Modular seat assembly

Abstract

A seat assembly for an automotive vehicle can include a frame and a seat module assembly. The frame can include a seat frame securable to a chassis of the automotive vehicle, and the frame can include a backrest frame connected to the seat frame and movable relative to the seat frame. The seat module assembly can include a seat module releasably securable to the seat frame, and the seat module assembly can include a pair of seat bolster modules individually releasably securable to the seat frame on opposite sides of the seat module. The seat module assembly can include a backrest module releasably securable to the backrest frame, and the seat module assembly can include a pair of side bolster modules individually releasably securable to the backrest frame on opposite sides of the backrest module.

Description

MODULAR SEAT ASSEMBLYCLAIM FOR PRIORITY

[0001] This application claims the benefit of priority of U.S. Provisional Application 63 / 574,190, filed April 3, 2024, which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] In the automotive industry, seat design is an important aspect of vehicle interior engineering, focusing on occupant comfort, safety, and aesthetic appeal. Automotive seats are typically composed of a structural frame, cushioning, and upholstery, each contributing to the overall functionality and comfort of the seat. Ergonomic considerations are important in seat design, with features such as lumbar support and side bolsters being standard to accommodate various body types and preferences. Adjustability features, including seat position and backrest angle, are commonly incorporated to enhance user customization. Material selection for seat components has evolved to include lightweight and high-strength materials, which can contribute to vehicle efficiency and performance. The integration of safety mechanisms, such as airbags, into seat designs has become increasingly complex.

[0003] Manufacturing processes for automotive seats often involves multiple stages and continue to be optimized through automation to improve production efficiency and maintain quality standards. The development of automotive seats continues to be influenced by advancements in materials, manufacturing technologies, and consumer expectations.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0004] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0005] FIG. 1 illustrates an isometric view of an automotive vehicle.

[0006] FIG. 2 illustrates a partially exploded isometric view of a seat assembly.

[0007] FIG. 3 illustrates an isometric view of a partially exploded seat assembly.

[0008] FIG. 4A illustrates an exploded isometric view of a portion of a seat assembly.

[0009] FIG. 4B illustrates an exploded isometric view of a portion of a seat assembly.

[0010] FIG. 5A illustrates an isometric view of a backrest module.

[0011] FIG. 5B illustrates a cross-sectional view of a backrest module.

[0012] FIG. 6 illustrates an isometric view of a seat module.

[0013] FIG. 7 illustrates an isometric view of a seat module.

[0014] FIG. 8 illustrates an isometric view of a portion of a seat module.

[0015] FIG. 9 illustrates a bottom isometric view of a portion of a seat assembly.

[0016] FIG. 10 illustrates a cross-sectional view of a seat assembly across indicators 10-10 of FIG. 9.

[0017] FIG. 11 illustrates a cross-sectional view of a seat assembly across indicators 10-10 of FIG. 9.

[0018] FIG. 12 illustrates an isometric view of a portion of the seat assembly.

[0019] FIG. 13 illustrates an isometric cross-sectional view of a portion of the seat assembly.

[0020] FIG. 14 illustrates an isometric cross-sectional view of a portion of the seat assembly.

[0021] FIG. 15A illustrates an isometric view of a portion of a seat assembly.

[0022] FIG. 15B illustrates an isometric cross-section view of a portion of a seat assembly.

[0023] FIG. 16 illustrates an isometric view of a seat assembly.

[0024] FIG. 17 illustrates an isometric view of a seat assembly.

[0025] FIG. 18 illustrates a cross-sectional view of a seat assembly.

[0026] FIG. 19 illustrates a cross-sectional view of a seat assembly.

[0027] FIG. 20 illustrates a cross-sectional view of a seat assembly.

[0028] FIG. 21 illustrates an isomeric view of a seat assembly.

[0029] FIG. 22A illustrates a cross-sectional view of a seat assembly.

[0030] FIG. 22B illustrates a cross-sectional view of a seat assembly.

[0031] FIG. 23 illustrates a cross-sectional view of a seat assembly.

[0032] FIG. 24 illustrates an isometric view of a seat assembly.

[0033] FIG. 25 illustrates an isometric cross-sectional view of a seat assembly.DETAILED DESCRIPTION

[0034] Seat assemblies are commonly used in automotive vehicles and especially in consumer vehicles; however, typical seat assemblies include a rigid frame covered in foam and surrounded by a trim layer (often fabric or leather). However, such assemblies can be difficult to contour to particular shapes and can be especially difficult to modify following installation. For example, if it is desired to install a seat with a different thickness or to install bolsters of different sizes, the entire seat assembly must be redesigned and often entirely torn down to make a desired change.

[0035] This disclosure helps to address these issues (among others) by providing a seat assembly including multiple seat modules that are discrete from each other and are independently secured to the frame to allow for seat customization. The modules can also be releasably secured to the frame to allow for modifications following initial assembly. For example, if it is desired to have a taller or more supportive seat (e.g., thicker), a seat module can be removed and replaced. If it is desirable to have backrest bolsters with more lateral support, the bolsters can be removed and replaced with thicker or otherwise different side bolsters. Such an assembly can also allow for the primary components to be reused across multiple vehicles in a platform without completely redesigning the seat assembly. These and various other features and benefits are discussed in further detail below.

[0036] The above discussion is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The description below is included to provide further information about the present patent application.

[0037] FIG. 1 illustrates an isometric view of an automotive vehicle 100. The automotive vehicle 100 can be a car, vehicle, automobile, or the like, operable to transport occupants or items over a road or other terrain. The automotive vehicle 100 can include a frame or chassis 102, a drivetrain 104, panels 106, and wheels 108. The wheels 108 can engage with a road or terrain and can be configured to support the automotive vehicle 100. The chassis 102 can support the drivetrain 104, which can be connected to the wheels 108. The drivetrain 104 can be operable to drive the wheels 108 to rotate such as to move the automotive vehicle 100. The panels 106 can be connected to the 102 and can help to reinforce the chassis 102 and improve drag or air resistance during transportation. As discussed in further detail below, the automotive vehicle 100 can also include one or more seats or seat assemblies securable to the chassis 102 and configured to support, and help restrain, occupants within the automotive vehicle 100.

[0038] FIG. 2 illustrates an isometric view of a partially exploded seat assembly 200 that can be located at least partially within the automotive vehicle 100 and can be secured to the chassis 102. FIG. 3 illustrates an isometric view of the seat assembly 200. FIGS. 2 and 3 are discussed together below. The seat assembly 200 can include a frame 202 including a seat frame 204, a backrest frame 206, and a headrest frame 208. The seat assembly 200 can also include a seat module assembly 212 including a seat module 214, seat bolsters 216, a backrest module 218, side bolster module 220, and a headrest module 222.

[0039] The frame 202 can be a rigid or semi-rigid body made of materials such as one or more of metals, plastics, ceramics, composites, combinations thereof, or the like, such as steel, aluminum, titanium, or alloys thereof. The frame 202 can be connected (e.g., bolted or welded) to the chassis 102 to secure the frame 202 to the automotive vehicle 100. As shown most clearlyin FIG. 3, the seat frame 204 can be connected to rails 210, which can be secured (e.g., bolted or welded) to the chassis 102. The seat frame 204 can be connected to the backrest frame 206 and the seat frame 204 and the backrest frame 206 can optionally be movable with respect to the chassis 102 and to each other. The headrest frame 208 can extend upward from the backrest frame 206 and can be connected to or secured to the backrest frame 206. Optionally, the headrest frame 208 can be movable with respect to the backrest frame 206.

[0040] The seat frame 204 can also include a seat actuator 224 operable to move the seat module 214. The seat actuator 224 can include or can be connected to a front seat support 226 or a rear seat support 228, which can be one or more components of the seat frame 204. The front seat support 226 and the rear seat support 228 can be together or individually movable with respect to the seat frame 204. As discussed in further detail below, the seat actuator 224 can be operable to move the front seat support 226 or the rear seat support 228 to move the seat module 214 with respect to the seat frame 204, the backrest frame 206, the seat bolsters 216, and generally the frame 202.

[0041] FIG. 2 shows that the various modules of the seat module assembly 212 can be separate or discrete from each other and from the frame 202. The seat module 214 can be an independent module releasably connectable to the seat frame 204, such as using one or more bolts, tabs, fasteners, or the like, as discussed in further detail below. The seat module 214 can be supported by one or more of the front seat support 226 and the rear seat support 228. The seat bolsters 216 can be seat bolsters or cushions individually releasably connectable to the seat frame 204 such as using one or more bolts, tabs, fasteners, or the like, as discussed in further detail below. The seat bolsters 216 can be located or positioned, when connected to the seat frame 204 on opposing sides of the seat module 214. The seat bolsters 216 can be laterally located or positioned relative to the seat frame 204 and the seat bolsters 216 can each extend upward from the seat frame 204 and optionally at least partially above the seat module 214. The seat module 214 such that the seat bolsters 216 are configured to provide lateral upper leg support, such as during turning of the automotive vehicle 100. Together or independently, theseat module 214 and the seat bolsters 216 can be configured to support the lower portion, e.g., below a waist, such as the posterior and lateral portions of the upper legs of a user, operator, or passenger of the automotive vehicle 100.

[0042] The backrest module 218 can be individually releasably secured or connected to the backrest frame 206 such as using one or more bolts, tabs, fasteners, or the like, as discussed in further detail below. The backrest module 218 can be centrally located (or substantially centrally located) with respect to the backrest frame 206. The side bolster module 220 can be individually releasably secured or connected to the backrest frame 206 such as using one or more bolts, tabs, fasteners, or the like, as discussed in further detail below. The side bolster module 220, when connected to the backrest frame 206, can be located or positioned on opposing lateral sides of the backrest module 218. Each of the side bolster module 220 can extend at least partially fore or forward of the backrest frame 206 and optionally of the backrest module 218. The backrest frame 206 and the side bolster module 220 can, together or independently, be configured to support a posterior portion of a torso, arms, or head of a user, operator, or passenger of the automotive vehicle 100.

[0043] The headrest module 222 can be individually releasably securable to the backrest module or the headrest frame 208. The headrest module 222 can be configured to support at least a posterior portion of a head or cranium of a user, operator, or passenger of the automotive vehicle 100. In operation of some examples, the headrest module 222 can be engageable with the headrest frame 208 to transfer force applied to the headrest module 222 to the headrest frame 208, such as via one or more posts 230. The posts 230 can be posts or pillars extending aft or rearward from the headrest module 222 such as through an opening 232 in an upper portion of the backrest module 218. The posts 230 can be relatively rigid (e.g., made of one or more metals or polymers) sufficient to transfer force to the headrest frame 208. Optionally, the posts 230 can be disconnected (e.g., not fastened or secured) from the headrest frame 208, allowing for transfer of force from the headrest module 222 to the headrest frame 208 while still allowing the headrest module 222 to be removed from the opening 232 following installation.

[0044] At a high level, the relative positioning of the seat module assembly 212 is designed to create a cohesive seating surface that supports the occupant's body in a natural and comfortable alignment. Because the modules of the seat module assembly 212 are independently connected and discrete or separate from each other, the seat module assembly 212 allows for each module to be independently attached and independently removed from the frame 202. This can allow for the seat assembly 200 to be customized by users, such as by including side bolster module 220 of different sizes, can allow for the seat assembly 200 to be modified for incorporation into various vehicles (e.g., allowing the seat assembly 200 to be used across multiple models or platforms), and can allow for the modules to be more easily and quickly be replaced or swapped for different modules. For example, a user may wish to replace standard side bolster module 220 with side bolster module 220 having more lateral support.

[0045] FIG. 4A illustrates an exploded isometric view of a portion of the seat module assembly 212. FIG. 4B illustrates an exploded isometric view of a portion of the seat module 214. The seat module assembly 212 and the seat module 214 can be consistent with FIGS. 2 and 3 discussed above. FIGS. 4A and 4B show additional details of the seat module assembly 212 and the seat module 214, respectively.

[0046] For example, FIG. 4 A shows, more clearly, that the seat module 214 can be shaped with a contoured profile to form the main seating surface. The seat module 214 can have a convex curvature along its length to support thighs or upper legs of an occupant and the seat module 214 can have a concave curvature across its width to cradle or support hips of the occupant, which can help to promote weight distribution and comfort.

[0047] Surrounding the seat module 214 are the seat bolsters 216, which can be positioned or located on either side of the insert. The seat bolsters 216 can have or define a relatively pronounced curvature, which can extend upwards and inwards, creating a boundary that enhances the lateral stability of the occupant. The seat bolsters 216 can be shaped with a smooth transition from the lower seating area to the upper lateral support region, ensuring a seamless interface between the components.

[0048] The backrest module 218 can have an ergonomic profile that aligns with the natural curvature of the spine. For example, the backrest module 218 can include a pronounced lumbar support area that protrudes slightly to provide targeted support to the lower back. The upper portion of the backrest module 218 can be shaped or sculpted to accommodate shoulder blades, allowing for a relaxed shoulder position. The headrest module 222 is situated at the top of the assembly and is designed with a shape that supports the head and neck. The headrest module 222 may have a slight forward tilt and a curvature that cradles the back of the head, ensuring comfort and safety.

[0049] As shown in FIG. 4B, the seat module 214 can include a seat substrate 234, a seat foam layer 236, and a seat cover layer 238. The seat substrate 234 can be a rigid or semi-rigid body made of materials such as one or more of metals, plastics, ceramics, composites, combinations thereof, or the like, such as steel, aluminum, titanium, polymer, carbon fiber, or the like. The seat substrate 234 can be securable to the seat frame 204, such as to secure the seat module 214 to the frame 202. The seat substrate 234 can be shaped to support the seat module 214 and the seat substrate 234 can include one or more contours configured to form a shape or profile of the seat module 214. In other words, the seat substrate 234 can be used to form precision comfort features of the seat module 214 to which the seat foam layer 236 and the seat cover layer 238 can conform.

[0050] The seat foam layer 236 can be a relatively soft body comprised of relatively flexible and conformable materials such as an elastomeric foam. For example, the seat foam layer 236 can be an elastomeric layer, the seat foam layer 236 can be adjacent a top portion or surface of the seat substrate 234. The seat foam layer 236 can be shaped to conform to the seat substrate 234 and the seat module 214, providing a cushioned layer that may vary in density and firmness to achieve the desired comfort level.

[0051] The seat cover layer 238 can be a fabric, leather, cloth, polymer, nylon, rayon, or other relatively thin, flexible, and durable material. The seat cover layer 238 can connected to or securable to the seat substrate 234 and can be configured to, together with the seat substrate 234, at least partially(e.g., totally) enclose the seat foam layer 236. The seat cover layer 238 can be configured or tailored to fit snugly over the seat foam layer 236, with a surface that can include texturing, stitching, or other design elements for aesthetic appeal and functionality. Overall, the components within FIG. 4A are arranged to create a harmonious and functional seat assembly, with each part contributing to the seat's ergonomic design and occupant comfort.

[0052] FIG. 5 A illustrates an isometric view of the backrest module 218 showing indicators 5B-5B. FIG. 5B illustrates a cross-sectional view of the backrest module 218 across indicators 5B-5B of FIG. 5A. FIGS. 5A and 5B are discussed together below. The backrest module 218 of FIGS. 5A and 5B can be consistent with the backrest module 218 discussed above. FIGS. 5A and 5B discuss additional details of the backrest module 218.

[0053] The backrest module 218 can be constructed similarly the seat module 214 in that the backrest module 218 can include a backrest substrate 240, a backrest foam layer 242, and a backrest cover layer 244. The backrest substrate 240 can be a structural component or assembly that forms or provides support or rigidity of the backrest module 218. The backrest substrate 240 can be vertically orientated to align with a spine of the seat occupant. The backrest substrate 240 can be constructed from materials that offer both rigidity and flexibility, such as polymer, reinforced polymers, composites, or lightweight metals, which can provide support and comfort for the back. As shown in FIG. 5A, the backrest substrate 240 can include a curvature that conforms to a natural shape of the human back, promoting an ergonomic seating posture. The upper portion of the backrest substrate 240 can be contoured to support shoulders and can include integrated features for attaching a headrest or other components.

[0054] The backrest foam layer 242 can be a relatively soft body comprised of relatively flexible and conformable materials such as an elastomeric foam. For example, the backrest foam layer 242 can be an elastomeric layer. The backrest foam layer 242 can be adjacent a front or forward portion or surface of the backrest substrate 240. The backrest foam layer 242 can be shaped to conform to the backrest substrate 240 and the backrest module 218, providing a cushioned layer that may vary in density and firmness to achievethe desired comfort level. The backrest module 218 can optionally include multiple pieces of foam or can include one continuous piece of foam.

[0055] The backrest cover layer 244 can be a fabric, leather, cloth, polymer, nylon, rayon, or other relatively thin, flexible, and durable material. The backrest cover layer 244 can connected to or securable to the backrest substrate 240 and can be configured to, together with the backrest substrate 240, at least partially (e.g., totally) enclose the backrest foam layer 242. The backrest cover layer 244 can be configured or tailored to fit snugly over the backrest foam layer 242, with a surface that can include texturing, stitching, or other design elements for aesthetic appeal and functionality.

[0056] As shown in FIG. 5B, the backrest substrate 240 of the backrest module 218 can include one or more character geometries 246, which can be breaks, forms, curves, bends, or the like formed into the 240. The backrest cover layer 244 can be configured such that when the backrest cover layer 244 is secured to the backrest substrate 240, the backrest cover layer 244 can conform to one or more of the character geometries 246 of the backrest substrate 240 to form one or more aesthetic features 248 when the backrest cover layer 244 is secured to or attached to one or more of the backrest substrate 240 and the backrest foam layer 242. In this way, the backrest substrate 240 (and the backrest module 218, generally) can be used to

[0057] Similarly, the backrest substrate 240 of the backrest module 218 can include one or more comfort geometries 250, which can be breaks, forms, curves, bends, or the like formed into the 240. The backrest cover layer 244 can be configured such that when the backrest cover layer 244 is secured to the backrest substrate 240, the backrest cover layer 244 can conform to one or more of the comfort geometries 250 of the backrest substrate 240 to form one or more comfort features 252 when the backrest cover layer 244 is secured to or attached to one or more of the backrest substrate 240 and the backrest foam layer 242.

[0058] FIG. 6 illustrates an isometric view of the seat module 214 from a bottom perspective. The seat module 214 of FIG. 6 can be consistent with the seat module 214 discussed above. FIG. 6 shows additional details of the seat module 214. For example, FIG. 6 shows how the seat cover layer 238can include end portions 254a-254d (collectively referred to as end portions 254). Each of the end portions 254 can be a portion of the seat cover layer 238 at or near a periphery or perimeter of the seat cover layer 238. As indicated by the arrows of FIG. 6, the end portions 254 can be configured to wrap around ends of the seat substrate 234 to at least partially surround the seat foam layer 236 and to secure the seat cover layer 238 to the seat substrate 234. Connection or securing of the seat cover layer 238 to the seat substrate 234 is discussed in further detail below.

[0059] FIG. 6 also shows that the seat substrate 234 can include or at least partially define conditioned air passages 266 that can be bores, holes, or openings extending at least partially through one or more of the seat substrate 234 and the seat foam layer 236. As discussed in further detail below, the conditioned air passage 266 can be configured to deliver conditioned air to the seat module 214 and therefore to an occupant.

[0060] FIG. 7 illustrates an isometric view of the seat module 214. The seat module 214 of FIG. 6 can be consistent with the seat module 214 discussed above. FIG. 7 shows additional details of the seat module 214. For example, FIG. 7 shows that the seat substrate 234 can include projection 256a - projection 256n (collectively referred to as projections 256). The projections 256 can each extend from a lower surface 258 of the seat substrate 234, such as on an underside of the seat substrate 234, and the projections 256 can each extend laterally inward such that the projections 256 along the perimeter face each other. The projections 256 can form gap between each of the projections 256 and the lower surface 258 of the seat substrate 234.

[0061] FIG. 7 also shows that the end portion 254b and the end portion 254d can include openings, such as opening 260a - 260n (collectively referred to as openings 260). Though FIG. 7 shows that each end portion can include 6 openings connecting to 6 projections, the seat cover layer 238 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or the like openings and the seat substrate 234 can include a matching number of projections 256.

[0062] As also shown in FIG. 7, the 238 can include a bar 262 (or bars 262) located at or near a perimeter of the seat cover layer 238, such as in each of the end portions adjacent or near the openings 260. The bars 262 can beconnected to or at least partially embedded in the seat cover layer 238. The bars 262 can be configured to reinforce the openings 260 and can be used to provide leverage or a grasping surface for an installing operator, a technician, or a machine installing the seat cover layer 238. That is, the bars 262 can be used to position the openings 260 over the projections 256 to hook the openings 260 on the projections 256 such that the bars 262 are located in the gap between the projections 256 and the lower surface 258, securing the seat cover layer 238 to the seat substrate 234. The end portion 254a, the end portion 254b, and the end portion 254c can be similarly connected to secure the seat cover layer 238 to the seat substrate 234.

[0063] FIG. 8 illustrates an isometric view of a portion of the seat module 214. The seat module 214 of FIG. 8 can be consistent with FIG. 2 - FIG. 7 discussed above. FIG. 8 shows additional details of the seat module 214. For example, FIG. 8 shows the projection 256a and how the projection 256a can extend upward from the lower surface 258 of the seat module 214 and can extend laterally inward to form a gap G between the projection 256a and the lower surface 258 that can be configured to receive, for example, the opening 260a and the bar 262 of the end portion 254a of the seat cover layer 238. As indicated by the arrow of FIG. 8, the seat cover layer 238 can be manipulated such that the bar 262 of the end portion 254a is pulled up and over the projection 256a into the gap G to secure the seat cover layer 238 to the seat substrate 234.

[0064] FIG. 9 illustrates a bottom isometric view of a portion of the seat assembly 200. More specifically, FIG. 9 shows an underside of the seat module 214 connected to the seat frame 204. The seat assembly 200 of FIG. 9 can be consistent with FIG. 2 - FIG. 8 discussed above; FIG. 9 shows additional details of the seat module 214. For example, FIG. 9 shows that front seat support 226 and the rear seat support 228 can be connected to the seat frame 204 (or can be a component thereof), seat actuator 224, which can be a motor, actuator, or the like, connected to the seat substrate 234 and the seat frame 204. As discussed in further detail below, the seat actuator 224 can be operable to move the seat substrate 234 with respect to the seat frame 204 and with respect to other modules of the seat assembly 200.

[0065] FIG. 9 also shows that the seat assembly 200 can include a plenum 268 connected to an underside of the seat substrate 234. The plenum 268 can be connected to the lower surface 258 of the seat substrate 234 (e.g., via bonding, adhesive, or fasteners), or can be integrally formed into the seat substrate 234. The seat assembly 200 can also include a seat fan 270 connected to the plenum 268. The seat fan 270 can be operable to generate flow of conditioned air through the conditioned air passage 266 or can motivate air to flow from (i.e., through the seat cover layer 238, the seat foam layer 236, and the seat substrate 234), as discussed in further detail below.

[0066] FIG. 10 illustrates a cross-sectional view of the seat assembly 200 across indicators 10-10 of FIG. 9. The seat assembly 200 of FIG. 10 can be consistent with FIG. 2 - FIG. 9 discussed above; FIG. 10 shows additional details of the seat module 214. For example, FIG. 10 shows that the seat module 214 can include several features configured to promote airflow through the seat module 214. As discussed above, the seat module 214 can include conditioned air passages 266, which can extend through the seat substrate 234 and through the seat foam layer 236. Some of the conditioned air passages 266 266 can extend only through the seat foam layer 236, while some of the conditioned air passage 266 can extend through both the seat substrate 234 and the seat foam layer 236. The conditioned air passages 266 266 can be integrally formed into the seat substrate 234 and the seat foam layer 236. The conditioned air passages 266 can optionally be at least partially defined by the seat substrate 234.

[0067] FIG. 10 also shows that the seat fan 270 can be connected to the plenum 268 by one or more fasteners 272, which can be clips, screws, bolts, adhesive, or the like. Optionally, the seat fan 270 can be directly connected to the plenum 268.

[0068] FIG. 11 illustrates a cross-sectional view of the seat assembly 200 across indicators 10-10 of FIG. 9. The seat assembly 200 of FIG. 11 can be consistent with FIG. 2 - FIG. 10 discussed above; FIG. 11 shows additional details of the seat module 214. For example, FIG. 11 shows how the seat module 214 can operate.

[0069] More specifically, in operation of some examples, the seat fan 270 can be operated to generate flow as indicated by the arrows. At location 1 (noted in FIG. 11), ambient air can enter the seat cover layer 238 through perforation holes in the seat cover layer 238. The air can then flow tangentially within a spacer 274 located at least partially within in the seat cover layer 238. The spacer 274 can be one or more opening, passageway, duct, or plenum within or of the seat cover layer 238, the seat foam layer 236, or therebetween. Within the spacer 274, air can flow to the seat foam layer 236 and can enter one or more of the conditioned air passages 266 to flow through the 236 and enter a channel 276 in or of the seat substrate 234. The channel 276 can be a portion of the plenum 268 or can be one or more opening, passageway, duct, or plenum within or of the seat substrate 234. The channel 276 can transmit or allow passage of air to the channel 276 and to the seat fan 270, which can discharge the air from the system (e.g., to an ambient environment of the automotive vehicle 100). In other instances, the flow can be reversed and conditioned air can be delivered to the seat module 214 via the seat fan 270 and the conditioned air can be discharged through the seat cover layer 238.

[0070] The seat module 214 can thereby provide cooling airflow through the seat cover layer 238 to help keep an occupant of the vehicle comfortable while providing all the flexibilities and benefits of a seat module (discussed above) and of a seat module assembly (also discussed above).

[0071] FIG. 12 illustrates an isometric view of a portion of the seat assembly 200 and shows portions of the seat module assembly 212 in phantom. More specifically, FIG. 12 shows a backrest rear cover 278 over the backrest substrate 240 of the seat module assembly 212. FIG. 12 also shows a backrest fan 280 connected to a rear portion of the backrest substrate 240. The backrest fan 280 can be located between the backrest substrate 240 and the backrest rear cover 278, such that the backrest fan 280 is not visible to occupants of the automotive vehicle 100.

[0072] FIG. 12 also shows that the backrest substrate 240 can include a backrest plenum 282 formed (e.g., integrally formed) at least partially into the backrest substrate 240. The backrest plenum 282 can be one or moreopening, passageway, ducts, or the like, configured to transmit fluid (e.g., air). The backrest plenum 282 can be connected to one or more air passages 284 that can extend through the backrest foam layer 242 and can deliver air from the backrest cover layer 244. In operation of some examples, the backrest fan 280 can be operable to generate air to flow through openings in the backrest cover layer 244 (and optionally through a channel between the backrest cover layer 244 and the backrest foam layer 242 (similar to the channel of the seat module 214)). The air can be motivated further by the backrest fan 280 to flow into the air passages 284 and into the backrest plenum 282 where the air can be collected and routed to the backrest fan 280 before being discharged to an environment of the automotive vehicle 100. By integrating the backrest plenum 282 into a rear portion of the backrest substrate 240, a front portion (or an occupant-facing portion or surface) can remain available to be configured or designed for comfort.

[0073] FIG. 13 illustrates an isometric cross-sectional view of the backrest module 218 across indicators 13-13 of FIG. 12. FIG. 14 illustrates an isometric cross-sectional view of a portion of the seat assembly across indicators 14-14 of FIG. 12. FIGS. 13 are 14 are discussed together below. The backrest module 218 of FIGS. 13 and 14 can be consistent with FIG. 2 - FIG. 12 as discussed above. FIG. 13 and FIG. 14 show additional details of the backrest module 218. For example, FIG. 13 shows, more clearly, how the backrest plenum 282 can be formed, at least in part, by the backrest substrate 240 (shown in phantom). The backrest plenum 282 can also be formed, at least in part, by the backrest foam layer 242, in that the backrest foam layer 242 can at least partially enclose the backrest plenum 282. That is, the backrest plenum 282 can be between the backrest foam layer 242 and the backrest substrate 240. In other portions or areas (or an entirety) of the backrest substrate 240, the backrest substrate 240 can form both sides (or all sides) of the backrest plenum 282. FIG. 13 also shows how the backrest fan 280 can connect to the backrest plenum 282 such that the backrest fan 280 and the backrest plenum 282 are fluidically connected.

[0074] FIG. 14 shows that, at a lower portion of the backrest module 218, the backrest plenum 282 can include channels 286. The channels 286 can be one or more opening, passageway, ducts, or the like, configured to transmitfluid (e.g., air). The channels 286 can be formed into the backrest foam layer 242, at least in part, such that air can travel in the backrest foam layer 242. This can allow the channels 286 to be located in front of one or more lumbar bladders 288, which can be located between the backrest substrate 240 and the backrest foam layer 242. The backrest module 218 can thereby allow for a multi-piece modular assembly that is discretized and can also accommodate seat conditioning and other comfort features.

[0075] FIG. 15A illustrates an isometric view of a portion of the seat assembly 200, namely the seat module 214. FIG. 15B illustrates an isometric cross-section view across the plane of FIG 15A of the seat module 214. The seat module 214 can be consistent with FIG. 1 - FIG. 14 discussed above. FIG. 15A and FIG. 15B show additional details of the seat module 214. For example, FIG 15A shows that the seat module 214 can include a fabric layer 290 connected to the seat substrate 234. The fabric layer 290 can be made of a polymer-elastic woven blend. However, the fabric layer 290 can be made of other materials including one or more of polymer, elastic, cotton, silk, or the like.

[0076] The fabric layer 290 be shaped to conform to the contours of the seating area of the seat module 214, such as to help improve comfort of the seat module 214. The fabric layer 290 can also be configured to obtain a desired flexibility of a portion of the seat module 214 such that the seat module 214 can have regions or zones of different stiffness or flexibility where a zone Z2 can have a higher flexibility (or lower stiffness) than a zone Z1 or a zone Z2 of the seat module 214. This can allow a stiffness of the zones of the seat substrate 234 to be precisely controlled.

[0077] FIG. 15B shows additional details of the fabric layer 290, such as that the substrate support 292 can be adjacent a substrate support 292, which can be a polymer (or other rigid or semi-rigid material, such as one or more lightweight metals). A thickness of the substrate support 292 can be relatively smaller or thinner than a thickness of the seat substrate 234 in other zones, helping to increase the flexibility in the zone Z2, while the fabric layer 290 can help to absorb shock and forces applied to the seatsubstrate 234, helping to reduce fatigue in the zone Z2 of the seat substrate 234.

[0078] The substrate support 292 can be a foundation layer upon which fabric layer 290 is affixed. The substrate support 292 and the fabric layer 290 can be bonded together using an overmolding process, where the substrate material is molded around the fabric layer 290 to create a secure and seamless bond. The overmolding process can allow the fabric layer 290 to become an integral part of the seat substrate 234, helping to enhance durability and wear resistance of the seat substrate 234. The relative positioning of the fabric layer 290 within the seat substrate 234 can be such that the fabric layer 290 is flush with or slightly recessed below the surrounding substrate surface. This arrangement can provide a smooth transition between the different materials of the seat substrate 234 and can contribute to the overall comfort and appearance of the seat module 214. The fabric layer 290 can also include one or more cooling ports 294 to allow for air to pass through the seat substrate 234 as discussed above.

[0079] FIG. 15B also shows that the seat substrate 234 can include a substrate clamp 296 that can be overmolded around at least a portion (or optionally an entirety) of a perimeter or periphery of the fabric layer 290 to provide support for the fabric layer 290 and to help prevent separation between the fabric layer 290 and the seat substrate 234. The substrate clamp 296 can include tool features 298 that can receive one or more tool components to hold the fabric layer 290 in place during the overmolding process. The fabric layer 290 can also include holes aligned with the substrate clamp 296 to receive the tool components to help secure the fabric layer 290 in place during overmolding.

[0080] FIG. 16 illustrates an isometric view of the seat assembly 200. The seat assembly 200 of FIG. 16 can be consistent with the seat assembly 200 of FIG. 2 - FIG. 15B discussed above. FIG. 16 shows additional details of the seat assembly 200. For example, FIG. 16 shows that the seat module 214 can be a movable component of the seat assembly 200, which can be motivated to move by the seat actuator 224. The seat module or insert 214 can be designed with a contoured surface to provide comfort and support to theoccupant's lower body. As discussed above, the seat bolsters 216 can be static or affixed to the seat frame 204 such that the seat bolsters 216 do not move or translate.

[0081] FIG. 16 shows one example of how the seat module 214 can move, which is such that a front portion of the seat module 214 can tilt, as indicated by the dashed lines (showing a range of motion) and an arrow (showing a direction of movement). The relative movement between the seat module 214 and the seat bolsters 216 can be a vertical adjustment, where lowering the seat module 214 can decrease thigh support while increasing the prominence of the bolsters 216 for enhanced lateral support, and vice versa. This independent adjustability of the seat module 214 can allow for a customizable seating experience, where the occupant can modify the level of support and comfort according to their preference.

[0082] FIG. 16 also indicates that the side bolster module 220 of the seat assembly 200 can be adjustable. For example, the side bolster module 220 can include one or more internal pneumatic bladders configured to be inflated to various pressure settings to increase or decrease in width or size as indicated by the arrow of the side bolster module 220. For example, one or more of the side bolster modules 220 (or the bladders thereof) can be inflated to expand and thus increase lateral support. Similarly, the side bolster modules 220 can be deflated to reduce a size of the side bolster modules 220 and provide more space between the side bolster modules 220 for an occupant. The movement of the various modules of the seat module 214 can enhance comfort of an occupant and can be adaptable to different body types and seating preferences.

[0083] FIG. 17 illustrates an isometric view of the seat assembly 200. The seat assembly 200 can be consistent with FIG. 2 - FIG. 16 above. FIGS. 17- 24 show additional features of the seat assembly 200, namely various connection features. For example, FIG. 17 shows that the headrest module 222 can include a connector hole 302 that extends through a substrate thereof. The connector hole 302 can be configured to receive a hook 304 of the headrest frame 208 to at least partially secure the headrest module 222 to the seat frame 204. FIG. 17 also shows tabs 306 of the backrest substrate 240that can extend outward and downward from the backrest substrate 240, such as to form a tab or hook feature.

[0084] FIG. 18 illustrates a cross-sectional view of the seat assembly 200 and shows, more clearly how the tab 306 can extend outward and downward from the backrest substrate 240, such as to form a tab or hook feature such as to at least partially wrap around the backrest frame 206, such as to engage a flat portion 308 of the backrest frame 206 to help secure the backrest substrate 240 to the backrest frame 206.

[0085] FIG. 19 illustrates a cross-sectional view of the seat assembly 200 and shows that the backrest frame 206 can include one or more windows 310, which can be holes, bores, openings, or the like, extending at least partially through a portion of the backrest frame 206. FIG. 19 also shows that the side bolster module 220 can include a tower 312, which can be a projection from the backrest substrate 240. The tower 312 can extend from the backrest substrate 240 and can be configured to extend through the window 310 to align the backrest module 218 on the backrest frame 206 and can help to secure the backrest module 218 to the backrest frame 206, such as by limiting lateral movement of the backrest module 218 with respect to the backrest frame 206 through engagement between the window 310 and the tower 312.

[0086] FIG. 20 illustrates a cross-sectional view of the seat assembly 200 and shows that the backrest substrate 240 can include one or more boss 314, which can be can a projection, standoff, or the like, extending at least partially from a rear surface of the backrest substrate 240. The boss 314 can include a bore (which can be threaded) that aligns with a bore of the backrest frame 206. The bores of the backrest frame 206 and the boss 314 can be configured to receive a fastener 316 at least partially therein or therethrough, such as to help secure the hook 304 to the backrest frame 206. Optionally, the fastener 316 can be threadedly secured to the boss 314. The backrest frame 206 can also include a lip 318, which can be a projection, break, or the like of the backrest frame 206 and can be configured to engage an outer portion of the boss 314 such as to help align the backrest substrate 240 with respect to the backrest frame 206.

[0087] FIG. 21 illustrates an isometric view of the seat assembly 200. FIG. 22A and FIG. 22B illustrates cross-sectional views of the seat assembly 200. These figures show how the side bolster module 220 can be connected to the backrest frame 206. As shown in FIG. 22B, the side bolster module 220 can include one or more locator pins 322 that can extend from the side bolster module 220 and can be configured to extends at least partially through bores in the backrest frame 206. The pins 322 can be configured to locate the side bolster module 220 with respect to the backrest frame 206. As shown in FIG. 22A, the seat assembly 200 can also include fasteners fastener 320 that can be configured to extend through holes or bores in the frame and can extend into threaded bores of the side bolster module 220 and can be configured to secure the side bolster module 220 to the backrest frame 206.

[0088] FIG. 23 illustrates a cross-sectional view of the seat assembly 200. The seat assembly 200 can be consistent with the seat assembly 200 of FIG.1 - FIG. 22B discussed above. FIG. 23 shows how the seat module 214 can engage with the seat frame 204. More specifically, FIG. 23 shows a front recess 324 and a rear recess 326 of the seat substrate 234. The front recess 324 can be a recess, saddle, indentation, or the like, which can be concave, curved, or shaped complementary to the front seat support 226 such that the front recess 324 can receive the front seat support 226 at least partially therein to position the seat substrate 234 on the seat frame 204. A rear seat support 228 can be secured to one or more of the seat substrate 234 and the seat frame 204 and can engage an underside of the rear seat support 228 to help prevent disengagement of the front seat support 226 from the seat substrate 234.

[0089] Similarly, the rear recess 326 can be a recess, saddle, indentation, or the like, which can be concave, curved, or shaped complementary to the rear seat support 228 such that the rear recess 326 can receive the rear seat support 228 at least partially therein to position the seat substrate 234 on the seat frame 204. Together, the front recess 324 and the rear recess 326 can orient and locate the seat substrate 234 on the seat frame 204. The seat substrate 234 can also include teeth 330 around the rear recess 326 that can engage a lower portion of the rear seat support 228 to help prevent disengagement of the rear seat support 228 from the seat substrate 234.

[0090] FIG. 24 illustrates an isometric view of the seat assembly 200. FIG. 25 illustrates an isometric cross-sectional view of the seat assembly 200. FIGS. 24 and 25 are discussed together. The seat assembly 200 can be consistent with FIG. 2 - FIG. 23 above. FIGS. 24-25 show additional features of the seat assembly 200, namely various connection features. For example, FIG. 24 shows that the seat assembly 200 can include fasteners 332 configured to secure the seat bolsters 216 to the seat frame 204. FIGS. 24 and 25 also show that the seat bolsters 216 can include one or more tabs 334 that can be configured to engage a laterally outer portion of the seat frame 204. As shown in FIG. 25, the tab 334 can also include ribs configured to engage with portions of the seat frame 204 and other surface geometries.NOTES AND EXAMPLES

[0091] The following, non-limiting examples, detail certain aspects of the present subject matter to solve the challenges and provide the benefits discussed herein, among others.

[0092] Example l is a seat assembly for an automotive vehicle, comprising: a frame comprising: a seat frame securable to a chassis of the automotive vehicle; and a backrest frame connected to the seat frame and movable relative to the seat frame; and a seat module assembly comprising: a seat module releasably securable to the seat frame; a pair of seat bolster modules individually releasably securable to the seat frame on opposite sides of the seat module; a backrest module releasably securable to the backrest frame; and a pair of side bolster modules individually releasably securable to the backrest frame on opposite sides of the backrest module.

[0093] In Example 2, the subject matter of Example 1 optionally includes wherein the seat module assembly comprises: a headrest module releasably securable to the backrest module, the headrest module engageable with the backrest frame to transfer force applied to the headrest module to the backrest frame.

[0094] In Example 3, the subject matter of any one or more of Examples 1- 2 optionally include wherein the backrest module includes a plurality of clips engageable with the backrest frame to releasably secure the backrest module to the backrest frame.

[0095] In Example 4, the subject matter of Example 3 optionally includes wherein each of the pair of side bolter modules includes a plurality of clips engageable with the backrest frame to releasably secure the pair of side bolter modules, independently, to the backrest frame.

[0096] In Example 5, the subject matter of any one or more of Examples 1-4 optionally include wherein each of the pair of side bolter modules and each of the pair of seat bolsters are individually replaceable.

[0097] In Example 6, the subject matter of any one or more of Examples 1-5 optionally include wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

[0098] In Example 7, the subject matter of Example 6 optionally includes wherein the backrest module comprises: a backrest substrate securable to the backrest frame independently of the seat substrate; a foam layer adjacent the backrest substrate; and a cover layer configured to, together with the backrest substrate, enclose the foam layer, the cover layer securable to the backrest substrate.

[0099] In Example 8, the subject matter of Example 7 optionally includes wherein the backrest module includes one or more character geometries, the cover layer configured to conform to the one or more character geometries of the backrest substrate to form one or more aesthetic features when the cover layer is secured to the backrest substrate.

[0100] In Example 9, the subject matter of any one or more of Examples 7- 8 optionally include wherein the seat substrate includes a rigid or semi-rigid polymer.

[0101] In Example 10, the subject matter of any one or more of Examples 7-9 optionally include wherein the backrest module includes one or more comfort geometries, the cover layer and the foam layer configured to conform to the one or more comfort geometries of the backrest substrate to form one or more comfort features when the cover layer and the foam layer are secured to the backrest substrate.

[0102] In Example 11, the subject matter of any one or more of Examples 1-10 optionally include wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

[0103] In Example 12, the subject matter of Example 11 optionally includes wherein the cover layer includes one or more openings each configured to receive a projection of the seat substrate to secure the cover layer to the seat substrate.

[0104] In Example 13, the subject matter of Example 12 optionally includes wherein projections are connected to an underside of the seat substrate and extend laterally inward.

[0105] In Example 14, the subject matter of any one or more of Examples 12-13 optionally include wherein the cover layer includes one or more bars at or near a perimeter of the cover layer.

[0106] In Example 15, the subject matter of Example 14 optionally includes wherein the one or more bars are embedded in the cover layer.

[0107] In Example 16, the subject matter of Example 15 optionally includes wherein the one or more bars are located near each of the one or more openings to reinforce the one or more openings.

[0108] In Example 17, the subject matter of any one or more of Examples 1-16 optionally include an actuator connected to the seat frame and connected to the seat module, the actuator operable to move the seat module relative to the frame and relative to the pair of seat bolsters.

[0109] In Example 18, the subject matter of Example 17 optionally includes a rear seat support connected to the frame and configured to support the seat module at least partially thereon; and a front seat support connected to the frame and configured to support the seat module at least partially thereon, the actuator connected to the frame and the front seat support, the actuator operable to move the front seat support to move the seat module relative to the frame and relative to the pair of seat bolsters.

[0110] In Example 19, the subject matter of Example 18 optionally includes wherein the front seat support is configured to tilt by raising andlowering a front portion of the seat module relative to the frame and relative to the seat bolsters.[OHl] In Example 20, the subject matter of any one or more of Examples 18-19 optionally include wherein the front seat support is configured to translate the seat module fore and aft relative to the frame and relative to the seat bolsters.

[0112] In Example 21, the subject matter of any one or more of Examples 1-20 optionally include wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

[0113] In Example 22, the subject matter of Example 21 optionally includes wherein the seat module comprises: a fabric layer connected to the seat substrate between a forward portion of the seat substrate and a rear portion of the seat substrate.

[0114] In Example 23, the subject matter of Example 22 optionally includes wherein the seat substrate is overmolded onto the fabric layer.

[0115] In Example 24, the subject matter of any one or more of Examples 22-23 optionally include wherein the seat substrate includes a first stiffness region and a second stiffness region, wherein the second stiffness region includes the fabric layer, and wherein the second stiffness region is lower than the first stiffness region.

[0116] In Example 25, the subject matter of Example 24 optionally includes wherein the seat substrate includes a third stiffness region, and wherein the second stiffness region is located between the first stiffness region and the third stiffness region.

[0117] In Example 26, the subject matter of any one or more of Examples 1-25 optionally include wherein the seat module comprises: a seat substrate securable to the seat frame, the seat substrate including one or more ducts integrated into the seat substrate and configured to receive air from the seat assembly.

[0118] In Example 27, the subject matter of Example 26 optionally includes wherein the seat module comprises: a plenum connected to anunderside of the seat substrate and configured to form, together with the seat substrate, the one or more ducts.

[0119] In Example 28, the subject matter of Example 27 optionally includes wherein the seat module comprises: a fan connected to the underside of the seat substrate and configured to be located between the seat substrate and the frame, the fan configured to generate or motivate the air through the one or more ducts and the plenum.

[0120] In Example 29, the subject matter of any one or more of Examples 26-28 optionally include wherein the seat module comprises: a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

[0121] In Example 30, the subject matter of any one or more of Examples 28-29 optionally include wherein the fan is directly connected to the plenum.

[0122] In Example 31, the subject matter of any one or more of Examples 26-30 optionally include wherein the backrest module comprises: a backrest substrate securable to the backrest frame, the backrest substrate including one or more ducts integrated into the backrest substrate and configured to receive air from the seat assembly.

[0123] In Example 32, the subject matter of Example 31 optionally includes wherein the backrest module comprises: a backrest plenum connected to a rear portion of the backrest substrate and configured to form, together with the backrest substrate, the one or more ducts.

[0124] In Example 33, the subject matter of Example 32 optionally includes wherein the backrest module comprises: a fan connected to a back side of the backrest substrate and configured to be located between the backrest substrate and the frame, the fan configured to generate or motivate the air through the one or more ducts and the backrest plenum.

[0125] In Example 34, the subject matter of Example 33 optionally includes wherein the fan is directly connected to the backrest plenum.

[0126] In Example 35, the subject matter of Example 34 optionally includes wherein the backrest module comprises: a backrest foam layeradjacent the backrest substrate; and a backrest cover layer configured to, together with the backrest substrate, enclose the backrest foam layer, the backrest cover layer securable to the backrest substrate.

[0127] In Example 36, the apparatuses or method of any one or any combination of Examples 1 - 35 can optionally be configured such that all elements or options recited are available to use or select from.

[0128] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

[0129] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls. In this document, the terms “including” and “in which” are used as the plain- English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim.

[0130] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

[0131] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

CLAIMSWhat is claimed is:

1. A seat assembly for an automotive vehicle, comprising: a frame comprising: a seat frame securable to a chassis of the automotive vehicle; and a backrest frame connected to the seat frame and movable relative to the seat frame; and a seat module assembly comprising: a seat module releasably securable to the seat frame; a pair of seat bolster modules individually releasably securable to the seat frame on opposite sides of the seat module; a backrest module releasably securable to the backrest frame; and a pair of side bolster modules individually releasably securable to the backrest frame on opposite sides of the backrest module.

2. The seat assembly of claim 1, wherein the seat module assembly comprises: a headrest module releasably securable to the backrest module, the headrest module engageable with the backrest frame to transfer force applied to the headrest module to the backrest frame.

3. The seat assembly of claim 1, wherein the backrest module includes a plurality of clips engageable with the backrest frame to releasably secure the backrest module to the backrest frame.

4. The seat assembly of claim 3, wherein each of the pair of side bolter modules includes a plurality of clips engageable with the backrest frame to releasably secure the pair of side bolter modules, independently, to the backrest frame.

5. The seat assembly of claim 1, wherein each of the pair of side bolter modules and each of the pair of seat bolsters are individually replaceable.

6. The seat assembly of claim 1, wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

7. The seat assembly of claim 6, wherein the backrest module comprises: a backrest substrate securable to the backrest frame independently of the seat substrate; a foam layer adjacent the backrest substrate; and a cover layer configured to, together with the backrest substrate, enclose the foam layer, the cover layer securable to the backrest substrate.

8. The seat assembly of claim 7, wherein the backrest module includes one or more character geometries, the cover layer configured to conform to the one or more character geometries of the backrest substrate to form one or more aesthetic features when the cover layer is secured to the backrest substrate.

9. The seat assembly of claim 7, wherein the seat substrate includes a rigid or semi-rigid polymer.

10. The seat assembly of claim 7, wherein the backrest module includes one or more comfort geometries, the cover layer and the foam layer configured to conform to the one or more comfort geometries of the backrest substrate to form one or more comfort features when the cover layer and the foam layer are secured to the backrest substrate.

11. The seat assembly of claim 1, wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; anda cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

12. The seat assembly of claim 11, wherein the cover layer includes one or more openings each configured to receive a projection of the seat substrate to secure the cover layer to the seat substrate.

13. The seat assembly of claim 12, wherein projections are connected to an underside of the seat substrate and extend laterally inward.

14. The seat assembly of claim 12, wherein the cover layer includes one or more bars at or near a perimeter of the cover layer.

15. The seat assembly of claim 14, wherein the one or more bars are embedded in the cover layer.

16. The seat assembly of claim 15, wherein the one or more bars are located near each of the one or more openings to reinforce the one or more openings.

17. The seat assembly of claim 1, comprising: an actuator connected to the seat frame and connected to the seat module, the actuator operable to move the seat module relative to the frame and relative to the pair of seat bolsters.

18. The seat assembly of claim 17, comprising: a rear seat support connected to the frame and configured to support the seat module at least partially thereon; and a front seat support connected to the frame and configured to support the seat module at least partially thereon, the actuator connected to the frame and the front seat support, the actuator operable to move the front seat support to move the seat module relative to the frame and relative to the pair of seat bolsters.

19. The seat assembly of claim 18, wherein the front seat support is configured to tilt by raising and lowering a front portion of the seat module relative to the frame and relative to the seat bolsters.

20. The seat assembly of claim 18, wherein the front seat support is configured to translate the seat module fore and aft relative to the frame and relative to the seat bolsters.

21. The seat assembly of claim 1, wherein the seat module comprises: a seat substrate securable to the seat frame; a foam layer adjacent the seat substrate; and a cover layer configured to, together with the seat substrate, enclose the foam layer, the cover layer securable to the seat substrate.

22. The seat assembly of claim 21, wherein the seat module comprises: a fabric layer connected to the seat substrate between a forward portion of the seat substrate and a rear portion of the seat substrate.

23. The seat assembly of claim 22, wherein the seat substrate is overmolded onto the fabric layer.

24. The seat assembly of claim 22, wherein the seat substrate includes a first stiffness region and a second stiffness region, wherein the second stiffness region includes the fabric layer, and wherein the second stiffness region is lower than the first stiffness region.

25. The seat assembly of claim 24, wherein the seat substrate includes a third stiffness region, and wherein the second stiffness region is located between the first stiffness region and the third stiffness region.

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