Seat Back for Vehicle

Abstract

A seat back assembly for a vehicle such as an automobile or an aircraft includes a foam support structure. The foam support structure panel is configured to provide a support structure against which the upper body and/or back of a user rests in use. The foam structure may include two or more regions having different foam density and/or firmness.

Claims

1. A seat back assembly comprising: a first support structure, the first support structure being made of a foam material and being configured to provide a support structure against which the upper body and/or back of a user rests in use.

2. A seat back assembly as claimed in claim 1, wherein the first support structure includes expanded polypropylene.

3. A seat back assembly as claimed in claim 1, wherein the first support structure has a molded density of between 30 g/liter and 65 g/liter and/or a firmness of at least 200 N.

4. A seat back assembly as claimed in claim 1, wherein the seat back assembly further includes a second support structure.

5. A seat back assembly as claimed in claim 4, wherein the second support structure includes a rigid panel.

6. A seat back assembly as claimed in claim 5, wherein the rigid panel includes molded plastic and/or a frame.

7. A seat back assembly as claimed in claim 6, wherein the frame includes carbon-fiber.

8. A seat back assembly as claimed in claim 1, wherein the first support structure includes first and second regions, and wherein a molded density of the first region is different from a molded density of the second region.

9. A seat back assembly as claimed in claim 1, wherein the first structure includes third and fourth regions, and wherein a surface compressibility of the third region is different from a surface compressibility of the fourth region.

10. A seat back assembly as claimed in claim 9, wherein the first and second regions are integrally formed.

11. A seat back assembly as claimed in claim 9, wherein the third and fourth regions are integrally formed.

12. A seat back assembly as claimed in claim 1, wherein the first support structure exhibits fire resistive properties.

13. A seat back assembly as claimed in claim 1, further including a cover that extends over at least a part of the surface of the first support structure.

14. A seat back assembly as claimed in claim 1, wherein a molded density and thickness of the first region are different from a molded density and thickness of the second region, and wherein the first region is provided at a position corresponding to the lower back of an occupant use, and the second region is provided at a position corresponding to the upper back of an occupant in use.

15. A seat having a seat back assembly according to claim 1.

16. A method of manufacturing a seat back comprising the step of forming a first support structure from a foam material, wherein the foam material is manipulated so as to have a selected shape and/or geometry.

17. A method as claimed in claim 16 further including the step of securing the first support structure relative to a second support structure such that the foam structure is arranged to provide a support structure against which the upper body and/or back of a user rests in use.

18. A method as claimed in claim 16 wherein the step of forming a first structure includes forming two or more regions from a foam material each region having different foam density and/or firmness.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 is an exploded perspective view showing a schematic illustration of a seat back assembly according to an exemplary embodiment of the present invention.

[0034] FIG. 2 is an enlarged cross-sectional view showing a portion of a seat back assembly according to a second exemplary embodiment.

[0035] FIG. 3a is a perspective view showing a row of aircraft seats each including a cushion assembly according to another exemplary embodiment of the present invention.

[0036] FIG. 3b is a series of perspective views schematically showing the manner of assembly of one of the cushion assemblies shown in FIG. 3a.

[0037] FIG. 4a is a front elevational view of a seat back including a foam structure according to a further exemplary embodiment.

[0038] FIG. 4b is a side elevational view of the seat back illustrated in FIG. 4a.

[0039] FIG. 4c is a sectional elevational view of the seat back illustrated in FIG. 4a taken along line A-A.

[0040] FIG. 4d is a rear perspective view of the seat back illustrated in FIG. 4a.

[0041] FIG. 4e is a front perspective view of the seat back illustrated in FIG. 4a.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] FIG. 1 shows a schematic illustration of a seat back assembly, generally designated 10 according to an embodiment of the present invention. The seat back assembly 10 includes a rigid back panel 2, a support frame 3, and a foam support structure 4. The support frame 3 forms a second support structure of the seat back assembly 10. An engagement mechanism (not shown) is provided to allow the foam support structure 4 to be connected to the support frame 3. For example, the engagement mechanism may include inter-engaging elements respectively located on the foam support structure 4 and the support frame 3. An engagement mechanism (not shown) is also provided to allow the rigid back panel 2 to be connected to the foam support structure 4 and/or the support frame 3.

[0043] In this example, the rigid back panel 2 includes molded plastic and forms a rear surface of “shell” of the seat back assembly 10. The support frame 3 may be made of any suitable metal, plastic, or composite material. The foam support structure 4 is formed of expanded polypropylene having a density of around 55 g/liter.

[0044] In this particular example, and in order to provide superior lumbar support in the region corresponding to the lower back of an occupant in use, the foam support structure 4 includes a first region 5 that exhibits a foam density and a firmness value that is greater than the foam density and the firmness values associated with the rest of the panel.

[0045] FIG. 2 shows a cross-sectional view of a seat back assembly, generally designated 20, according to a second example embodiment. The seat back assembly 20 includes a rigid back panel 22, a support frame 23, and a foam structure 24. The support frame 23 forms a second support structure of the present invention. In this example, the seat assembly is further provided with a cover 25 that extends over the support surface of the seat back assembly 20 and is folded at a top portion thereof and secured to the rigid support back panel 22. Thus, the foam structure 24 is effectively secured in place relative to the support frame 23, which forms a component of the rigid support structure in this embodiment, by the cover 25.

[0046] FIG. 3a shows a row of aircraft seats 31 each including a seat back assembly 30 according to another example embodiment of the present invention. A schematic view of the seat back assembly 30 is shown in FIG. 3b and includes a support frame 33, a foam structure 34, and a cover 35. In this exemplary embodiment, the support frame 33 forms a second support structure of the present invention. The rear surface of the foam structure 34 exhibits a shaped profile including a series of projecting foam elements 34a through 34d. These projecting foam elements 34a through 34d are formed during the molding of the foam structure and serve to cooperate with apertures 33a through 33d provided in the support frame 33 in order to facilitate connection of the foam structure 34 to the support frame 33 and thereby secure the foam structure 34 relative to the support frame 33.

[0047] FIGS. 4a though 4e show a further example of a seat back assembly, generally designated at 40, including a foam structure. FIG. 4a shows a front view of the foam structure which exhibits a varied surface geometry as indicated by contour lines. Thus, either side of the center-line A, and in the mid to lower portion of the seat back, the thickness of the foam structure increases towards the lateral side edges (41a and 41b) of the foam structure. This can be seen more clearly in FIG. 4e, which shows an elevational view of the foam structure. FIG. 4b shows a side view of the foam structure and shows a number of surface features that are integrally formed during the molding of the foam structure. FIG. 4c shows a side-view cross-section of the foam structure, while FIG. 4d shows a rear elevation view of the foam structure.

[0048] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single feature or other unit may fulfill the functions of several units recited in the claims. Any reference signs in the claims shall not be construed so as to limit their scope.

[0049] The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.