FOAM SEAT CUSHION WITH COVER AND SENSOR FIXINGS

Abstract

A seat cushion comprises a foam body having a first surface and a second surface facing opposite the first surface. A plurality of recesses extends outwards from at least one of the first and second surfaces, and a plurality of recesses are spaced apart from a plurality of protrusions. Each recess extends through one thickness of the foam body from the first surface to the second surface, and at least one recess is associated with at least one sensor and one reference component.

Description

BACKGROUND

[0001] A vehicle seat may have support structures for the seat base and seat back, which include foam padding. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of an example seat. Fig. Figure 2 is a B-side view of a foam body for a seat cushion. Fig. Figure 3 is an enlarged view of a central section of the seat cushion. Fig. 2. Fig. Figure 4 is a view of an opposite side of the seat cushion. Fig. 3. DETAILED DESCRIPTION

[0002] Extensive reference will now be made to embodiments, examples of which are shown in the accompanying drawings. The following detailed description presents numerous specific details to enable a comprehensive understanding of the various described embodiments. However, it will be apparent to a person skilled in the art that the various described embodiments can be implemented without these detailed descriptions. In other cases, known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0003] “One or more” includes a function performed by one element, a function performed by more than one element, e.g. in a distributed form, multiple functions performed by one element, multiple functions performed by multiple elements, or any combination of the foregoing.

[0004] It should also be understood that, although the terms "first / first / first", "second / second / second", etc., are used herein in some instances to describe different elements, these elements should not be restricted by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be referred to as a second contact, and similarly, a second contact could be referred to as a first contact, without altering the scope of the various embodiments described. The first and the second contact are both contacts, but they are not the same contact.

[0005] The terminology used in the description of the various embodiments described herein serves only to describe specific embodiments and is not to be understood as limiting. As used in the description of the various described embodiments and the accompanying claims, the singular forms "a" and "the" also include the plural forms, unless the context clearly indicates otherwise. It is also understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the listed elements.It is further to be understood that the terms “have”, “having”, “including”, “comprises” and / or “comprehensive”, when used in this patent specification, specify the presence of certain features, integers, steps, operations, functions, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, functions, elements, components and / or groups thereof.

[0006] As used here, the term "if" can be understood, depending on the context, as "when" or "at" or "in response to a determination" or "in response to a recognition." Likewise, the phrase "when determined" or "when [a certain condition or event] is recognized" can be interpreted, depending on the context, as meaning "at the time of a determination" or "in response to a determination" or "at the time of recognition [of the certain condition or event]" or "in response to a recognition [of the certain condition or event]."

[0007] It should be understood that terms such as "approximately", "essentially" and "general" are not intended to be limitless and should be interpreted in accordance with how a person skilled in the field would interpret these terms.

[0008] This disclosure relates to a foam seat cushion comprising a plurality of reinforcing elements and a plurality of recessed sections for attaching a cover and sensors, wherein the recesses are arranged in a predetermined ratio to the reinforcing elements.

[0009] Fig. Figure 1 illustrates a seating arrangement 10 according to an exemplary embodiment. The seating arrangement 10 can be used as a vehicle seating arrangement 10 for sitting in a vehicle, such as an automobile, an aircraft, a watercraft, or another seating environment. The seating arrangement 10 has a seat base 12 that can be mounted in a vehicle for motorized adjustable forward and backward as well as up and down movement. The seating arrangement 10 has a seat back 14 that can be pivotally connected to the seat base 12 to generally extend upright with respect to the seat base 12 and to pivot about an axis with respect to the seat base 12.

[0010] The seat back 14 may include a headrest 16, which may be designed to support the head of a seat user. The headrest 16 may be located on the top of the seat back 14. The headrest 16 may be integral with the seat back 14 or be a separate component that is adjustable relative to the top of the seat back 14. The seat base 12 may be designed to support a seat user. In a vehicle application, the seat base 12 may be mounted to a support surface, such as a vehicle floor. It should also be understood that this is only one example of a seat configuration, and that other configurations can also be used.

[0011] In embodiments, the seating arrangement can include one or more sensors 20 that monitor data relating to the seating arrangement 10 and transmit it to one or more vehicle system controllers. In one example, at least one of the sensors 20 includes a seat occupant sensor that can be used to detect the presence of a seat occupant in the seating arrangement 14. In embodiments, the presence of a seat occupant can be used to monitor whether a restraint device 24, e.g., a seat belt mechanism, has been properly secured.

[0012] In embodiments, the seat back 14 and seat base 12 each comprise a foam cushion 22. The foam cushion 22 can be attached to a seat frame (not shown) in a conventional manner using any method generally known in the art. Each foam cushion 22 can consist of one or more foam parts joined together to form the seat component. For example, the foam cushion 22 of the backrest 14 can have a main seat section and various cushion sections. The foam cushions 22 can be of any suitable size and formed from any suitable component configuration. In embodiments, the foam cushions 22 form a contoured shape, e.g., a concave shape, for a suitable seat user seating surface, the concavity of the foam cushions 22 enhancing the seat user comfort and the aesthetic design of the seating arrangement 10.The foam padding 22 of the seat backrest 14 and the foam padding 22 of the seat base 12 can be made independently of each other from any suitable comfort foam material, such as, but not limited to, a suitable elastic polymer, and can be formed independently of each other in any suitable manner. For example, the foam pads 22 can be made of conventional polyurethane foam, soy-based foam, silicone, thermoplastic olefins, thermoplastic urethanes and / or foamed polyurethanes based on natural oils, soy-based polyurethane, polymer fibers, polyester nonwovens, latex foams, and the like. The foam pads 22 are made of any suitable comfort material that provides a soft elasticity when the seating arrangement is flexed during use while a seat user is in a seated position.

[0013] In some embodiments, a cover 26 can be arranged over or on top of the cushions 22 and cover the sensors 20. The cover 26 provides for at least a section of a visible outer surface of the seating arrangement 10. In some embodiments, the cover 26 can comprise a plurality of cover fabric panels that can be joined together in any suitable way, for example, by sewing. The cover fabric panels can be made of any suitable material, such as fabric, leather, vinyl, or combinations thereof.

[0014] In some versions, a seat cushion has a foam core of 30, as in the Fig. Figures 2-4 illustrate the foam body 30, which has a first surface 32 and a second surface 34 facing opposite the first surface 32. In one example, the first surface 32 has an A-side, outwardly facing contoured surface, and the second surface 34 is a B-side, inwardly facing surface. In embodiments, the foam body 30 has a plurality of projections 36 extending outward from the second surface 34. In one example, the projections 36 comprise ribs, webs, bands, or other similar structures.

[0015] In embodiments, the foam body 30 also has a plurality of recesses 38 spaced apart from the plurality of projections 36. In one example, the recesses 38 comprise open areas such as holes, slots, openings, or other similar openings. In embodiments, each recess 38 extends through one thickness of the foam body 30 from the first surface 32 to the second surface 34. In embodiments, the recesses 38 are associated with at least one sensor 20 and a reference component of the reference 26.

[0016] In one example, the majority of projections 36 are formed in a central region of the second surface 34, as shown in Fig. 2 shown.

[0017] In one example, one or more of the recesses 38 are nested within the projections 36. For example, the recesses 38 can be arranged between adjacent projections 36.

[0018] In one example, one or more of the recesses 38 are arranged outside the projections 36.

[0019] In one example, the recesses 38 have one or more sensor recesses 38a and one or more reference component recesses 38b.

[0020] In one example, the reference component recesses 38b are arranged outside the majority of projections 36 and the sensor recesses 38a.

[0021] As in the Fig. As shown in Figures 3-4, in at least one sensor 20 is supported by the foam body 30 by means of the sensor recesses 38a. In one example, the sensor 20 is a seat occupancy sensor as described above. An arrangement of electrical connectors 40 can be used to connect the sensor 20 to one or more system controllers (not shown) in a known manner.

[0022] In one example, one or more sections of the cover 26 are attached to the foam body 30 by means of the cover component recesses 38b. Thus, the cover component recesses 38b serve as attachment points for securing sections of the cover to the seat assembly 10.

[0023] In embodiments, the majority of projections 36 have a majority of ribs extending outwards from the second surface 34. In one example, the ribs have elongated bodies that are longer than they are wide.

[0024] In one example, the majority of ribs have at least one first rib 42 and a majority of second ribs 44 that are oriented transversely, e.g. not parallel, to the first rib 42.

[0025] In one example, the first rib 42 and the plurality of second ribs 44 are each defined by a length L and a width W, where the length L is greater than the width W for each of the first rib 42 and the second ribs 44.

[0026] In one example, the length L of the first rib is 42 greater than the lengths L of the second ribs 44.

[0027] In most embodiments, the majority of second ribs 44 have at least two second ribs 44 that intersect the first rib 42. In one example, this configuration has an H-shape.

[0028] In one example, the two second ribs 44 are perpendicular to the first rib 42 and the two second ribs 44 are parallel to each other.

[0029] In embodiments, the majority of sensor recesses 38a have at least a first and a second sensor recess, wherein the first sensor recess is located on one side of the first rib 42 and the second sensor recess is located on an opposite side of the first rib 42, and wherein the first and the second sensor recess are arranged between the two second ribs 44.

[0030] In embodiments, the majority of reference recesses 38b have at least two pairs of reference component recesses located outside the first and second sensor recesses 38a. For example, the sensor recesses 38a are located near a central region of the foam body 30, and the reference recesses 38b are located outside the central region and adjacent to outer circumferential edges of the foam body 30. In one example, one pair of reference component recesses 38b is located on one side of the first rib 42, and the other pair of reference component recesses 38b is located on the opposite side of the first rib 42, as shown in Fig. 2 shown.

[0031] The present disclosure provides a foam pad design that meets requirements for hip point positioning, comfort, and durability by incorporating an inwardly directed, laterally hollowed-out, H-shaped projection in the foam body of the rear seat cushion. In embodiments, the H-shape increases deflection to achieve the desired hip point while still providing comfort.

[0032] In embodiments, a device comprises: a foam body having a first surface and a second surface facing opposite the first surface; a plurality of projections extending outwards from at least one of the first surface and the second surface; and a plurality of recesses spaced apart from the plurality of projections, each recess extending through a thickness of the foam body from the first surface to the second surface, and at least one recess being associated with at least one of a sensor and a reference component.

[0033] In various embodiments, the device may have any of the following features, either alone or in any combination. For example, the device may further include the first surface having a contoured surface, and the plurality of protrusions being formed in a central region of the second surface.

[0034] For example, the device may further include the fact that the majority of the recesses comprise one or more sensor recesses and one or more reference component recesses.

[0035] For example, the device may further include the fact that one or more sensor recesses are nested within a plurality of protrusions.

[0036] For example, the device may further include the arrangement of one or more of the reference component recesses outside the plurality of protrusions and the plurality of sensor recesses.

[0037] For example, the device may further comprise a cover, wherein the cover is attached to the foam body by means of one or more cover component recesses, and at least one sensor which is supported by the foam body by means of one or more sensor recesses.

[0038] For example, the device may further include the fact that the majority of projections have a majority of ribs extending outwards from the second surface.

[0039] For example, the device may further comprise that the plurality of ribs has at least one first rib and a plurality of second ribs oriented transversely to the at least one first rib.

[0040] For example, the device may further comprise that the at least one first rib and the plurality of second ribs are each defined by a length, a width and a height, wherein the length is greater than the width and the height for each of the at least one first rib and the plurality of second ribs.

[0041] For example, the device may further include the length of the at least one first rib being greater than the lengths of the majority of second ribs.

[0042] For example, the device may further include the fact that the majority of second ribs have at least two second ribs that intersect the at least one first rib.

[0043] For example, the device may further include the fact that the at least two second ribs are perpendicular to the at least one first rib and the at least two second ribs are parallel to each other.

[0044] For example, the device can further have wherein the plurality of recesses has at least one first sensor recess and one second sensor recess, and wherein the first sensor recess is located on one side of the at least one first rib and the second sensor recess is located on an opposite side of the at least one first rib, and wherein the first sensor recess and the second sensor recess are arranged between the at least two second ribs.

[0045] For example, the device may further comprise that the plurality of recesses has at least two pairs of reference component recesses arranged outside the first sensor recess and the second sensor recess, wherein one pair of reference component recesses is arranged on one side of the at least one first rib and the other pair of reference component recesses is arranged on the opposite side of the at least one first rib.

[0046] In embodiments, a seating arrangement comprises: at least one seat cushion comprising a foam body, having a first surface and a second surface facing opposite the first surface; at least one sensor supported by the foam body; a cover arrangement, wherein the cover arrangement covers the at least one sensor and the foam body; and wherein the foam body has: a plurality of projections extending outwards from the second surface; and a plurality of recesses spaced apart from the plurality of projections, each recess extending through one thickness of the foam body from the first surface to the second surface, and wherein at least one recess is associated with at least one of the at least one sensor and the cover arrangement.

[0047] In various embodiments, the seating arrangement can comprise any of the following, either alone or in any combination. For example, the seating arrangement can further comprise the plurality of recesses having a plurality of sensor recesses and a plurality of cover component recesses, wherein the at least one sensor is supported by the foam body by means of one or more sensor recesses, and wherein the cover arrangement is attached to the foam body by means of one or more cover component recesses.

[0048] For example, the seating arrangement may further include the fact that the majority of protrusions have a majority of ribs, including at least one first rib and a majority of second ribs oriented transversely to the at least one first rib.

[0049] For example, the seating arrangement may further comprise that the at least one first rib and the plurality of second ribs are each defined by a length, a width and a height, and wherein the length is greater than the width and the height for each of the at least one first rib and the plurality of second ribs, and wherein the length of the at least one first rib is greater than the lengths of the plurality of second ribs.

[0050] For example, the seating arrangement may further include the fact that the majority of second ribs have at least two second ribs which intersect the at least one first rib.

[0051] For example, the seating arrangement may further comprise that: the one or more sensor recesses have at least one first sensor recess and one second sensor recess, wherein the first sensor recess is located on one side of the at least one first rib and the second sensor recess is located on an opposite side of the at least one first rib, and wherein the first sensor recess and the second sensor recess are arranged between the at least two second ribs; and the one or more reference component recesses have at least two pairs of reference component recesses arranged outside the first sensor recess and the second sensor recess, wherein one pair of reference component recesses is located on one side of the at least one first rib and the other pair of reference component recesses is located on the opposite side of the at least one first rib.

[0052] Although the various examples feature the specific components illustrated in the figures, the embodiments described in this disclosure are not limited to these particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another of the examples. Furthermore, the various figures accompanying this disclosure are not necessarily to scale, and some features may be exaggerated or minimized to show certain details of a particular component or arrangement.

[0053] A person skilled in the art will understand that the embodiments described above are exemplary and not limiting. This means that modifications to this disclosure would be covered by the scope of the claims. Accordingly, the following claims should be examined to determine their actual scope and content.

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