under the weight of a passenger, thereby providing additional comfort for a passenger. The flexible intermediate section 230 is arranged centrally in the seat pan 222 and can be made of a similar or different material as the seat pan 222. In the embodiment shown in Fig. 22 and Fig. 23, the flexible intermediate section 230 is wider at a front end and narrower at a rear end.

[0023] Again referring to Fig. 20-23, the seat pan 222 also includes an anti-submarining feature in the form of a forwardly rounded hump 238 that prevents the passenger from sliding forward during use. For the purposes of this disclosure, "submarining" generally refers to a passenger being forced under a seat belt by the forward edge of the seat during a collision. The flexible intermediate portion 230 includes eyelets 231 configured to engage hooks on the seat pan 222. The flexible intermediate portion 230 also includes a plurality of upwardly extending nubs 232 that provide additional grip and flexibility to the flexible intermediate portion 230. A bottom surface of the flexible intermediate portion 230 includes a circumferential flange 233. A front portion 240 of the seat pan 222 includes a latch 242 configured to engage a catch 227 on the support frame 216 of the vehicle seat assembly 210.When the seat pan 222 is in the open position, the cup holders 244 are available for use. Additionally, a storage compartment 248 is provided behind the cup holders 244 for storing small items. A bottom surface of the seat pan 222 includes lateral supports 250 that provide structural rigidity to the seat pan 222.

[0024] Now referring to Fig. 24-26, another embodiment of the present invention includes a vehicle seat assembly 310 having a backrest 312, a seat 314, and a headrest 315. The seat 314 is supported on a lower frame 316. The lower frame 316 is pivotally connected to an upper frame 317 that supports the backrest 312. A back panel 318 of the backrest 312 includes cup holders 320 and a storage compartment 322. Thus, the backrest 312 can be rotated relative to the seat 314 so that the cup holders 320 and the storage compartment 322 are ready for use by passengers. The upper frame 317 defines a cavity 324 into which the cup holders 320 and the storage compartment 322 extend. A flexible support member 330 with slots or notches 329 extends across the upper frame 317 and supports a comfort support or cushion assembly. A rear surface of the upper frame 317 includes a grid of structural fabric 332.

[0025] Now referring to Fig. 27, the vehicle seatback 312 includes an upper portion 331 defining the cup holders 320. A lower portion 333 includes the storage compartment 322. A second, smaller raised compartment 334 is located below and rearward of the storage compartment 322 and is separated from the storage compartment 322 by a wall 335. The seatback 312 can be rotated about hinge elements 336.

[0026] Now referring to Fig. 28A and Fig. 28B, the seat 314 includes a seat pan 350 of the vehicle seat assembly 310 and has a forwardly rounded hump 352 intended to minimize submarining effects and provide a lightweight yet rigid solution for passenger seating comfort. The seat pan 350 is rotatable about a rear pivot member 351 between closed and open positions, allowing access to a storage compartment 354 beneath the seat pan 350. In the closed position, the seat pan 350 can be held closed via a locking arrangement 352. As shown in Fig. 29-32, the seat pan 350 may further include a grid of structural supports 356 that provide rigidity to the seat pan 350, and may also include a polymer or metal support member 360 that further supports the seat pan 350. The support member 360 has a contoured surface 362 that generally follows the contours of the underside of the seat pan 350. In the illustrated embodiment, the support member 360 extends substantially across the entire underside of the seat pan 380.

[0027] Now referring to Fig.33-35, in another embodiment of the present invention, a seat pan 380 is provided having a small storage compartment 382 forwardly on the underside of the seat pan 380. The seat pan 380 has a matrix of support flanges 384 disposed on a top surface of the seat pan 380 beneath a cushioning material 381 configured to support the weight of a passenger. The small storage compartment 382 may include a lid or door for securing smaller items within the small storage compartment 382. A forward portion of the seat pan 380 includes a latch 385, and a rearward portion of the seat pan 380 includes a pivot member 386 configured to engage the frame 316 of the seat 314 so that the seat pan 380 can be pivoted between closed and open positions.

[0028] It will be understood by one of ordinary skill in the art that the construction of the described invention and other components is not limited to any particular material. Other exemplary embodiments of the invention disclosed herein may be formed from a variety of different materials, unless otherwise described herein.

[0029] For the purposes of this disclosure, the term "connected" (in all its forms, connect, connection, joined, etc.) generally means the direct or indirect connection of two components (electrical or mechanical) to one another. Such a connection may be stationary or movable. Such a connection may be with the two components (electrical or mechanical) and any additional intermediate parts integrally formed as a unitary body, to one another, or to the two components. Such a connection may be permanent, removable, or detachable, unless otherwise specified. LIST OF REFERENCE SYMBOLS 10 Vehicle seat arrangement 11 seats 12 Backrest 14 Polymer body section 16 support frames 18 connecting pins 20 Front of the support frame 22 Comfort support 24 openings 26 Support matrix 28 slots, keyhole slots 30 cushioning layers 32 Headrest 40 page sections 41 excerpts 44 pivot openings 46 rotary knobs 48 Headrest 49 widened section of the slots 28 50 headrest 52 narrowed section of the slots 28 60 neck 62 heads 64 Wall 70 support flanges 72 flat sections 74 Recording arrangement 76 posts, support posts 77 posts, support posts 78 posts, support posts 79 bars 84 foam material 90 rings 92 reinforced section 93 reinforcement rings 94 Intermediate section 95 scope 97 engagement holes 98 Headrest 99 Opening 100 retaining hooks 101 flanges 102 page elements 103 reinforcement elements 105 Stop element 108 Vehicle seating arrangement 110 Cup holder arrangement 112 Base Section 114 cup holders 116 inner supports 117 solid polymer section 118 Headrest 120 pivot opening 210 Vehicle seating arrangement 212 Backrest 213 upper section of the backrest 212 214 Headrest 215 lower section of the backrest 212 216 support frames 220 seats 222 seat shell 223 Frame arrangement 224 upwardly facing section of the frame assembly 223 225 Base Section 226 front section of the frame assembly 223 227 trap 230 Intermediate section 231 eyelets 232 studs 233 circumferential flange 238 humps 240 front section of the seat shell 222 242 bars 244 cup holders 248 storage compartment 250 supports 310 Vehicle seating arrangement 312 backrest 314 seats 315 Headrest 316 frames 318 back plate 320 cup holders 322 storage compartment 324 cavity 329 Notch 330 support element 331 upper section of the vehicle backrest 312 332 structural fabrics 333 lower section of the vehicle backrest 312 334 compartments 335 Wall 336 hinge elements 350 seat shell 351 Swivel element 352 humps 352 locking arrangement 354 storage compartment 356 supports 360 support element 362 Surface 380 seat shell 381 Upholstery material 382 storage compartment 384 Support flange 385 bars 386 rotating element

Claims

[1] Vehicle seat assembly (10, 108, 210, 310) comprising: a backrest (12, 212, 312) having a polymer body portion (14) defining a support frame (16, 216, 316) with a plurality of forwardly extending connecting pins (18) disposed around a periphery of a front side of the support frame (16, 216, 316); a flexible comfort support (22) disposed over a front surface of the polymer body portion (14) and having a plurality of openings (24) defining a support matrix (26) that supports the weight of a passenger, the flexible comfort support (22) also having a plurality of slots (28) configured to receive and engage the plurality of forwardly extending connecting pins (18); a cushioning layer (30) extending over the flexible comfort support (22); and a headrest (32) extending upwardly from the front support frame (16, 216, 316). [2] The vehicle seat assembly (10, 108, 210, 310) of claim 1, wherein the headrest (32, 48) is fixedly attached to the seatback (12, 212, 312). [3] The vehicle seat assembly (10, 108, 210, 310) of claim 1, wherein the support frame (16, 216, 316) has a front side (20) with a plurality of planar portions (72). [4] The vehicle seat assembly (10, 108, 210, 310) of claim 3, wherein a connecting pin (18) extends from each of the plurality of planar portions (72). [5] The vehicle seat assembly (10, 108, 210, 310) of claim 4, wherein the plurality of slots (28) in the flexible comfort support (22) are shaped as keyhole slots (28), wherein each of the keyhole slots (28) is configured to align with and engage one of the connecting pins (18). [6] The vehicle seat assembly (10, 108, 210, 310) of claim 4, wherein the flexible comfort support (22) includes a plurality of horizontal and vertical rings (90) defining openings (24) that expand and contract when a load is applied to the seat back (12, 212, 312). [7] Vehicle seat assembly (10, 108, 210, 310) comprising: a backrest (12, 212, 312) having a polymer body portion (14) having cup holders (114, 244, 320) and a storage compartment (248, 322, 354) on a rear side thereof and defining a support frame (16, 216, 316) having linearly vertically extending side portions (40) and a plurality of forwardly extending connecting pins (18) disposed around a periphery of a front side (20) of the support frame (16, 216, 316); and a flexible comfort support (22) disposed over a front surface of the polymer body portion (14) and having a plurality of openings (24) defining a support matrix (26) that supports the weight of a passenger, the flexible comfort support (22) also having a plurality of slots (28) configured to receive and engage the plurality of forwardly extending connecting pins (18). [8] The vehicle seat assembly (10, 108, 210, 310) of claim 8, wherein the cup holders (114, 244, 320) and the storage compartment (248, 322, 354) are integrated into a hard seatback cover. [9] Vehicle seat assembly (10, 108, 210, 310) according to claim 8, wherein the support frame (16, 216, 316) has planar side portions (40). [10] The vehicle seat assembly (10, 108, 210, 310) of claim 8, wherein the support frame (16, 216, 316) includes a headrest receiving assembly (74) configured to receive a support post (76, 77, 78) having a planar construction. [11] The vehicle seat assembly (10, 108, 210, 310) of claim 8, wherein the support frame (16, 216, 316) includes side portions having a plurality of slots for receiving and retaining a trim fabric or a cushion. [12] The vehicle seat assembly (10, 108, 210, 310) of claim 8, wherein the flexible comfort support (14) includes a plurality of horizontal and vertical rings (90) defining openings (24) that expand and contract when a load is applied to the seat back (12, 212, 312). [13] The vehicle seat assembly (10, 108, 210, 310) of claim 8, wherein the support frame (16, 216, 316) includes a plurality of vertically and horizontally extending support flanges (70) that provide increased structural rigidity and overall strength to the support frame (16, 216, 316). [14] Vehicle seat assembly (10, 108, 210, 310) comprising: A backrest (12, 212, 312) having a polymer body portion (14) defining a front support frame (16, 216, 316) with a plurality of forwardly extending connecting pins (18), and a flexible comfort support (22) disposed over a front surface of the polymer body portion (14) and having a plurality of openings (24) defining a support matrix, the flexible comfort support (22) also having a plurality of keyhole slots (28) configured to receive the plurality of forwardly extending connecting pins (18). [15] Vehicle seat assembly (10, 108, 210, 310) according to claim 15, wherein the support frame (16, 216, 316) has planar side portions (40). [16] The vehicle seat assembly (10, 108, 210, 310) of claim 15, wherein the support frame (16, 216, 316) includes a headrest receiving assembly (74) configured to receive a support post (76, 77, 78) having a planar construction. [17] The vehicle seat assembly (10, 108, 210, 310) of claim 15, wherein the support frame (16, 216, 316) includes side portions having a plurality of slots for receiving and retaining a cover fabric or a cushion. [18] The vehicle seat assembly (10, 108, 210, 310) of claim 15, wherein the flexible comfort support (22) includes a plurality of horizontal and vertical rings (90) defining openings (24) that expand and contract when a load is applied to the seat back (12, 212, 312). [19] The vehicle seat assembly (10, 108, 210, 310) of claim 15, wherein each of the plurality of keyhole slots (28) is surrounded by a reinforcing ring (93).

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