SEAT WITH UNIVERSAL BASE AND SPECIAL UPPER PARTS

Abstract

A method comprises forming a quantity of universal foam backing plates with a base compressive strength, top surfaces and bottom surfaces configured for mounting on a frame; determining desired parameters for a desired seat; constructing trim pieces to form an outer surface; bringing each trim piece into contact with a foam material to form intermediate products, each intermediate product comprising a foam layer and a trim layer, the foam layer having a thickness of at least forty millimeters and having a top compressive strength that is less than the base compressive strength; processing the intermediate products to form shaped top seat sections with a uniform shape, the thickness of each intermediate product ranging from less than ten millimeters to at least forty millimeters;and attaching each molded upper seat section directly to a corresponding universal foam support base to form the seats.

Description

INTRODUCTION

[0001] The technical field generally refers to vehicle seats for motor vehicles, in particular to a seat consisting of a universal base and a top.

[0002] Modern production vehicles, such as the contemporary automobile, are originally equipped with bench seats on the driver's and front passenger's sides, as well as in the rear, providing comfortable seating for the occupants. A vehicle seat assembly may consist of an inner, skeletal seat frame, which is attached to the vehicle body, for example, by a longitudinal sliding rail assembly. The foam cushions lie over and are attached to the frame's complementary wire suspension segments to isolate the occupant from the rigid seat frame. Flexible covers, such as fabric, leather, or vinyl upholstery, conceal any easily visible segments of the frame and foam cushions, forming the seat's usable outer surfaces. Driver-side and front-seat assemblies are characterized by an upper, generally vertical, backrest section that tilts relative to a lower, generally horizontal, seat section.

[0003] As a rule, the seat assemblies for each vehicle model are unique in production. For example, a smaller sports car might have a lower and narrower seat, while an SUV might have a higher and larger seat.

[0004] Accordingly, it is desirable to provide vehicle seats and methods for manufacturing vehicle seats that utilize a universal base suitable for a variety of vehicles and with special upper parts configured to fit the universal base. Furthermore, other desirable features and characteristics of the present description will become apparent from the detailed description below and the attached claims in conjunction with the accompanying drawings and the preceding introduction. DESCRIPTION

[0005] In one embodiment, a method for manufacturing vehicle seats comprises forming a set of universal foam backing plates, each universal foam backing plate having a base compression strength, each universal foam backing plate having a top surface and a bottom surface, and the bottom surface being configured for attachment to a vehicle seat frame; determining desired parameters for a desired vehicle seat; constructing trim pieces to form an outer surface for the desired vehicle seat; contacting each trim piece with a foam material to form intermediate products, each intermediate product comprising a foam layer and a trim layer, the foam layer having a thickness of at least forty millimeters and the foam layer having a top compressive strength that is lower than the base compressive strength;Processing the intermediate products to form shaped upper seat sections with a uniform shape, the thickness of each intermediate product ranging from less than ten millimeters to at least forty millimeters; and attaching each shaped upper seat section directly to the upper surface of a suitable universal foam pad to form the vehicle seats with the desired parameters.

[0006] In certain embodiments, the method further comprises determining second desired parameters for a second desired vehicle seat; constructing second trim parts to form the outer surface for the second desired vehicle seat; contacting each second trim part with the foam material to form second intermediate products, each second intermediate product comprising a second foam layer and a second trim layer, the second foam layer having a second thickness of at least forty millimeters, and the second foam layer having a second upper compressive strength that is lower than the base compressive strength;Processing the second intermediate products to form second molded upper seat sections with a second uniform shape, wherein a second thickness of each intermediate product is in the range of less than ten millimeters to at least forty millimeters; and attaching each second molded upper seat section directly to the upper surface of a respective second universal foam pad to form the second desired vehicle seat with the second desired parameters.

[0007] In certain embodiments of the method, bringing the cladding piece into contact with the foam to form the intermediate product includes pouring a liquid foam onto the cladding piece.

[0008] In certain embodiments of the method, bringing the cladding part into contact with the foam material to form the intermediate product involves placing a foam plate onto the cladding part.

[0009] In certain embodiments of the process, the processing of the intermediate product to manufacture the shaped upper seat part includes the shaping of the intermediate product.

[0010] In certain embodiments of the process, the processing of the intermediate product to manufacture the shaped upper seat part includes thermoforming the intermediate product.

[0011] In certain embodiments, the method further includes the installation of a corresponding vehicle seat into a frame structure located in a vehicle.

[0012] In certain embodiments of the method, each universal foam pad has a circumferential edge; each shaped upper seat part has a hook part; and the attachment of each shaped upper seat part directly to the upper surface of a corresponding universal foam pad to form the vehicle seats with the desired parameters involves the engagement of the corresponding hook part and the circumferential edge.

[0013] In certain embodiments of the method, the universal foam pad and the foam material consist of polyurethane.

[0014] In another embodiment, a seat for a vehicle is provided. The seat comprises a universal foam support base with an upper surface, wherein the universal foam support base has a first compressive strength; a molded upper seat section attached directly to the upper surface of the universal foam support base, wherein the molded upper seat section comprises: a covering layer forming an outer surface of the seat; and a foam layer with a second compressive strength that is lower than the first compressive strength, wherein the thickness of the foam layer varies from less than ten millimeters to at least forty millimeters.

[0015] In certain embodiments of the seat, the universal foam pad is attached to and engaged with a frame structure located in the vehicle.

[0016] In certain embodiments of the seat, the foam layer is formed by pouring a liquid foam onto the covering layer.

[0017] In certain embodiments of the seat, the foam layer is formed by placing a foam plate onto the covering layer.

[0018] In certain embodiments of the seat, the foam layer and the trim layer are processed together to form a molded upper seat part.

[0019] In certain designs of the seat, the foam layer and the trim layer are thermoformed together.

[0020] In certain embodiments of the seat, the universal foam pad has a circumferential edge; the shaped upper seat part has a hook part; and the shaped upper seat part is directly attached to the upper surface of the universal foam pad by the hook part engaging in the circumferential edge of the universal foam pad.

[0021] In certain embodiments of the seat, the universal foam pad and the foam layer are made of polyurethane.

[0022] In another embodiment, a vehicle is provided and comprises a cabin floor; a frame structure attached to the cabin floor; and a vehicle seat engaging with the frame structure, the vehicle seat comprising: a universal foam pad with an upper surface, the universal foam pad having a first compressive strength; a molded upper seat section attached directly to the upper surface of the universal foam pad, the molded upper seat section comprising: a trim layer forming an outer surface of the seat; and a foam layer having a second compressive strength less than the first compressive strength, the thickness of the foam layer varying between less than ten millimeters and at least forty millimeters.

[0023] In certain embodiments of the vehicle, the universal foam pad and the foam layer are made of polyurethane.

[0024] In certain embodiments of the vehicle, the universal foam pad has a circumferential edge; the molded upper seat part has a hook part; and the molded upper seat part is directly attached to the upper surface of the universal foam pad by the hook part engaging in the circumferential edge of the universal foam pad. DESCRIPTION OF THE FIGURES

[0025] The present description is further described below in conjunction with the following drawings, where identical numbers denote identical elements: Fig. 1 is a functional block diagram of a vehicle with one seat according to an example; Fig. 2 is a side view of a vehicle seat frame in the vehicle of Fig. 1, according to exemplary embodiments; Fig. Figure 3 is a schematic cross-sectional view of a vehicle seat, which is located in the seat frame of the Fig. 1 and Fig. 2 is included, according to exemplary embodiments; Fig. Figure 4 is a schematic cross-sectional view of a shaped upper seat part of the vehicle seat. Fig. 3. Fig. Figure 5 is a schematic cross-sectional view of a universal foam pad for the vehicle seat. Fig. 3. Fig. Figure 6 is a flowchart for a process for manufacturing vehicle seats. DETAILED DESCRIPTION

[0026] The following detailed description is merely exemplary and is not intended to limit the application and use of the embodiments described herein. Furthermore, there is no intention to be bound by any express or implied theory set forth in the preceding introduction, the brief summary, or the following detailed description.

[0027] Certain embodiments provide a modular seating system comprising a common lower cushion layer (connected to the seat frame / suspension) that is bonded to an interchangeable upper A-surface (STO) cushion unit made of molded material, the A-surface being available in various shapes and surface finishes. For economies of scale, the lower base layer may be the same for several seat types and is bonded and connected to the frame structure and associated common components, such as springs, etc. The lower base layer may be tuned for comfort support, for example, to test its rigidity so that it does not rest on a metal substrate. This base layer may be made of foam, thermoformed fibers, or a bladder system. Variations of the base layer may exist to accommodate ventilated and non-ventilated seats.

[0028] The upper A-surface layer can have various shapes and designs and is designed to fit together with the lower base layer like a combinable "hat-on-head" system. The upper A-surface layer consists of a molded facing, providing a decorative, aesthetic surface (e.g., vinyl, polyurethane, or fabric), with a comfortable underlay of variable thickness and contour to create the desired A-surface design. The facing and soft backing material composite can be molded or thermoformed. The thickness of the upper A-surface layer can range from 3 mm to over 50 mm. The soft backing material can be polyurethane foam, thermoplastic fibers, or another suitable material.

[0029] The present embodiments are intended to improve the comfort and performance of vehicle seats. Furthermore, the present embodiments enable the manufacture of vehicle seats tailored to specific vehicle models, using a universal base support suitable for a range of vehicle models.

[0030] In certain embodiments, a frame structure is provided to accommodate a vehicle seat for a range of different vehicle models. In other words, various vehicles are equipped with the same frame design. Furthermore, a universal foam pad is configured for attachment to an upper surface of the frame. Finally, a molded upper seat section is designed with a desired shape and size, which can be unique to each specific vehicle model. In other words, each vehicle model can be equipped with its own molded upper seat section. Each molded upper seat section design is configured to be mounted or attached to the universal foam pad.

[0031] The universal foam bases and the specially shaped upper seat parts can be manufactured and then assembled to create the desired vehicle seat, which is then installed in the frame of a vehicle.

[0032] These embodiments provide improved comfort. For example, the universal foam bases can be molded with a first firmness, and each specially shaped upper seat section can be molded with a second firmness that is lower than the first. These embodiments can offer higher quality when two opposing A-surfaces are joined. For example, a lower seat section with an exposed lower STO surface, commonly referred to as the B-surface, can be molded in the lower shell of the foam tool. In this way, liquid polyurethane can be poured directly onto the surface that forms the B-surface of the lower seat section with the same quality as a conventional A-surface.Furthermore, the embodiments contained herein can reduce costs, which is possible through the use of a universal foam pad for all vehicle models due to size advantages.

[0033] In Fig. Figure 1 shows certain features of a vehicle 10 in the form of a functional block diagram. It should be noted that the connecting lines shown in the various figures contained herein serve to illustrate exemplary functional relationships and / or physical connections between the various elements. It should be noted that in an embodiment of the present description, many alternative or additional functional relationships or physical connections may exist.

[0034] In certain examples, vehicle 10 is an automobile. In various examples, vehicle 10 can be any type of automobile, such as a sedan, station wagon, truck, or sport utility vehicle (SUV), and it can have two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), four-wheel drive (4WD), or all-wheel drive (AWD), and / or various other types of vehicles or mobile platforms in certain examples.

[0035] As in Fig. As shown in Figure 1, the example vehicle 10 generally comprises a body 14 and wheels 16. The body 14 essentially encloses the components of the vehicle 10. The body 14 can form an interior cabin 20 with a cabin floor 26. The wheels 16 are each rotatably connected to the vehicle 10 near a corner of the body 14.

[0036] The vehicle 10 further comprises a steering wheel 24 and a vehicle seat backrest 30, which is spaced longitudinally from the steering wheel 24. As indicated, vehicle floor rails 32 can be attached to the cabin floor 26. Furthermore, seat rails 36 can interact with the vehicle base rails 32 to enable sliding engagement. The base rails 32 and / or seat rails 36 can form a vehicle seat frame or a frame structure 40.

[0037] Fig. Figure 2 illustrates the intervention and positioning of the frame structure 40, the seat rail 36 and the vehicle base rail 32.

[0038] As in Fig. As shown in Figure 2, the vehicle base rail 32 extends from a front end 33 to a rear end 34. Furthermore, the seat rail 36 extends from a front end 37 to a rear end 38. The frame 40 and the seat rail 36 can move in a forward direction 21 towards the front end 33 or in a backward direction 22 towards the rear end 34.

[0039] Fig. Figure 3 is a schematic cross-sectional view of a vehicle seat 100 for use with the frame 40 of Fig. 2. As shown, the frame 40 has a top surface 42 and an outer perimeter 45.

[0040] In Fig. 3 The vehicle seat 100 includes a universal foam pad 110. As shown, the universal foam pad 110 has a lower surface 111 and an upper surface 112. In certain embodiments, the universal foam pad 110 is made of polyurethane, polyethylene terephthalate (PET), low-density linear polyethylene, or other suitable materials.

[0041] Furthermore, the vehicle seat 100 contains a foam layer 120. The foam layer 120 has a lower surface 121 and an upper surface 122. In certain embodiments, the universal foam pad 110 is made of polyurethane, polyethylene terephthalate (PET), linear low-density polyethylene, or other suitable materials.

[0042] In certain embodiments, the universal foam pad 110 is firmer than the foam layer 120. Such an arrangement can provide additional comfort. When evaluating a foam product for use in a comfort application, compressive strength can be used. Compressive strength assesses the feel and firmness of a foam by testing how the foam material yields to or supports weight. Compressive strength values ​​can be used to categorize foams.

[0043] Compressive strength is typically assessed using a test called Compression Force Deflection (CFD), also known as Compression Load Deflection (CLD). This is a performance evaluation, and standardization allows for the comparison of all materials tested using this method. The strength of foam can be tested in various ways, but the most common is the 40% compression test according to the ISO 3386-1 test method. This test is typically performed with a foam sample measuring 25 mm thick, 50 mm wide, and 50 mm long. Maintaining this consistency across all tests is crucial because foams can withstand different weights and pressures depending on their thickness and size, even if the sample is cut from the same base material. Thinner foam sections yield more readily under weight, while thicker sections are more elastic.Furthermore, testing products with different dimensions eliminates control over the test and thus the possibility of comparing the results from one material to another.

[0044] The lowest CFD values ​​indicate the softest and best-cushioning foams, as they require the fewest kilopascals to compress. CFD values ​​between 3 and 8 kilopascals generally mean that the foam offers a balanced ratio of comfort and support. CFD values ​​of 9 kilopascals and above represent the most supportive and firmest foams. They are most commonly used for seat cushions that bear the entire weight of a body over a smaller area, such as car seats.

[0045] In addition to the standard 40% compression test, there are additional compressive strength ratings that provide more information about a material. Often, a 50% compression value is determined alongside the 40% CFD data. This value measures the kilopascals required to compress a foam sample to half its height, while a 25% compression value measures the kilopascals required to compress a foam sample to a quarter of its height. This is tested because compression is not necessarily linear, so you cannot simply multiply the 40% compression value to know how it will respond to a greater or lesser force. Many foam types have similar 40% CFD values ​​but very different 25% CFD values.

[0046] Another test is the support factor, also known as the deflection factor or compression modulus. This value is a comparison ratio between the 25% compression value and a lower compression level of 65%. The 25% value is divided by the 65% value, typically resulting in a value between 1 and 3 that more accurately reflects the support capacity than a single test. Since foam is more often compressed to 65% than 25% in practice, this combination yields a performance value, still using the 25% CFD value. The higher the support factor value, the more supportive the material.

[0047] In the present embodiments, the universal foam pad 110 has a higher compressive strength than the foam layer 120. For example, the universal foam pad 110 can have a 40% CFD that is 1.1 to 2.0 times greater than the 40% CFD of the foam layer 120. For example, the universal foam pad 110 can have a 40% CFD that is 1.2 to 1.5 times greater than the 40% CFD of the foam layer 120. Furthermore, the composite of the foam layer 120 and the universal foam pad 110 can have a combined support factor that is at least 1.6, at least 1.7, at least 1.8, at least 1.9, at least 2, at least 2.5, at least 3, at least 4, or at least 5.

[0048] Furthermore, the vehicle seat 100 comprises a trim layer 130. The trim layer 130 comprises a lower surface 131 and an upper surface 132. In certain embodiments, the trim layer 130 is made of a finished material such as leather, imitation leather, vinyl, fabric or another suitable material.

[0049] The foam layer 120 and the covering layer 130 together form a molded upper seat part 200. The molded upper seat part 200 includes an outer edge 205. As in Fig. As shown in Figure 3, the outer edge 205 can form a hook section that engages in the circumference 45 of the frame 40 and / or the circumference 115 of the universal foam pad 110.

[0050] As in Fig. As shown in Figure 3, the lower surface 111 of the universal foam pad 110 fits into or rests against the upper surface 42 of the frame 40. The lower surface 121 of the foam layer 120 fits into or engages with the upper surface 112 of the universal foam support base 110.

[0051] The lower surface 131 of the lining layer 130 fits into or rests against the upper surface 122 of the foam layer 120. Furthermore, the upper surface 132 of the lining layer 130 forms the outer surface 102 of the vehicle seat 100.

[0052] Fig. Figure 4 shows the molded upper seat part 200, which consists of the foam layer 120 and the covering layer 130. As shown, the molded upper seat part 200 has a varying vertical thickness 220. In a thick area, for example, the molded upper seat part 200 may have its greatest thickness, or maximum thickness, from the bottom 121 to the top 132. In a thin area, the molded upper seat part 200 may have its smallest thickness, or minimum thickness, from the bottom 121 to the top 132.

[0053] In certain embodiments, the maximum thickness is at least 30 millimeters (mm), e.g., at least 35 mm, at least 40 mm, at least 45 mm, or at least 50 mm. In certain embodiments, the maximum thickness is not more than 60 mm, e.g., not more than 55 mm, not more than 50 mm, not more than 45 mm, not more than 40 mm, or not more than 35 mm.

[0054] In certain embodiments, the minimum thickness is at least 1 mm, e.g., at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, or at least 10 mm. In certain embodiments, the minimum thickness is not more than 20 mm, e.g., not more than 15 mm, not more than 10 mm, not more than 9 mm, not more than 8 mm, not more than 7 mm, not more than 6 mm, not more than 5 mm, not more than 4 mm, or not more than 3 mm.

[0055] The molded upper seat part 200 can have a thickness difference corresponding to the difference between the maximum and minimum thicknesses. In certain embodiments, the molded upper seat part 200 has a thickness difference of at least 20 mm, such as at least 25 mm, at least 30 mm, at least 31 mm, at least 32 mm, at least 33 mm, at least 34 mm, at least 35 mm, at least 36 mm, at least 37 mm, at least 38 mm, at least 39 mm, at least 40 mm, at least 41 mm, at least 42 mm, at least 43 mm, at least 44 mm, at least 45 mm, at least 46 mm, at least 47 mm, at least 48 mm, at least 49 mm, or at least 50 mm.

[0056] Fig. Figure 5 illustrates the universal foam pad 110. The cross-reference to the Fig. 4 and Fig. Figure 5 shows that the shaped upper seat part 200 is designed and configured to fit onto the upper surface 112 of the universal foam base 110. In particular, the universal foam base 110 can be designed and manufactured such that the upper surface 112 has a known size and contour. Thus, each individually or specially shaped upper seat part 200 is provided with a universal base 121 that fits the upper surface 112.

[0057] It is noted that haptic components 119 can be integrated into the universal foam pad 110 to provide haptic feedback to the driver or passengers. Furthermore, heating components 209 can be integrated into the molded upper seat section 200. The heating components 209 can include heating elements and / or ventilation elements.

[0058] Fig.Figure 6 illustrates a method 600 for manufacturing vehicle seats. As shown, method 600 at 610 can include the design and manufacture of a universal foam support base 110. For example, a universal foam support base 110 can be designed for engagement with and mounting on a standardized frame structure 40.

[0059] Method 600 can be used at 620 to store a quantity of manufactured universal foam underlays 110

[0060] Method 600 includes, in 630, the determination of the desired parameters for a molded upper seat part 200. For example, the space available in a vehicle and other design considerations can be evaluated to determine the shape and size of the vehicle seat as well as the shape and size of the molded upper seat part 200 required to form such a vehicle seat.

[0061] At 640, the process 600 can produce an intermediate product 300 with a foam layer 120 and a trim layer 130. For example, as shown in 641, a trim layer 130 can be selected and cut from a trim material with the desired area. Then, a liquid foam material 129 can be poured onto the trim layer 130 to form a foam layer 120. Alternatively, a solid foam layer 120 can be cut from foam and placed onto the trim layer 130 at 642.

[0062] At 650, process 600 transports the intermediate product 300 for further processing.

[0063] For example, the process at 660 can use the corresponding machine 661 to bring the intermediate product 300 into the desired shape of the formed upper seat part 200. At 660, the process 600 can use a thermoforming process or a forming process to bring the intermediate product 300 into the desired shape of the formed upper seat part 200.

[0064] At 670, the molded upper seat part 200 can be removed from the machine 661 and stored or transported for later use.

[0065] At 680, the process 600 can be continued by placing the molded upper seat part 200 onto a universal foam base 110. As mentioned above, the molded upper seat part 200 can be formed with a hook part that engages in the universal foam base 110. Alternatively or additionally, the molded upper seat part 200 can be glued to the universal foam base 110 at the intermediate interface.

[0066] In the case of 690, the procedure 600 includes the interlocking of the universal foam support base 110 with the frame structure 40 of the vehicle 10, for example to install the vehicle seat 100 in the vehicle 10.

[0067] Although at least one exemplary embodiment has been presented in the preceding detailed description, it should be understood that a multitude of variants exist. It should also be noted that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the description in any way. Rather, the preceding detailed description is intended to provide the person skilled in the art with a practical guide for implementing the exemplary embodiment or embodiments. It is understood that various modifications to the function and arrangement of the elements can be made without departing from the scope of the description as set out in the appended claims and their statutory equivalents.

Claims

[1] A method for manufacturing vehicle seats, wherein the method comprises the following Forming a stack of universal foam support bases, each universal foam support base having a base compressive strength, each universal foam support base having a top surface and a bottom surface, and the bottom surface being configured for attachment to a vehicle seat frame; Determining the desired parameters for a desired vehicle seat; Construction of trim panels that form an outer surface for the desired vehicle seat; Contacting each cladding part with a foam to form intermediate products, each intermediate product comprising a foam layer and a cladding layer, the foam layer having a thickness of at least forty millimeters and the foam layer having a top compressive strength that is less than the base compressive strength; Processing the intermediate products to form shaped upper seat parts with a uniform shape, the thickness of each intermediate product ranging from less than ten millimeters to at least forty millimeters; and Each molded upper seat section is mounted directly onto the top of a suitable universal foam pad to form the vehicle seats with the desired parameters. [2] The method of claim 1, further comprising: Determining the second desired parameter for a second desired vehicle seat; Manufacturing second trim panels to form the outer surface for the second desired vehicle seat; Contacting each second trim piece with the foam to form second intermediate products, each second intermediate product comprising a second foam layer and a second trim layer, the second foam layer having a second thickness of at least forty millimeters and the second foam layer having a second upper compressive strength which is less than the base compressive strength; Processing the second intermediate products to form second shaped upper seat sections with a second uniform shape, wherein a second thickness of each intermediate product is in the range of less than ten millimeters to at least forty millimeters; and Attaching each second molded upper seat section directly to the upper surface of a respective second universal foam pad to form the second desired vehicle seat with the second desired parameters. [3] Method according to claim 1, wherein bringing the cladding part into contact with the foam to form the intermediate product comprises pouring a liquid foam onto the cladding part. [4] Method according to claim 1, wherein bringing the cladding part into contact with the foam to form the intermediate product comprises placing a foam plate onto the cladding part. [5] Method according to claim 1, wherein the processing of the intermediate product to form the shaped upper seat part comprises the shaping or thermoforming of the intermediate product. [6] Method according to claim 1, further comprising the installation of a corresponding vehicle seat in a frame structure located in a vehicle. [7] Method according to claim 1, wherein Every universal foam pad has a surrounding edge; Each shaped upper seat part has a hook part; and the mounting of each shaped upper seat part directly onto the upper surface of a corresponding universal foam pad to form the vehicle seats with the desired parameters, featuring the interlocking of the corresponding hook part and the circumferential edge. [8] A seat for a vehicle which has the following features: a universal foam pad with a top surface, wherein the universal foam pad has a first compressive strength; a shaped upper seat part that is attached directly to the upper surface of the universal foam pad, wherein the shaped upper seat part has: a cladding layer that forms an outer surface of the seat; and a foam layer with a second compressive strength that is lower than the first compressive strength, wherein the thickness of the foam layer varies between less than ten millimeters and at least forty millimeters. [9] Seat according to claim 8, wherein the universal foam pad is attached to and engages with a frame structure located in the vehicle. [10] Seat according to claim 8, wherein: the foam layer and the cladding layer are thermoformed together; the universal foam pad has a surrounding edge; the shaped upper seat part has a hook part; and the shaped upper seat part is attached directly to the upper surface of the universal foam pad by the hook part engaging in the circumferential edge of the universal foam pad.

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