Cushion with a retaining clip for a speaker

Abstract

Vehicle seat (100), comprising: a seat cushion (102) formed from a foam material defining a seating surface (120) for supporting an occupant and a rear surface (130) opposite the seating surface (120), wherein a speaker cavity (104) for receiving a speaker assembly (300) is formed in the seat cushion (102) and extends from the rear surface (130) to the seating surface (120), and at least one speaker retaining clip (200) disposed in the speaker cavity (104), wherein the speaker retaining clip (200) is molded together with the seat cushion (102) such that at least a portion of a flange (202) of the speaker retaining clip (200) is enclosed in the foam material to retain the speaker retaining clip (200) in the speaker cavity (104), wherein the speaker retaining clip (200) has at least one retaining feature (208) extending into the speaker cavity (104) to cooperate with the speaker assembly (300) and retain the speaker assembly (300) in the seat cushion (102), wherein the speaker retaining clip (200) is configured to mount the speaker assembly (300) in the speaker cavity (104) configured to transmit sound waves through the foam material to a seated occupant.

Description

TECHNICAL FIELD

[0001] The present invention relates to systems and methods for supporting a speaker assembly in a vehicle seat. BACKGROUND

[0002] Vehicle occupants often listen to music, sports broadcasts, audiobooks, podcasts, or other audio while driving. By incorporating a speaker array into a vehicle seat, the listening experience for a seated occupant can be enhanced. US 2013 / 0 076 090 A1 discloses a vibration-transducing chair that enables the transmission of vibration energy from a transducer to a user.

[0003] The object of the invention is to give the seat from US 2013 / 0 076 090 A1 a different functionality.

[0004] The object of the invention is achieved by an article or a method according to at least one of the independent claims. SUMMARY

[0005] According to at least one embodiment, a vehicle seat is provided with a seat cushion formed from a foam material defining a seating surface for supporting an occupant and a rear surface opposite the seating surface. A speaker cavity for receiving a speaker assembly is formed in the seat cushion and extends from the rear surface toward the seating surface. At least one speaker retaining clip is disposed within the speaker cavity. The speaker retaining clip is co-molded with the seat cushion such that at least a portion of the speaker retaining clip is encased in the foam material to retain the speaker retaining clip within the speaker cavity, wherein the speaker retaining clip includes at least one retaining feature extending within the speaker cavity to cooperate with the speaker assembly and retain the speaker assembly within the seat cushion.The speaker retaining clip is configured to mount a speaker assembly within the speaker cavity, allowing sound waves to be transmitted through the foam material to a seated occupant.

[0006] In another embodiment, the speaker cavity extends from the rear surface to the seat surface. The speaker retaining clip is arranged at a central position within the speaker cavity, spaced from the seat surface, and does not protrude beyond the seat surface or the rear surface.

[0007] In another embodiment, the speaker retaining clip includes a flange that is substantially planar and extends to define a perimeter of the speaker retaining clip. At least a portion of the flange is encased in the foam material of the seat cushion to retain the speaker retaining clip within the seat cushion.

[0008] In another embodiment, a mounting opening is defined in the flange and dimensioned such that the loudspeaker assembly can be received in the mounting opening.

[0009] In another embodiment, the mounting opening includes at least one guide recess configured to align the speaker enclosure relative to the speaker support bracket during installation.

[0010] In another embodiment, the speaker retaining clip has a ridge extending transversely of the flange toward the seating surface of the seat cushion. The ridge has at least one notch, and the retaining device is defined by the notch.

[0011] In another embodiment, the vehicle seat includes the speaker assembly with a transducer in a speaker enclosure. The speaker enclosure has at least one retaining member, and the retaining member engages the notch and holds the speaker assembly to the speaker retaining bracket with an interference fit.

[0012] In another embodiment, the retaining member includes a flexible tab extending from the speaker enclosure, wherein the tab flexes when the tab is inserted through the mounting opening and engages the notch with an interference fit.

[0013] In another embodiment, the tab has a hooked end that snaps over the ridge to lock the speaker assembly to the speaker retaining bracket.

[0014] In another embodiment, the speaker retaining bracket or the speaker enclosure defines a cable opening configured to connect a speaker cable to a speaker disposed in the speaker enclosure.

[0015] In another embodiment, the ridge is disposed along the flange and extends to define at least a portion of the mounting opening.

[0016] In another embodiment, the flange of the speaker support bracket includes a circumferential guide configured to align the speaker support bracket into the seat cushion.

[0017] In another embodiment, the loudspeaker retaining clip is made of polyamide.

[0018] In another embodiment, the vehicle seat includes a frame and the back surface of the seat cushion is disposed on the frame and configured to support an upper body of the occupant.

[0019] In another embodiment, the speaker cavity and the speaker support bracket are arranged along a lumbar region of the seat cushion.

[0020] In another embodiment, the at least one speaker retaining bracket comprises a first bracket and a second bracket arranged symmetrically about a vertical centerline of the seat cushion along first and second lateral sides.

[0021] According to at least one embodiment, a method for assembling a vehicle seat by co-molding a foam material with a speaker retaining clip to form a seat cushion is provided. At least a portion of the speaker retaining clip is encased in the foam material such that the speaker retaining clip is disposed within a speaker cavity sized to receive a speaker assembly. The speaker retaining clip includes at least one retaining feature extending within the speaker cavity to engage the speaker assembly and retain the speaker assembly within the seat cushion.

[0022] In another embodiment, the speaker assembly is inserted into a speaker cavity from a front surface of the speaker retaining clip.

[0023] In another embodiment, the speaker assembly is held to the speaker retaining bracket by means of a press fit.

[0024] In another embodiment, a second speaker retaining clip is molded together and symmetrically into the seat cushion. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a front view of a vehicle seat assembly having a speaker assembly in a seat cushion assembly according to one embodiment. Fig. 1A is a front view of a portion of the vehicle seat assembly of Fig. 1 and shows a speaker cavity in the seat cushion with the speaker assembly removed. Fig. 2 is a rear view of the vehicle seat of Fig. 1. Fig. 2A is a front view of a portion of the vehicle seat assembly of Fig. 1 and shows a rear view of the speaker cavity in the seat cushion with the speaker assembly removed. Fig. 3 is a rear perspective view of a speaker retaining clip for use in the vehicle seating assembly of Fig. 1. Fig. 4 is a rear perspective view of a speaker assembly for mounting in the vehicle seating assembly of Fig. 1 Fig. 5 is a rear view of the speaker retaining bracket mounted to the speaker assembly and removed from the vehicle seat assembly. DETAILED DESCRIPTION

[0025] Embodiments of the present invention are described in detail below. However, it should be understood that the embodiments described herein are merely exemplary of the invention, which may be embodied in various alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or reduced to show details of particular components. The details of construction and function described herein are not to be considered limiting, but merely as a representative basis for one skilled in the art to practice the invention.

[0026] Fig. 1 is a front view of a vehicle seat assembly 100 having a speaker assembly 300 mounted in a seat cushion 102. Fig. 1 shows a seat back 112, but the speaker assembly 300 may also be mounted in a seat cushion of a seat bottom or in another suitable seat cushion for transmitting sound waves to the occupant. In one embodiment, the speaker assembly 300 may be a vibrator speaker or a tactile transducer that emits a bass output at a low frequency. Vibrations at very low frequencies cannot be heard with the ears but can be felt by the seated occupant. By mounting the speaker assembly 300 in the seat cushion 102, the low-frequency signals can enhance the listening experience by providing an additional level of sensory experience to the acoustic output. However, in a vehicle, the vehicle seat assembly 100 and the speaker assembly 300 must meet all safety requirements for protecting the seated occupant.

[0027] The seat cushion 102 is formed from a foam material. For example, the seat cushion 102 may be formed from a polyurethane foam. The seat cushion 102 may be formed from any foam material that provides the required comfort and support for the occupant. Foam materials that meet emissions requirements may also be selected. The foam material may be injection-molded to form the shape of the seat cushion 102.

[0028] As in Fig. 1A in greater detail, the seat cushion 102 defines a speaker cavity 104. The speaker cavity 104 is sized to receive a speaker retaining clip 200 for mounting the speaker assembly 300. The speaker cavity 104 may be sized to accommodate a portion of a speaker retaining clip molded together with the vehicle seat assembly 100 within the speaker cavity 104.

[0029] The seat cushion 102 further defines a lumbar region 106 along a lower portion of the seat back 112 for supporting the lumbar region of an occupant's spine. The speaker cavity 104 may be defined in the lumbar region 106. The occupant's lower spine along the lumbar region 106 is one of the most sensitive areas in the human body, which is also most sensitive to vibrations at an acoustic frequency from the speaker assembly 300.

[0030] The seat cushion 102 may include a plurality of speaker cavities 104. The speakers may be arranged symmetrically about a centerline 114 of the seat back 112. As shown in Fig. 1 to 2, one of the speaker cavities 104 may be disposed in a left portion 108, while another of the plurality of speaker cavities 104 may be disposed in a right portion 110.

[0031] The seat cushion 102 defines a seating surface 120. The seating surface 120 defines the seating surface for supporting the occupant. As shown in Fig. 1, the seat surface 120 defines a front seat surface having a contour including a central seat surface and side cushion surfaces. The speaker cavity 104 may extend from the front seat surface 120 to a rear cushion surface 130 opposite the seat surface 120 as shown in Fig. 2. The speaker cavity 104 may be configured to receive a speaker assembly from the front seat surface 120 as shown in Fig. 1 shown. Fig. 2A is a rear view of the speaker cavity 104. A Fig. The front opening 124 of the speaker cavity 104 shown in Figure 1A has a different shape than one shown in Fig. 2A. The shape of the front opening 124 may be asymmetrical to ensure installation of the speaker assembly 300 with proper alignment.

[0032] Fig. 3 is a rear view of a speaker support bracket 200. The speaker support bracket 200 is configured for mounting a speaker assembly within the speaker cavity 104 so that sound waves can be transmitted through the foam material to a seated occupant. The speaker support bracket 200 may be formed from a plastic material. The speaker support bracket 200 may generally be made from a rigid plastic material sufficiently stiff to allow transmission of vibrations in all desired directions of travel from the speaker assembly 300 including a vibrator or tactile transducer. In one embodiment, the speaker support bracket 200 may be formed from a plastic composite material including glass fibers. In another embodiment, the speaker support bracket 200 may be formed from a plastic composite material including a polyamide composition.The polyamide plastic allows the speaker retaining clip 200 to sufficiently adhere to the foam material of the seat cushion 102 during co-molding so that the speaker retaining clip 200 cannot be easily removed. The speaker retaining clip 200 must be sufficiently secured to the seat cushion 102 so that the speaker assembly 300 can be installed and removed for maintenance without damaging the seat cushion 102, and to ensure that the speaker retaining clip 200 remains attached to the seat cushion 102. In one example, the speaker retaining clip 200 may be formed from polyamide nylon 6.6-30% glass fiber. The speaker retaining clip 200 formed from polyamide with glass fibers may securely adhere to the foam cushion and be sufficiently rigid to retain the speaker assembly 300.Furthermore, an embodiment with a polyamide speaker retaining clip 200 may be suitable for holding the speaker retaining clip 200 in the seat cushion 102 using adhesive substances. In another embodiment, the speaker retaining clip 200 may be formed from a composite material or any other suitable material for attachment to the seat cushion 102 and for holding the speaker assembly 300.

[0033] The speaker mounting bracket 200 is at least partially encased in the foam material of the seat cushion 102. The speaker mounting bracket 200 is disposed at a central position within the speaker cavity 104. The speaker assembly 300 is installed in the speaker mounting bracket 200 such that it does not protrude beyond a predetermined threshold position. The predetermined threshold position may be beyond the seat surface 120. Additionally or alternatively, the predetermined threshold position may be the rear cushion surface 130.

[0034] The speaker mounting bracket 200 has a flange 202. As shown in Fig. 3, the flange 202 may be substantially flat and planar. The flange 202 extends to define a perimeter of the speaker support bracket 200. At least a portion of the flange 202 is encased in the foam material of the seat cushion 102 to retain the speaker support bracket 200 within the seat cushion 102 when the seat cushion 102 is co-molded with the speaker support bracket 200.

[0035] Fig. Figure 4 is a rear view of the speaker assembly 300. The speaker assembly 300 includes a transducer body 306 for generating the acoustic output and converting the electrical input to a mechanical output. The speaker support bracket 200 defines a mounting opening 210 in the flange 202 and is sized to receive at least the transducer body 306 of the speaker assembly 300.

[0036] The speaker support bracket 200 includes a ridge 204 extending transversely from the flange 202. The ridge 204 may define the mounting opening 210. The ridge 204 may include notches 206 that extend less far from the flange 202 than adjacent ridge segments. The notches 206 may be configured to interact with retention members 310 of the speaker assembly 300 to retain the speaker assembly 300 to the speaker support bracket 200 and thereby retain the speaker assembly 300 within the seat cushion 102.

[0037] For example, as in Fig. 4, the retention member 310 may be a flexible tab extending from the speaker enclosure 302. Each tab bends inward when inserted through the mounting opening 210 and then snaps back to engage the notch 206 and retain the speaker assembly 300 to the speaker retention bracket 200 with an interference fit, such as a snap fit. In some embodiments, the flexible tabs may interact with portions of the perimeter of the speaker retention bracket 200 that define the speaker cavity 104.

[0038] As continued in Fig. As shown in Figure 4, the retaining member 310 may include a locking portion 312. The locking portion 312 has a hooked end that snaps over the ridge 204 to snap over the notches.

[0039] The speaker support bracket 200 further defines a front bracket surface 220 and a rear bracket surface 230. The speaker support bracket 200 may be disposed in the seat cushion 102 such that the front bracket surface 220 is offset from the seat surface 120 and the rear bracket surface 230 is offset from the rear cushion surface 130.

[0040] The speaker retaining clip 200 may also include retaining members 208. The retaining members 208 may be used to hold the speaker assembly when inserted into the speaker retaining clip 200.

[0041] The speaker mounting bracket 200 may also include at least one guide recess 212 extending outwardly from the mounting opening 210. The guide recess 212 may cooperate with a guide spring 316 on the speaker assembly 300 to align the speaker assembly 300 during installation of the speaker assembly into the speaker mounting bracket 200.

[0042] Fig. 4 shows a speaker assembly 300. The speaker assembly 300 includes a speaker enclosure 302 and a contact surface 304. The mounting opening 210 of the speaker retaining clip 200 may be sized such that the contact surface 304 cannot pass through the mounting opening 210 and the contact surface 304 abuts the flange 202 along the front surface 220.

[0043] As in Fig. As shown in Figure 5, the speaker assembly 300 is attached to the speaker retaining bracket 200. When the speaker assembly 300 is inserted into the speaker retaining bracket 200, the locking portion 312 can snap over the notch 206 of the speaker retaining bracket 200 and secure the speaker assembly 300 in the speaker retaining bracket 200.

[0044] The speaker assembly 300 may include a cable opening 314 configured to allow a speaker cable to be inserted into the speaker assembly 300. The speaker assembly 300 further includes a guide spring 316 sized to fit within the guide recess 212 of the speaker support bracket 200. When the guide spring 316 is disposed within the guide recess 212, radial and lateral movement of the speaker assembly 300 relative to the speaker bracket 200 may be restricted, thereby securely mounting the speaker assembly 300 within the seat cushion 102. After the speaker assembly 300 is inserted into the speaker support bracket 200, the retention member 208 may contact the speaker enclosure 302 to further restrict lateral movement of the speaker assembly 300.

[0045] The speaker assembly 300 may include a retaining rib 318. As shown, the retaining rib extends between the retaining members 312. The rib 318 may be connected to a corresponding retaining slot 218 in the speaker retaining bracket 200 as shown in Fig. 5 shown interact.

[0046] The vehicle seat arrangement 100 of Fig.15 is formed by co-molding the foam material for the seat cushion 102 and the speaker support bracket 200 to form a seat cushion assembly 116. To this end, the speaker support bracket 200 is positioned within a mold for the seat cushion 102. The flange 202 includes a recess 216 extending inwardly from the periphery and providing a key-lock feature for ensuring proper alignment of the speaker support bracket 200 within the mold. The speaker support bracket 200 may also include additional recesses 214 extending outwardly from the mounting opening 210. The periphery of the speaker support bracket 200 may include protrusions adjacent the recesses 214. The recesses 214 and the corresponding protrusions help ensure that the speaker support bracket 200 does not rotate relative to the seat 102 or the mold.

[0047] The foam material is injected into the mold, and at least a portion of the speaker support bracket is encased in the foam material. In the seat cushion assembly 116, the speaker support bracket 200 is disposed within the speaker cavity 104 formed during injection molding. Co-molding allows the speaker support bracket 200 and the seat cushion 102 to be formed from two different materials with different functional and mechanical properties.

[0048] The speaker assembly 300 is inserted into the speaker cavity after the seat cushion assembly 116 is molded. The speaker assembly 300 is retained in the seat cushion 102 by an interference fit to the speaker retaining clip 200. The interference fit between the speaker assembly 300 and the speaker retaining clip 200 allows the speaker assembly 300 to be retained in the seat assembly 100 without separate mounting hardware.

[0049] The seat cushion 102 may be supported by a seat frame. For example, the rear cushion surface 130 may be positioned on the seat back frame. The seat cushion 102 may also be covered by a covering material such as textile or leather. List of reference symbols 100 Vehicle seating arrangement 102 seat cushions 104 speaker cavity 106 lumbar vertebrae 108 left section 110 right section 112 seat back 114 Center line 120 front seat 124 front cavity opening 130 rear upholstery area 134 rear cavity opening 200 speaker retaining clips 202 flange 204 Ridge 206 notch 208 Holding link 210 Mounting opening 212 Leadership Development 214 opposite recess 216 circumferential recess 218 slot 220 front clamp surface 230 rear clamp surface 300 speaker arrangement

Claims

[1] Vehicle seat (100), comprising: a seat cushion (102) formed from a foam material defining a seating surface (120) for supporting an occupant and a rear surface (130) opposite the seating surface (120), wherein a speaker cavity (104) for receiving a speaker assembly (300) is formed in the seat cushion (102) and extends from the rear surface (130) to the seating surface (120), and at least one speaker retaining clip (200) disposed in the speaker cavity (104), wherein the speaker retaining clip (200) is molded together with the seat cushion (102) such that at least a portion of a flange (202) of the speaker retaining clip (200) is enclosed in the foam material to retain the speaker retaining clip (200) in the speaker cavity (104), wherein the speaker retaining clip (200) has at least one retaining feature (208) extending into the speaker cavity (104) to cooperate with the speaker assembly (300) and retain the speaker assembly (300) in the seat cushion (102), wherein the speaker retaining clip (200) is configured to mount the speaker assembly (300) in the speaker cavity (104) configured to transmit sound waves through the foam material to a seated occupant. [2] The vehicle seat of claim 1, wherein the speaker cavity (104) extends from the rear surface (130) to the seat surface (120), the speaker retaining clip (200) being disposed at a central position in the speaker cavity (104) spaced from the seat surface (120) and not projecting beyond the seat surface (120) and the rear surface (130). [3] The vehicle seat of claim 1 or 2, wherein the flange (202) is substantially planar and extends to define a perimeter of the speaker support bracket (200), at least a portion of the flange (202) being encased in the foam material of the seat cushion (102) to retain the speaker support bracket (200) in the seat cushion (102). [4] A vehicle seat according to any one of the preceding claims, wherein a mounting opening (210) is defined in the flange (202) and is dimensioned such that the loudspeaker assembly (300) can be received in the mounting opening (210). [5] The vehicle seat of claim 4, wherein the mounting opening (210) includes at least one guide recess (212) configured to align the speaker enclosure (302) relative to the speaker support bracket (200) during installation. [6] The vehicle seat of claim 4, wherein the speaker retaining clip (200) further comprises a ridge (204) extending transversely of the flange (202) toward the seating surface (120) of the seat cushion (102), the ridge (204) having at least one notch (206), and the retaining means (208) being defined by the notch (206). [7] The vehicle seat of claim 6, further comprising the speaker assembly (300) having a transducer (306) in a speaker enclosure (302), the speaker enclosure (302) having at least one retaining member (310), and the retaining member (310) engaging the notch (206) and retaining the speaker assembly (300) to the speaker retaining bracket (200) with an interference fit. [8] The vehicle seat of claim 7, wherein the retaining member (310) includes a flexible tab extending from the speaker housing (302), the tab flexing when the tab is inserted through the mounting opening (210) and engaging the notch (206) with an interference fit. [9] The vehicle seat of claim 8, wherein the tab has a hooked end that snaps over the ridge (204) to lock the speaker assembly (300) to the speaker support bracket (200). [10] The vehicle seat of any one of claims 7 to 9, wherein the speaker retaining clip (200) or the speaker housing (302) defines a cable opening (314) configured to connect a speaker cable to a speaker disposed in the speaker housing (302). [11] A vehicle seat according to any one of claims 6 to 10, wherein the ridge (204) is disposed along the flange (202) and extends to define at least a portion of the mounting opening (210). [12] The vehicle seat of any preceding claim, wherein the flange (202) of the speaker support bracket (200) further comprises a circumferential guide means (216) configured to align the speaker support bracket (200) into the seat cushion (102). [13] Vehicle seat according to one of the preceding claims, wherein the loudspeaker retaining clip (200) is made of polyamide. [14] The vehicle seat of any preceding claim, further comprising a frame, wherein the rear surface (130) of the seat cushion (102) is disposed on the frame and configured to support an upper body of the occupant. [15] A vehicle seat according to any one of the preceding claims, wherein the speaker cavity (104) and the speaker support bracket (200) are arranged along a lumbar region (106) of the seat cushion (102). [16] A vehicle seat according to any one of the preceding claims, wherein the at least one speaker support bracket (200) comprises a first bracket and a second bracket arranged symmetrically about a vertical centerline (114) of the seat cushion (102) along first and second lateral sides (108, 110). [17] Assembly method comprising: jointly molding a foam material, a seat cushion (102) of a vehicle seat (100), with a first speaker retaining clip (200), and Enclosing at least a portion of a flange (202) of the first speaker support bracket (200) in the foam material such that the first speaker support bracket (200) is disposed within a speaker cavity (104) sized to receive a speaker assembly (300), wherein the first speaker support bracket (200) includes at least one retainer (208) extending within the speaker cavity (104) and configured to cooperate with the speaker assembly (300) and retain the speaker assembly (300) in the seat cushion (102). [18] The mounting method of claim 17, further comprising inserting the speaker assembly (300) into a speaker cavity (104) from a front surface of the speaker support bracket (200). [19] The assembly method of claim 17 or 18, further comprising holding the speaker assembly (300) to the speaker support bracket (200) with a press fit. [20] The assembly method of claim 17, 18 or 19, further comprising co-molding a second speaker support bracket (200) symmetrically with the seat cushion (102).

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