VEHICULAR SEAT

Abstract

There is described a vehicular seat comprising a back element. The back element comprises: (a) a rigid support element having coupled thereto an anchor element, the anchor element configured to be detachably coupled to an article; and (b) a resilient foam element secured with respect to the rigid support element, the resilient foam element configured to be in contact with the back of an occupant of the vehicular seat. In a preferred embodiment, the article is one or more of an occupant restraint element, a cargo element and an automotive accessory. Advantageously, this combination of elements results in a vehicular seat which is of light weight construction and passes the FMVSS 225 test requirement.

Claims

1. A vehicular seat comprising a back element, the back element comprising: (a) a rigid support element having coupled thereto an anchor element, the anchor element configured to be detachably coupled to an article; and (b) a resilient foam element secured with respect to the rigid support element, the resilient foam element configured to be in contact with a back of an occupant of the vehicular seat.

2. The vehicular seat defined in claim 1, wherein the article is one or more of an occupant restraint element, a cargo element and an automotive accessory.

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. The vehicular seat defined in claim 1, wherein the rigid support element has a density in the range of from 1,000 grams per square meter to about 5,000 per square meter

9. (canceled)

10. The vehicular seat defined in claim 1, wherein the rigid support element has a thickness in the range of from about 5 mm to about 25 mm.

11. (canceled)

12. The vehicular seat defined in claim 1, wherein at least a portion of the anchor element is molded into the rigid support element.

13. The vehicular seat defined in claim 1, wherein the anchor element is coupled to the rigid support element with an adhesive.

14. The vehicular seat defined in claim 1, wherein the anchor element is mechanically coupled to the rigid support element.

15. (canceled)

16. The vehicular seat defined in claim 1, further comprising at a plurality of fastener elements, each fastener element configured to mechanically couple the anchor element to the rigid support element.

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. The vehicular seat defined in claim 1, wherein the anchor element comprises at least one first flange portion configured to have a first flange major portion aligned substantially perpendicular with respect to a major surface of the rigid support element.

22. (canceled)

23. (canceled)

24. The vehicular seat defined in claim 1, wherein the anchor element comprises at least one second flange portion configured to have a second flange major portion aligned substantially parallel with a rigid support element major surface.

25. (canceled)

26. (canceled)

27. (canceled)

28. The vehicular seat defined in claim 1, wherein the anchor element has a substantially U-shaped configuration.

29. (canceled)

30. (canceled)

31. The vehicular seat defined in claim 1, wherein the anchor element comprises an attachment portion for coupling to the article.

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. The vehicular seat defined in claim 31, wherein the attachment portion is constructed from a ductile material.

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. The vehicular seat defined in claim 1, wherein the rigid support element is free of a metal frame element.

43. The vehicular seat defined in claim 1, wherein the rigid support element comprises a rigid foam element.

44. (canceled)

45. (canceled)

46. (canceled)

47. The vehicular seat defined in claim 43, wherein the rigid foam element has an indentation force deflection at 25% deflection of from about 500 pounds to about 2,500 pounds when measured pursuant to ASTM 3574-B1.

48. (canceled)

49. (canceled)

50. (canceled)

51. (canceled)

52. The vehicular seat defined in claim 43, wherein the rigid foam element is selected from the group consisting of polyurethane foam, expanded polypropylene, expanded polyethylene and expanded polystyrene.

53. (canceled)

54. (canceled)

55. (canceled)

56. The vehicular seat defined in claim 43, wherein the rigid foam element further comprises a pair of opposed reinforcing layers, each reinforcing layer coupled to a major surface of the rigid foam element.

57. The vehicular seat defined in claim 1, wherein the rigid support element is a laminate comprising a core layer interposed between a pair of opposed reinforcing layers, each reinforcing layer coupled to a major surface.

58. The vehicular seat defined in claim 57, wherein the core layer is a non-foam core layer.

59. The vehicular seat defined in claim 57, wherein the core layer is a non-foam core layer has a substantially honeycomb configuration.

60. (canceled)

61. (canceled)

62. The vehicular seat defined in claim 56, wherein each reinforcing layer comprises a fibrous reinforcing layer.

63. (canceled)

64. (canceled)

65. (canceled)

66. (canceled)

67. (canceled)

68. (canceled)

69. (canceled)

70. (canceled)

71. (canceled)

72. (canceled)

73. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:

[0020] FIGS. 1 and 2 illustrate a preferred embodiment of a portion of the present vehicular seat;

[0021] FIG. 3 illustrates a top view of a preferred embodiment of the anchor portion used in the present vehicular seat;

[0022] FIG. 4 illustrates a side view of the anchor portion illustrated in FIG. 3;

[0023] FIGS. 5 and 6 illustrate isometric views of the anchor portion illustrated in FIG. 3;

[0024] FIGS. 7 and 8 illustrate testing of a preferred embodiment of the back element of the present vehicular seat; and

[0025] FIG. 9 illustrates the forces applied to the back element in the testing done with reference to FIGS. 7 and 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] The present invention relates to a vehicular seat comprising a back element, the back element comprising: a rigid support element having coupled thereto an anchor element, the anchor element configured to be detachably coupled to an article; and a resilient foam element secured with respect to the rigid support element, the resilient foam element configured to be in contact with the back of an occupant of the vehicular seat. Preferred embodiments of this vehicular seat may include any one or a combination of any two or more of any of the following features: [0027] the article is one or more of an occupant restraint element, a cargo element and an automotive accessory; [0028] automotive accessory is a vehicular jack; [0029] the automotive accessory is a cargo mesh element [0030] automotive accessory is an audio system; [0031] the automotive accessory is a child vehicular seat; [0032] the automotive accessory is a child vehicular seat booster; [0033] the rigid support element has a density in the range of from about 1000 grams per square meter to about 5000 per square meter; [0034] the rigid support element has a density in the range of from about 1500 per square meter to about 3500 per square meter; [0035] the rigid support element has a thickness in the range of from about 5 mm to about 25 mm; [0036] the rigid support element has a thickness in the range of from about 10 mm to about 18 mm; [0037] at least a portion of the anchor element is molded into the rigid support element; [0038] the anchor element is coupled to the rigid support element with an adhesive; [0039] the anchor element is mechanically coupled to the rigid support element; [0040] the vehicular seat further comprises at least one fastener element configured to mechanically couple the anchor element to the rigid support element; [0041] the vehicular seat further comprises at a plurality of fastener elements, each fastener element configured to mechanically couple the anchor element to the rigid support element; [0042] the fastener element comprises a push pin; [0043] the fastener element comprises a rivet; [0044] the fastener element comprises a rivet nut; [0045] the fastener element comprises a screw; [0046] the anchor element comprises at least one first flange portion configured to have a first flange major portion aligned substantially perpendicular with respect to the rigid support element major surface; [0047] the at least one first flange portion is configured to be in contact with an inner surface of the rigid support element; [0048] the anchor element comprises a plurality of first flange portions; [0049] the anchor element comprises at least one second flange portion configured to have a second flange major portion aligned substantially parallel with a rigid support element major surface; [0050] anchor element comprises a plurality of second flange portions, each second flange portion configured to have a second flange major portion aligned parallel with a rigid support element major surface; [0051] second flange major portion is configured to be in contact with an outer surface of the rigid support element; [0052] the anchor element comprises a plurality of second flange portions; [0053] the anchor element has a substantially U-shaped configuration; [0054] the U-shaped configuration comprises a cross member interconnect to side members; [0055] the cross member comprises a major axis substantially parallel to a top edge of the rigid support element; [0056] wherein the anchor member comprises an attachment portion for coupling to the article; [0057] the anchor member comprises an attachment portion for coupling to a tether element of a child vehicular seat; [0058] the attachment portion comprises a cross bar element; [0059] the attachment portion comprises a loop element; [0060] the attachment portion comprises a buckle element [0061] the attachment portion comprises a clip element; [0062] the attachment portion is constructed from a ductile material; [0063] the attachment portion is constructed from a metal material; [0064] the anchor element is a unitary element; [0065] the anchor element comprises a first anchor portion and a second anchor portion coupled to each other the first anchor portion and the second anchor portion contact opposed major surfaces of the rigid support element; [0066] the rigid support element is free of a metal frame element; [0067] the rigid support element comprises a rigid foam element; [0068] the rigid foam element has a density in the range from about 1.5 to about 24 pcf; [0069] the rigid foam element has a density in the range from about 2.5 to about 12 pcf; [0070] the rigid foam element has an indentation force deflection at 25% deflection of from about 200 pounds to about 4,000 pounds when measured pursuant to ASTM 3574-B1; [0071] the rigid foam element has an indentation force deflection at 25% deflection of from about 500 pounds to about 2,500 pounds when measured pursuant to ASTM 3574-B1; [0072] the rigid foam element has an indentation force deflection at 25% deflection of from about 900 pounds to about 2,000 pounds when measured pursuant to ASTM 3574-B1, [0073] the rigid foam element has a specific gravity of less than about 0.40; [0074] the rigid foam element has a specific gravity in the range of from about 0.10 to about 0.25; [0075] the rigid foam element comprises an iscyanate-based polymer foam; [0076] the rigid foam element comprises polyurethane foam; [0077] the rigid foam element comprises expanded polypropylene; [0078] the rigid foam element comprises expanded polyethylene; [0079] the rigid foam element comprises expanded polystyrene; [0080] the rigid foam element further comprises a pair of opposed reinforcing layers, each reinforcing layer coupled to a major surface of the rigid foam element; [0081] the rigid support element is a laminate comprising a core layer interposed between a pair of opposed reinforcing layers, each reinforcing layer coupled to a major surface; [0082] the core layer is a non-foam core layer; [0083] the core layer is a non-foam core layer has a substantially honeycomb configuration; [0084] the core layer is a non-foam core layer has a substantially honeycomb configuration such that walls in the honeycomb configuration are oriented transverse to the pair of opposed reinforcing layer; [0085] core layer is a non-foam core layer has a substantially honeycomb configuration such that walls in the honeycomb configuration are oriented orthogonal to the pair of opposed reinforcing layer; [0086] each reinforcing layer comprises a fibrous reinforcing layer; [0087] each reinforcing layer comprises a fiberglass reinforcing layer; [0088] the resilient foam element comprises an isocyanate-based foam; [0089] the resilient foam element comprises a polyurethane foam; [0090] the resilient foam element has a density in the range of from about 1.5 pcf to about 4.5 pcf; [0091] the resilient foam element has an indentation force deflection at 25% deflection of from about 15 pounds to about 175 pounds when measured pursuant to ASTM 3574-B1, [0092] the rigid support element and the resilient secured to one another by an adhesive; [0093] the rigid support element and the resilient secured to one another by a mechanical faster; [0094] the vehicular seat further comprises a trim cover; [0095] the trim cover is configured to substantially all cover exposed surfaces of the resilient foam element; [0096] the trim cover is configured to secure the resilient foam element to the rigid support element; and/or [0097] the trim cover fastened to the rigid support element thereby to secure the resilient foam element to the rigid support element.

[0098] The present vehicular seat comprises a back element. The back element comprises a rigid support element having coupled thereto an anchor portion.

[0099] In one preferred embodiment, the rigid support element is an engineered board comprising rigid foam core such as a polyurethane foam. Non-limiting and preferred examples of suitable polyurethane foams for use in producing the rigid foam element are available from Woodbridge Foam Corporation under the tradename Stratas™. In a highly preferred embodiment the rigid foam core is interposed between a pair of fibrous reinforcing layers secured to major surfaces of the foam core.

[0100] Generally, the polyurethane foam suitable for use in producing the rigid foam element and having the requisite characteristics may be produced from the following general non-limiting formulation (all parts are parts by weight):

TABLE-US-00001 Component Amount Polymer polyol 100-0 parts Polyol 0-100 parts Crosslinker 0-30 parts/100 parts polyol Catalyst 0.05-3.5 parts/100 parts polyol Silicone surfactants 0-1.5 parts/100 parts polyol Water 0.5-3.5 parts/100 parts polyol Isocyanate Adequate quantity for an index of from about 0.60 to about 1.30 ratio of NCO equivalents of NCO reactive sites

[0101] Suitable polymer polyols, polyols and isocyanates are described in U.S. Pat. Nos. 3,304,273, 3,383,351, 3,523,093, 3,939,106 and 4,134,610, Belgian patent 788,115, Canadian Patent 785,835 and “Polymer/Polyols, a New Class of Polyurethane Intermediate”, Kuryla, W. C. et al., J. Cellular Plastics, March (1966). Suitable crosslinkers, catalysts and silicone surfactants are described in U.S. Pat. Nos. 4,107,106 and 4,190,712.

[0102] The preferred foam suitable for use in producing the rigid foam element may produced from the following formulation:

TABLE-US-00002 Component Amount Polymer polyol 100-20 parts Polyol  0-80 parts Crosslinker 5-15 parts/100 parts polyol Catalyst 0.5-1.2 parts/100 parts polyol Silicone surfactants 0.3-1.1 parts/100 parts polyol Water 1.75-2.75 parts/100 parts polyol Isocyanate Adequate quantity for an index of from about 0.80 to about 1.10 ratio of NCO equivalents of NCO reactive sites.

[0103] In another preferred embodiment, the rigid support element comprises a composite laminate structure which need not necessarily comprise a foam core. An example of such a composite laminate structure is commercially available Covestro under the tradename Baypreg™.

[0104] The present vehicular seat also comprises a resilient foam element secured with respect to the rigid foam element, the resilient foam element configured to be in contact with the back of an occupant of the vehicular seat. Preferably, the resilient foam element is a polyurethane foam, more preferably as so-called high resilience (HR) polyurethane foam.

[0105] Preferably, the foamable polymeric composition comprises a polyurethane derived from a to diphenylmethane diisocyanate (MDI)-based system of low index and of a high molecular weight conventional polyol. Such a system is typically completely “water blown” using highly-catalysed odourless amines and a cell regulator. Typically, this system cures at room temperature in about 3 minutes or less. Alternatively, the polyurethane is a tolylene diisocyanate (TDI)-based system of low index and of a high molecular weight conventional polyol. When such a TDI-based system is used, the cells of the foam in the finished padded element must be substantially open. Opening of such foam cells is within the purview of a person skilled in the art and can be accomplished by any convenient means such as crushing, kneading, roll pressing, chemical treatment and the like of the padded element while ensuring that the trim cover is not damaged during this step. It will be appreciated that the liquid foamable polymeric composition may comprise a mixture of MDI-based and TDI-based systems.

[0106] A preferred combination of the rigid foam element and the resilient foam element is commercially available from Woodbridge Foam Corporation under the tradename StructureLite™.

[0107] The back element of the present vehicular seat further comprises an anchor portion that is configured to be coupled to an articule such as a tether element of a child vehicular seat. Preferred features of the anchor portion have been described above. The following description of anchor portion is a preferred embodiment in the context of testing done by the inventor.

[0108] With reference to FIGS. 1-2, there is illustrated a rigid foam element 10. An anchor portion 20 is coupled to rigid foam element 10 in a central portion of the latter. FIG. 2 illustrates an enlarged view from the opposite side of rigid foam element 10 shown in FIG. 1. As can be seen, anchor portion 20 comprises a crossbar 25. Crossbar 25 is configured to be coupled to a tether portion of a child vehicular seat (not shown for clarity).

[0109] Anchor portion 20 is secured to rigid foam element 10 by a series of push pins 30.

[0110] FIGS. 3-6 illustrate various views of anchor portion 20 wherein crossbar 25 has been omitted for clarity.

[0111] Thus, anchor portion 20 comprises a body portion 35 for contact with rigid foam element 10. Anchor portion 20 further comprises a pair of opposed flange portions 40,45 which are configured to contact the side of an aperture in rigid foam element 10 that is configured to receive anchor portion 20.

[0112] Anchor portion 20 further comprises a top flange portion 50 also configured to contact an aperture in rigid foam element 10 configured to receive anchor portion 20.

[0113] Anchor portion 20 further comprises apertures 55 which are configured to receive pushpins 30 to secure anchor portion 20 to rigid foam element 10.

[0114] FIGS. 7-8 illustrate a test rig used for testing the embodiment used in FIGS. 1-2 for compliance with (FMVSS 225) regulatory testing). As shown, a testing rig mimics the forces applied to the seatback during a frontal crash. The purpose of the test to assess whether a particular combination of rigid foam element and anchor portion can withstand vertically applied load of 17.5 kN for 2 seconds (30 seconds ramp up) where the 17.5 kN load is distributed between 3 anchor points. The force applied to the seatback can be seen schematically in FIG. 9 with reference to arrows A.

[0115] The result of the test was that anchor portion 20 remained secured to rigid foam element 10 at the conclusion of the test. There was no failure observed in the test.

[0116] Based on these test results, the inventors have a reasonable basis to predict that similar results would be seen for different rigid foam elements and different designs of the anchor portion. Further, it is believed similar results would be seen once rigid foam element 10 is coupled to a resilient foam element in a vehicular seat where the anchor portion is coupled to the rigid foam element.

[0117] While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.

[0118] All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.