Backrest module for a vehicle seating arrangement

Abstract

Vehicle seating arrangement (10) comprising the following: a seat frame (12) defined by a seat back frame (14) and a seat frame (16); several individual arrangement modules (18) configured for attachment to the seat frame (12), the several individual arrangement modules (18) comprising the following: a backrest module (20); a hard back panel module (22); a seat cushion module (24); and a headrest module (26); wherein the back cushion module (20) and the hard back wall module (22) are operatively coupled to each other and wherein the headrest module (26) extends over the back cushion module (20) and operatively couples it to the seat cushion module (24), to substantially surround the seat frame (12), wherein the seat cushion module (24) is positioned on the seat frame (26) in front of the seat frame (26); and a first and a second side panel (30) configured to extend over the seat frame (16) and to cover side sections of the seat cushion module (24).

Description

AREA OF REVELATION

[0001] The present invention relates generally to a back cushion and more particularly to a back cushion module for a vehicle seating assembly. BACKGROUND OF REVELATION

[0002] Vehicle seats are known from US 3 695 696 A, DE 10 2008 014 061 A1 and DE 10 2013 017 408 A1

[0003] Vehicle seating assemblies typically include a seatback for supporting the back of an occupant in an upright seating position and various reclined positions. Similar to other parts of a vehicle seating assembly, seatbacks are commonly designed to support an occupant in the upright seating position during vehicle acceleration, directional changes, and collisions. Accordingly, seatbacks are generally rigid and fairly large.

[0004] It is therefore an object of the invention to provide more flexible seat backs with less installation space required.

[0005] This object of the invention is achieved by the subject matter of the independent patent claims. Advantageous further developments are the subject matter of the dependent claims. SUMMARY OF REVELATION

[0006] According to another aspect of the present disclosure, a vehicle seat assembly includes a seat frame defined by a seatback frame and a seat frame. A plurality of individual assembly modules are configured for attachment to the seat frame. The plurality of individual assembly modules include a back cushion module, a hard rear panel module, a seat cushion module, and a headrest module. The back cushion module and the hard rear panel module are operatively coupled to one another. The headrest module extends over the back cushion module and operatively couples it to the seat cushion module to substantially surround the seat frame. The seat cushion module is positioned on the seat frame forward of the seat frame. First and second side trim pieces are configured to extend over the seat frame and conceal side portions of the side cushion module.

[0007] According to yet another aspect of the present disclosure, a vehicle seat assembly includes a seatback frame surrounded by a plurality of individual assembly modules, including a back cushion module, a hard back panel module, a seat cushion module, and a headrest module. The back cushion module and the hard back panel module are operatively coupled to each other. The headrest module extends over the back cushion module and operatively couples it to the seat cushion module to substantially surround the seat frame.

[0008] According to one aspect of the present disclosure, a method of manufacturing a vehicle seat assembly includes constructing a seat assembly frame having a seatback frame. A plurality of individual assembly modules are provided, including a back cushion module, a hard rear panel module, and a headrest module. The back cushion module and the hard rear panel module are coupled to conceal the seatback frame. A base of the headrest module is coupled to an upper portion of the back cushion module and the seat cushion module.

[0009] According to yet another aspect of the present disclosure, a vehicle seat assembly includes a plurality of individual assembly modules constructed at a remote location and transported to an assembly facility for final construction. The individual assembly modules include a back cushion module, a hard back panel module, a seat cushion module, and a headrest module. Each of the modules includes quick-attach assemblies so that a minimal number of tools are required to assemble the seat back. Furthermore, due to the pre-assembly of each of the modules, the vehicle seat assembly can be constructed with minimal time and cost.

[0010] These and other aspects, objects and features of the present disclosure will become understandable and apparent to those skilled in the art upon reading the following description, claims and appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The drawings show: Fig. 1 is a front perspective view of an embodiment of a vehicle seat assembly of the present disclosure; Fig. 2 is a partially exploded perspective front view of the vehicle seating arrangement of Fig. 1; Fig. 3 is a front perspective view of an embodiment of a seat back of the present disclosure; Fig. 3A is a partially exploded perspective front view of the seat back of Fig. 3, showing a back cushion module, a hard back panel module and a headrest module separated from an underlying frame; Fig. 4 is a front perspective view of a headrest module of the present disclosure; Fig. 4A is an exploded front perspective view of the headrest module of Fig. 4; Fig. 5 a perspective front view of the back cushion module; Fig. 6 is a front perspective view of a cover removed from a cushion portion of the back cushion module; Fig. 7 a partially exploded perspective front view of the back cushion module of Fig. 5; Fig. 8 is a front perspective view of a composite back panel support of the back cushion module; Fig. 9 a front elevation of the composite backplane of Fig. 8; Fig. 10 a perspective rear view of the composite backplane support of Fig. 8; Fig. 11 a rear elevation of the composite rear wall support of Fig. 8; Fig. 12 is a top perspective view of a seat cushion module of the present disclosure; Fig. 13 a partially exploded perspective view of the seat cushion module of Fig. 12 from the top; Fig. 14 is a top perspective view of the seat cushion module with the underlying support frame removed; Fig. 15 a partially exploded perspective view of the seat cushion module of Fig. 14 from above; and Fig. 16 is another partially exploded perspective view of the seat cushion module of Fig. 14 from the top. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0012] For the purposes of this description, the terms “upper”, “lower”, “right”, “left”, “rear”, “front”, “vertical”, “horizontal” and derivatives thereof shall refer to the disclosure as set forth in Fig. 1. It is to be understood, however, that the disclosure may assume various alternative orientations unless expressly stated to the contrary. Further, it is to be understood that the specific devices and methods illustrated in the appended drawings and described in the following description are simply 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 to the contrary in the claims.

[0013] In this document, relational terms such as first and second, upper and lower, and the like are used merely to distinguish one entity or action from another entity or action, without actually requiring or implying any such relationship or ordering of such entities or actions. The terms "comprises," "comprising," or any other variations thereof are intended to refer to non-exclusive inclusion, such that a process, method, article, or device comprising a list of elements includes not only those elements, but may also include other elements not expressly listed or inherent in such a process, method, article, or device. An element that is assigned a "comprises"...a' does not exclude, without more restrictions, the presence of additional identical elements in the process, method, article or apparatus incorporating that element.

[0014] With reference to the Fig. 1-16, reference numeral 10 generally designates a vehicle seat assembly including a seat frame 12 defining a seatback frame 14 and a seat frame 16. A plurality of individual assembly modules 18 are configured for attachment to the seat frame 12. The plurality of individual assembly modules 18 include a back cushion module 20, a hard back panel module 22, a seat cushion module 24, and a head restraint module 26. The back cushion module 20 and the hard back panel module 22 are operatively coupled together. The head restraint module 26 extends over the back cushion module 20 and operatively couples it to the seat cushion module 24 to substantially surround the seat frame 12. The seat cushion module 24 is positioned on the seat frame 16 forward of the seat frame 14. Side trim pieces 30 are configured to extend over the seat frame 16 and conceal side portions 34 of the side cushion module 24.

[0015] With reference to Fig. 1 and Fig. 2, the vehicle seat assembly 10 is configured for installation in a vehicle, such as a car, truck, or van. A seat base 38 of the vehicle seat assembly 10 is supported on a track slide assembly 40 that allows fore and aft movement of the vehicle seat assembly 10 relative to the vehicle. Rails 42 are secured to a floor of the vehicle, while slides 44 are operatively coupled to the vehicle seat assembly 10. The slides 44 are slidably engaged with the rails 42. The slides 44 can be adjusted and locked by a user using a forward slide control 46.Additionally, a variety of lateral controls, including a lumbar support control 48, a thigh support control 50, and a seatback pivot control 52 that allows pivotal movement of a seatback 53, are provided proximate the seat cushion module 24 and allow adjustment of the seatback 53 and the seat base 38 to accommodate occupants. A receptacle 54 for a seatbelt assembly for securing an occupant during a collision event is disposed on the vehicle seat assembly 10. Additionally, a front trim component 56 and the side trim pieces 30 are disposed around the seat base 38. The trim components 56 cover the seat frame 16 and structural components of the seat base 38 and the seat cushion module 24. As shown in FIG. Fig. 2, the seat back 53 is pivotable relative to the seat base 38 about a pivot rod (or torsion bar) 58 near a rear portion 60 of the seat base 38.

[0016] With reference to Fig. 3 and Fig. 3A, the seat back 53 is operatively coupled to the seat base 38 and includes seat back side cushions 70 that support an occupant leaning against the seat back 53. The cushions 70 are formed in the back cushion module 20 and may be partially supported by the hard rear wall module 22. The Fig. 3 includes a hard backplane module 22 having a lower lip 72 that extends beneath the remainder of the seat back 53 and the seat cushion module 24 and that partially wraps around a rear portion of the seat cushion module 24. Furthermore, the hard backplane module 22 includes scalloped areas 69 at a lower portion thereof. The scalloped areas 69 are configured to receive the seat back adjustment mechanism associated with the relative tilt of the seat back 53. The hard backplane module 22 further includes a plurality of attachment mechanisms 75 disposed around a perimeter of the hard backplane module 22. The attachment mechanisms 75 allow for direct connection of the hard backplane panel 71 to the back cushion module 20. As a result, the hard backplane panel 71 abuts the seat back frame 14 but is not directly coupled thereto.Furthermore, the hard backplane module 22 includes a centrally positioned wall 77 configured as a pocket to provide additional storage space for passengers. The wall 77 may be constructed of the same or a different material than the hard backplane panel 71. A gap 79 is formed at an upper portion of the hard backplane panel 71 and is configured to receive the headrest module 26.

[0017] As in Fig. 3A, the back cushion module 20, the head restraint module 26, and the hard rear wall module 22 surround the seatback frame 14 and a side airbag 74 such that the seatback frame 14 is not visible after assembly of the back cushion module 20, the head restraint module 26, and the hard rear wall module 22. The seatback frame 14 includes an inboard side support 73, an outboard side support 76, and upper and lower cross members 78 and 80, respectively. In particular, the head restraint module 26 includes a headrest 81 with engagement posts 68 configured to insert through a headrest shell 83 and into the upper cross member 78 of the seatback frame 14. The headrest shell 83 includes a downwardly tilted front lip 85 and an upwardly extending rear rear wall 87.The headrest shell 83 further includes two downwardly extending supports 89 that engage the seatback frame 14 and the back cushion module 20. Furthermore, the side airbag 74 is disposed on the outboard side support 76 of the seatback frame 14 and configured to deploy between the back cushion module 20 and the rigid rear panel module 22.

[0018] With reference to the Fig. 4 and Fig. 4A, the head restraint module 26 includes a frame 90 operatively coupled to the engagement pillars 68. The frame 90 supports a front structural member 91 and a rear structural member 92. The front structural member 91 and the rear structural member 92 are connected via mechanical fasteners 93 extending through the frame 90 of the head restraint module 26. The front structural member 91 supports a head restraint cushion 94. A cover 95 and an intermediate fabric 96 are disposed over the head restraint cushion 94 and securely engage the front structural member 91 of the head restraint module 26. A rear side of the rear structural member 92 includes a head restraint back plate 97 that conceals the structural components of the head restraint module 26 from occupants seated behind the vehicle seating assembly 10.The frame 90 of the head restraint module 26 includes a locking mechanism 98 to accommodate rotational movement of the frame 90 with respect to the engagement columns 68. Accordingly, the relative angle of the frame 90 and thus the head restraint cushion 94 can be adjusted to a desired position to accommodate occupants of different sizes.

[0019] With reference to Fig. 5-7, the back cushion module 20 includes a seat back cover 100 that extends over a back cushion 102 of the back cushion module 20. Furthermore, various types of seat back covers 100 can be used to cover the back cushion 102 of the back cushion module 20. In the illustrated embodiment, a first cover material 104 is used to cover the cushions 70 and a lower back region 106 of the back cushion module 20. A second cover material 107 covers a middle and upper back region 108. Mechanical fasteners, adhesive, or other types of attachment can be used to secure the seat back cover 100 to the back cushion module 20.

[0020] With reference to the Fig. 6, the back cushion 102 of the back cushion module 20 includes integrally formed slots 110 configured to receive fasteners disposed on a rear surface 112 of the seat back cover 100. Furthermore, an upper portion of each of the seat back cover 100 and the back cushion 102 includes a recess 114 configured to receive the headrest shell 83 and the headrest module 26. Also included is a lumbar adjustment assembly 120 ( Fig. 7) mounted in the back cushion module 20 and configured to be controlled by the lumbar support control 48 ( Fig. 1 and Fig. 2) to be hired.

[0021] With reference to Fig. 7, the back cushion module 20 includes a back support 122 configured to support the lumbar adjustment assembly 120 and further receive the back cushion 102 and the seat back cover 100. It is generally contemplated that the back support 122 be constructed from a polymeric material. However, the back support 122 could also be constructed from various other materials, including metals or composites.

[0022] With reference to Fig. 8-11, the rear support beam 122 is shown in more detail. The rear support beam 122 includes a plurality of frame attachment features 124 in the form of side tabs 126 and a lower cross member support 127. The side tabs 126 actively engage and secure the inboard side support 73 and the outboard side support 76 of the seatback frame 14 to the seatback frame 14. The rear support beam 122 includes two upper recesses 128 configured to receive the engagement posts 68 of the headrest 81. In addition, the rear support beam 122 includes an inner flange 144 that provides additional rigidity to the rear support beam 122. Attachment recesses 132 are disposed around a perimeter of the rear support beam 122 and configured to receive attachment features to the seatback frame 14 and / or the back cushion 102. The backplane support 122 generally includes side members 134 coupled to an upper member 136 and a lower member 138.The lower member 138 comprises an arcuate support in the form of the lower cross member support 127, which is open to the rear and supports the torsion bar 58 (. Fig. 2) of the vehicle seat assembly 10. A support flange 145 extends upwardly from the arcuate support 127 and includes flange reinforcements 146 extending beyond the support flange 145.

[0023] With reference to Fig. 10 and Fig. 11, the frame attachment features 124 are designed to fit within the inboard side support 73 and the outboard side support 76 to hold the backplane support 122 in position on the seatback frame 14. At the same time, the upper member 136 of the backplane support 122 is aligned adjacent the upper cross member 78 of the seatback frame 14. Accordingly, the backplane support 122 tightly receives the seatback frame 14 such that there is minimal space between the backplane support 122 and the seatback frame 14.

[0024] With reference to Fig. 12 and Fig. 13, the illustrated seat base 38 includes the sliders 44 of the seat cushion module 24, which are supported by the rails 42. Seat side supports 170 support the seat cushion module 24 above the rails 42 and the sliders 44. As shown in Fig. 13, the seat cushion module 24 is supported by connecting brackets 172 on the seat side supports 170. In addition, the seat belt buckle receptacle 54 is also disposed adjacent to the seat cushion module 24 and operatively coupled to the vehicle.

[0025] With reference to Fig. 13-16, the seat cushion module 24 includes a seat cover 176 extending over a seat cushion 178. Similar to the back cushion module 20, the seat cover 176 may comprise various styles over different portions of the seat cushion 178. The seat cover 176 and the seat cushion 178 are operatively coupled to a composite cushion socket 180. The composite cushion socket 180 includes a rear support 182 defining an open intermediate region 184 and a front support 186 pivotally coupled to the rear support 182 at pivots 183. The front support 186 is pivotally coupled to the rear support 182 to provide adjustability and increased or decreased support to an occupant's thighs. Side thigh supports 185 also provide thigh support for occupants.The front support 186 includes an array of upwardly extending flanges 191 in a honeycomb structure 192 across a bottom wall 193 of the front support 186.

[0026] With further reference to Fig. 13-16, the front support 186 includes hook tabs 187 extending below the front support 186 and forward. The hook tabs 187 engage an adjustable crossbar 189 that can be raised or lowered to accommodate the legs of occupants of various sizes. The front support 186 can be adjusted manually or by a motorized assembly. The front support 186 is pivotally adjustable up and down with respect to the rear support 182. The front support 186 includes a plurality of recesses 188 configured to receive mechanical fasteners that wrap the seat cover 176 around a forward portion of the seat cushion module 24. In addition, a suspension assembly 190 is disposed in the open intermediate region 184 of the rear support 182.The suspension assembly 190 supports the seat cushion 178 and the seat cover 176 and is configured to withstand both the static and dynamic loads associated with a seated occupant during driving.

[0027] With further reference to Fig.13-16, the vehicle seat assembly 10 disclosed herein is constructed from the various modules detailed above. It should be understood that the back cushion module 20, the hard back module 22, the seat cushion module 24, and the head restraint module 26 are integrally formed as separate and individual modules at remote locations. Thereafter, after construction, each of the modules is sent to a manufacturing facility where the modules are assembled over the seat frame 12. This construction allows for quick and easy manufacturing and self-contained design of each of the modules. This means that modules can be interchanged by inserting and removing them into and from the vehicle seat assembly 10 without disassembling the entire vehicle seat assembly 10. This provides for minimized production time, increased manufacturing savings, and an overall better product.In addition, additions or changes can be made to separate modules without affecting other modules on the vehicle seating assembly 10.

[0028] Vehicle seating assemblies are traditionally assembled piece by piece from the ground up. Using this method, seat assemblies of varying complexity can be achieved, but the process is time-consuming and costly. Furthermore, a lack of modularity leads to costly and time-consuming repairs and replacements. A modular system, such as the one outlined above, provides an ideal way to construct multiple modules at different sites or facilities in different geographical locations and transport them to a single site for completion of the final vehicle seating assembly. Furthermore, this system provides a lightweight process for manufacturing a seat assembly. In particular, only a few parts (each of the modules) are brought together and secured to the seat frame. Accordingly, few fasteners and tools are required to tighten these fasteners.Additionally, repairs or replacements of parts are easier. For example, if the seat cushion assembly malfunctions or is damaged, the seat cushion assembly can be removed from the vehicle's seating assembly and replaced in just a few minutes.

[0029] It will be understood by one of ordinary skill in the art that the construction of the described disclosure and other components is not limited to any particular material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a variety of materials, unless otherwise described herein.

[0030] For purposes of the present disclosure, the term "coupled" (in all its forms, coupling, coupled, etc.) generally means the direct or indirect interconnection of two components (electrical or mechanical). Such a connection may be stationary or movable. Such a connection may be achieved with the two components (electrical or mechanical) and any additional intermediate elements integrally connected to each other or to the two components as a single, one-piece body. Such a connection may be permanent or removable or detachable, unless otherwise specified.

[0031] It is also important to note that the construction and arrangement of the elements of the disclosure, as shown in the exemplary embodiments, are merely exemplary. While only a few embodiments of the present innovations have been described in detail in this disclosure, one skilled in the art who reads this disclosure will readily recognize that many modifications are possible (e.g., variations in the size, dimensions, structures, shapes, and proportions of the various elements, parameter values, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter presented.For example, elements shown as being integral may be constructed from multiple parts, or elements shown as being comprised of multiple parts may be integral, the function of the interfaces may be reversed or otherwise different, the length or width of the structures and / or links or connectors or other elements of the system may be different, the type or number of adjustment positions provided between the elements may be different. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be made to the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0032] It is understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are illustrative and should not be construed as limiting.

[0033] It is also to be understood that changes and modifications may be made to the above structures and methods without departing from the concepts of the present disclosure, and it is further understood that such concepts are intended to be covered by the following claims unless such claims expressly state otherwise. List of reference symbols 10 Vehicle seat arrangement 12 seat frame 14 seat back frame 16 seat frames 18 Arrangement module 20 back cushion module 22 Rear wall module 24 seat cushion module 26 Headrest module 30 side panel parts 34 page sections 38 seat base 40 Rail sliding arrangement 42 rail 44 Sliding device 46 Forward glide control 48 Lumbar support control 50 Thigh support control 52 Seat back swivel control 53 seat back 54 recording 56 cladding component 58 Swivel rod, torsion bar Section 60 68 intervention column 69 Area 70 seat back side cushions 71 Rear panel 72 Lippe 73 Side support 74 side airbag 75 fastening mechanisms 76 Side support 77 Wall 78 cross members 79 gap 80 cross members 81 Headrest 83 Headrest shell 85 Lippe 87 Rear wall 89 supports 90 frames 91 structural element 92 structural element 93 Fasteners 94 headrest cushions 96 Cover 96 Interstitial tissue 97 Headrest back plate 98 Locking mechanism 100 seat back covers 102 back cushions 104 Covering material 106 back area 107 Covering material 108 back area 110 slots 112 back surface 114 Deepening 120 Lumbar adjustment arrangement 122 rear wall supports 124 Frame mounting feature 126 side flap 127 Crossbeam support, arched support 128 recesses 132 Mounting recess 134 side links 136 link 138 members 144 inner flange 145 Support flange 146 flange reinforcements 170 seat side supports 172 connecting bracket 176 seat cover 178 seat cushions 180 composite cushion pan 182 support 183 Swivel joint 184 Intermediate area 185 lateral thigh supports 186 support 187 hook tab 188 recess 189 Crossbar 190 Suspension arrangement 191 flange 192 honeycomb structure 193 Wall

Claims

[1] Vehicle seating arrangement (10) comprising: a seat frame (12) defined by a seat back frame (14) and a seat frame (16); a plurality of individual arrangement modules (18) configured to be attached to the seat frame (12), the plurality of individual arrangement modules (18) comprising: a back cushion module (20); a hard backplane module (22); a seat cushion module (24); and a headrest module (26); wherein the back cushion module (20) and the hard rear wall module (22) are operatively coupled to one another and wherein the headrest module (26) extends over the back cushion module (20) and operatively couples it to the seat cushion module (24), to substantially surround the seat frame (12), wherein the seat cushion module (24) is positioned on the seat frame (26) in front of the seat frame (26); and a first and a second side trim part (30) configured to extend over the seat frame (16) and to conceal side portions of the seat cushion module (24). [2] The vehicle seat assembly (10) of claim 1, wherein the hard rear wall module (22) is mechanically secured to the back cushion module (20). [3] Vehicle seat assembly (10) according to claim 1 or 2, further comprising: a headrest shell (83) which operatively couples the back cushion module (20), the seat back frame (14) and the hard rear wall module (22). [4] The vehicle seat assembly (10) of claim 3, wherein the headrest shell (83) further comprises an upwardly extending rear wall (87) and a downwardly extending front lip (85). [5] Vehicle seat assembly (10) according to one of claims 1 to 4, further comprising: a back panel support (122) which provides structural rigidity to the back cushion module (20) and which rests against the seat back frame (14) and is directly operatively coupled to the hard back panel module (22). [6] The vehicle seat assembly (10) of claim 5, wherein the rear wall support (122) includes two upper recesses (128) aligned with the recesses (128) in the seat back frame (14) and configured to receive engagement columns (64) of the headrest module (26). [7] The vehicle seat assembly (10) of any one of claims 1 to 6, wherein the rear wall support (122) includes a lower member having an arcuate support open rearwardly. [8] Vehicle seating arrangement (10) comprising: a seat back frame (14) surrounded by a plurality of individual arrangement modules (18) comprising: a back cushion module (20); a hard backplane module (22); a seat cushion module (24); and a headrest module (26); wherein the back cushion module (20) and the hard rear wall module (22) are operatively coupled to one another, wherein the headrest module (26) extends over the back cushion module (20) and operatively couples it to the seat cushion module (24) to substantially surround the seat back frame (14). [9] The vehicle seat assembly (10) of claim 8, wherein the hard back panel module (22) includes a lower lip extending beneath the back cushion module (20) and partially enveloping a portion of the seat cushion module (24). [10] Vehicle seat assembly (10) according to claim 8 or 9, wherein the hard rear wall module (22) is mechanically attached to the back cushion module (20). [11] Vehicle seat assembly (10) according to one of claims 8 to 10, further comprising: a headrest shell (83) which operatively couples the back cushion module (20), the seat back frame (14) and the hard rear wall module (22). [12] The vehicle seat assembly (10) of claim 11, wherein the headrest shell (83) further comprises an upwardly extending rear wall (87) and a downwardly extending front lip (85). [13] Vehicle seat assembly (10) according to one of claims 8 to 12, further comprising: a back panel support (122) which provides structural rigidity to the back cushion module (20) and which rests against the seat back frame (14) and is directly operatively coupled to the hard back panel module (22). [14] The vehicle seat assembly (10) of claim 13, wherein the rear wall support (122) includes two upper recesses (128) aligned with the recesses (128) in the seat back frame (14) and configured to receive engagement columns (64) of the headrest module (26). [15] A method of manufacturing a vehicle seat assembly (10) comprising: Constructing a seat assembly frame with a seat back frame (14); providing a plurality of individual assembly modules (18), including: a back cushion module (20); a hard backplane module (22); and a headrest module (26); Coupling the back cushion module (20) and the hard back panel module (22) to conceal the seat back frame (14); and Coupling a headrest shell (83) of the headrest module (26) with an upper part of the back cushion module (20) and the seat cushion module (24). [16] The method of claim 15, further comprising: Positioning a headrest shell (83) over the back cushion module (20), the seat back frame (14) and the hard rear wall module (22), which operatively couples the back cushion module (20), the seat back frame (14) and the hard rear wall module (22). [17] The method of claim 16, further comprising: forming the headrest shell (83) to include an upwardly extending rear wall (87) and a downwardly extending front lip (85). [18] The method of claim 17, wherein the hard back panel module (22) is mechanically attached to the back cushion module (20). [19] A method according to any one of claims 15 to 18, further comprising: coupling a back panel support (122) to the back cushion module (20); and direct coupling of the rear wall support (122) with the hard rear wall module (22). [20] A method according to any one of claims 15 to 19, further comprising: Forming two upper recesses (128) in the rear wall support (122) which are aligned with the recesses (128) in the seat back frame (14) and which are configured to receive engagement columns (64) of the headrest module (26).

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