U.S. patent application number 10/287138 was filed with the patent office on 2004-05-06 for vehicle seat component and method for making same.
Invention is credited to Berta, Michael J..
Application Number | 20040084937 10/287138 |
Document ID | / |
Family ID | 32175616 |
Filed Date | 2004-05-06 |
United States Patent
Application |
20040084937 |
Kind Code |
A1 |
Berta, Michael J. |
May 6, 2004 |
Vehicle seat component and method for making same
Abstract
A vehicle seat component (14, 14a, 14') and its method for
making same with a seating portion (20) molded from either expanded
polyethylene or expanded polypropylene to have a density in the
range of 0.3 to 2.8 pounds per cubic foot with a softness to
provide seating comfort. A seat support (22) of the seat component
is molded from expanded polypropylene and has a density in the
range of 5 to 10 pounds per cubic foot so as to provide structural
support. The seating portion (14, 14a) can be molded from either
expanded pellets (28) or extruded and expanded tubes (34) of either
polyethylene or polypropylene, while the seat support (22) is
molded from expanded polypropylene pellets (30). The seat component
(14') may have a cover (36') molded to the seating portion (20),
and both the moldings may be sequentially in the same mold
(44).
Inventors: |
Berta, Michael J.;
(Rochester Hills, MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C.
1000 TOWN CENTER
TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075
US
|
Family ID: |
32175616 |
Appl. No.: |
10/287138 |
Filed: |
November 4, 2002 |
Current U.S.
Class: |
297/180.14 |
Current CPC
Class: |
B29C 44/0461 20130101;
B60N 2/7017 20130101; B60N 2/5891 20130101; A47C 7/18 20130101 |
Class at
Publication: |
297/180.14 |
International
Class: |
A47C 007/72 |
Claims
What is claimed is:
1. A vehicle seat component comprising: a seating portion molded
from an expanded polymer selected from the group consisting of
expanded polyethylene and expanded polypropylene with the seating
portion having a density in the range of 0.3 to 2.8 pounds per
cubic foot so as to have softness to provide seating comfort; and a
seat support for mounting the seating portion on a vehicle body,
and the seat support being molded from expanded polypropylene and
having a density in the range of 5 to 10 pounds per cubic foot so
as to have sufficient rigidity to provide structural support.
2. A vehicle seat component as in claim 1 wherein the seating
portion and the seat support have a molded interface with each
other.
3. A vehicle seat component as in claim 1 wherein the seating
portion is made from expanded polymeric pellets that are fused to
each other during the molding, and wherein the seat support is made
from expanded polypropylene pellets also fused to each other during
molding.
4. A vehicle seat component as in claim 1 wherein the seating
portion is made from extruded polymeric tubes that are expanded and
then fused to each other during the molding, and wherein the seat
support is made from expanded polypropylene pellets fused to each
other during molding.
5. A vehicle seat component as in claim 1 further including a cover
to which the softer seating portion is molded.
6. A vehicle seat component as in claim 1 wherein the seating
portion has vent passages through which air passes to provide
cooling to the seat.
7. A vehicle seat component as in claim 6 further including a fan
mounted by the seat support to supply air to the vent passages of
the seating portion.
8. A vehicle seat component as in claim 7 wherein the seat support
includes a vent opening in which the fan is mounted to supply the
air to the vent passages of the seating portion.
9. A vehicle seat component comprising: a seating portion molded
from an expanded polymer selected from the group consisting of
expanded polyethylene and expanded polypropylene with the seating
portion having a density in the range of 0.3 to 2.8 pounds per
cubic foot so as to have softness to provide seating comfort; a
seat support for mounting the seating portion on a vehicle body,
and the seat support being molded from expanded polypropylene and
having a density in the range of 5 to 10 pounds per cubic foot so
as to have sufficient rigidity to provide structural support; the
seat support and the seating portion having a molded interface with
each other; and a cover to which the softer seating portion is
molded.
10. A method for making a vehicle seat component comprising:
injecting an expanded polymer selected from the group consisting of
expanded polyethylene and expanded polypropylene into a mold and
heating thereof to provide molding that provides a seating portion
having a density in the range of 0.3 to 2.8 pounds per cubic foot
so as to have softness to provide seating comfort; injecting
expanded polypropylene into a mold and heating thereof to provide
molding that provides a seat support having density in the range of
5 to 10 pounds per cubic foot so at to have sufficient rigidity to
provide structural support; and securing the seating portion to the
seat support.
11. A method for making a vehicle seat component as in claim 10
wherein the seating portion and the seat support are molded in the
same mold so as to have a molded interface that provides the
securement thereof to each other.
12. A method for making a vehicle seat component as in claim 10
wherein the seating portion is made from expanded polymeric pellets
that are fused to each other during the molding and wherein the
seat support is also made from expanded polypropylene pellets fused
to each other during the molding.
13. A method for making a vehicle seat component as in claim 10
wherein the seating portion is made extruded polymeric tubes that
are expanded and fused to each other during the molding and wherein
the seat support is made from expanded polypropylene pellets fused
to each other during the molding.
14. A method for making a vehicle seat component as in claim 10
wherein a cover is initially inserted into the mold in which the
expanded polymer is subsequently injected into the mold and heated
to provide the seating portion which is molded to the cover, and
wherein the expanded polypropylene is subsequently injected into
the same mold and heated to provide the seat support which has an
interface with the seating portion.
15. A method for making a vehicle seat component as in claim 10
wherein the seating portion is molded with vent passages for air
flow that provides cooling.
16. A method for making a vehicle seat component as in claim 15
wherein a fan is mounted by the seat support to provide cooling air
to the vent passages of the seating portion.
17. A method for making a vehicle seat component as in claim 16
wherein the seat support is molded with an opening through which
the air flows to the fan for flow to the vent passages of the
seating portion.
18. A method for making a vehicle seat component comprising:
inserting a cover into a mold; injecting an expanded polymer
selected from the group consisting of expanded polyethylene and
expanded polypropylene into the mold and heating thereof to provide
molding that provides a seating portion secured to the cover and
having a density in the range of 0.3 to 2.8 pounds per cubic foot
so as to have softness to provide seating comfort; and injecting
expanded polypropylene into the mold and heating thereof to provide
molding that provides a seat support having a molded interface with
the seating portion and a density in the range of 5 to 10 pounds
per cubic foot so as to have sufficient rigidity to provide
structural support.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a vehicle seat component and also
relates to a method for making the seat component.
[0003] 2. Background Art
[0004] Most current vehicle seats are made with polyurethane foam
to provide seating comfort. Such polyurethane foam is not
recyclable and thus does not help in preserving our natural
resources.
[0005] Patent references noted during an investigation conducted in
accordance with the present invention include U.S. Pat. No.
3,823,980 Harnick; U.S. Pat. No. 5,100,204 Makihara et al.; U.S.
Pat. No. 5,522,645 Dahlbacka; U.S. Pat. No. 5,533,789 McLarty, III
et al.; U.S. Pat. No. 6,027,171 Partington et al.; U.S. Pat. No.
6,234,578 Barton et al.; and U.S. Pat. No. 6,423,388 Bateson et
al.
SUMMARY OF THE INVENTION
[0006] One object of the present invention is to provide an
improved vehicle seat component.
[0007] In carrying out the above object, the vehicle seat component
of the invention includes a seating portion molded from an expanded
polymer that is either expanded polyethylene or expanded
polypropylene such that the seating portion has a density in the
range of 0.3 to 2.8 pounds per cubic foot so as to have softness to
provide seating comfort. A seat support of the seat component
mounts the seating portion on a vehicle body. The seat support is
molded from expanded polypropylene and has a density in the range
of 5 to 10 pounds per cubic foot so as to have sufficient rigidity
to provide structural support.
[0008] The construction of the seat component not only provides
seating comfort in a manner that can be efficiently produced but
also provides recyclability since the expanded polyethylene and
expanded polypropylene can be recycled unlike prior seats utilizing
polyurethane foams.
[0009] In the preferred construction of the seat component, the
seating portion and the seat support have a molded interface with
each other.
[0010] In one embodiment of the seat component, the seating portion
is made from expanded polymeric pellets that are fused to each
other during the molding and the seat support is made from expanded
polypropylene pellets fused to each other during molding, while
another embodiment of the seat component has the seating portion
made from extruded polymeric tubes that are expanded and then fused
to each other during the molding and has the seat support made from
expanded polypropylene pellets fused to each other during
molding.
[0011] The seat component also includes a cover to which the softer
seating component is molded in one practice of the invention. In
addition, the seat component in one embodiment has the seating
portion provided with vent passages through which air passes to
provide cooling to the seat, and this embodiment further includes a
fan mounted by the seat support to supply air to the vent passages
of the seating portion. More specifically, the seat support
includes a vent opening in which the fan is mounted to supply the
air to the vent passages of the seating portion.
[0012] Another object of the present invention is to provide an
improved method for making a vehicle seat component.
[0013] In carrying out the immediately preceding object, the method
for making a vehicle seat component in accordance with the
invention is performed by injecting an expanded polymer of either
expanded polyethylene or expanded polypropylene into a mold and
heating thereof to providing molding that provides a seating
portion having a density in the range of 0.3 to 2.8 pounds per
cubic foot so as to have softness to provide seating comfort.
Expanded polypropylene is injected into a mold and heated to
provide molding that provides a seat support having a density in
the range of 5 to 10 pounds per cubic foot so as to have sufficient
rigidity to provide structural support. The seating portion and the
seat support are secured to each other to provide the vehicle seat
component.
[0014] In the preferred practice of the method, the seating portion
and the seat support are molded in the same mold so as to have a
molded interface that provides the securement thereof to each
other.
[0015] In one practice of the method, the seating portion is made
from expanded polymeric pellets that are fused to each other during
the molding and the seat support is also made from expanded
polypropylene pellets fused to each other during the molding.
[0016] In another practice of the method, the seating portion is
made from extruded polymeric tubes that are expanded and then fused
to each other during the molding and the seat support is made from
expanded polypropylene pellets fused to each other during the
molding.
[0017] In one practice of the method, a cover is initially inserted
into the mold in which the expanded polymer is subsequently
injected and heated to provide the seating portion which is molded
to the cover, and the expanded polypropylene is subsequently
injected into the same mold and heated to provide the seat support
which has an interface with the seating portion.
[0018] One practice of the method is performed by molding the
seating portion with vent passages for air flow that provides
cooling. In this practice, a fan is mounted by the seat support to
provide cooling air to the vent passages of the seat portion.
Furthermore, the seat support is molded with an opening through
which the air flow to the fan for flow to the vent passages of the
seating portion.
[0019] The objects, features and advantages of the present
invention are readily apparent from the following detailed
description of the preferred embodiments when taken in connection
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a side elevational view of a vehicle seat that
includes a seat component constructed in accordance with the
present invention.
[0021] FIG. 2 is a perspective view of a portion of one embodiment
of the seat component.
[0022] FIG. 3 is a perspective view of a portion of another
embodiment of the seat component.
[0023] FIG. 4 is a schematic view that illustrates the manner in
which the seat components of FIGS. 1-3 are molded.
[0024] FIG. 5 is a perspective view illustrating another embodiment
of a vehicle seat component constructed in accordance with the
invention.
[0025] FIG. 6 is a sectional view taken through the vehicle
component along the direction of line 6-6 in FIG. 5.
[0026] FIG. 7 is a sectional view of the seat component taken along
the direction of line 7-7 in FIG. 6.
[0027] FIG. 8 is a schematic view that illustrates the manner in
which the seat component of FIGS. 5-7 is molded.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] With reference to FIG. 1 of the drawings, a vehicle seat
generally indicated by 10 is mounted on the floor 12 of an
associated vehicle body and includes a seat cushion component 14
constructed in accordance with the present invention as well as
including a seat back component 16 having a headrest component 18.
While the vehicle seat component of this invention is specifically
disclosed as a seat cushion 14, it will be appreciated that the
invention also has use in other seating components such as with the
seat back 16, the headrest 18, an armrest, or other vehicle seat
components. Both the seat component and the method for making the
component will be described in an integrated manner to facilitate
an understanding of all aspects of the invention.
[0029] With continuing reference to FIG. 1, the vehicle seat
component 14 includes a seating portion 20 that is molded from an
expanded polymer that most preferably is expanded polyethylene, but
can also be expanded polypropylene, and the molded seating portion
has a density in the range of 0.3 to 2.8 pounds per cubic foot so
as to have softness to provide seating comfort. The molded seating
portion of expanded polyethylene with its specified density in the
range of 0.3 to 2.8 pounds per cubic foot is capable of providing
greater softness, although the expanded polypropylene can also
function adequately even though the expanded polyethylene is
preferred. The seat component 14 also includes a seat support 22
for mounting the seating portion on the associated vehicle body.
This seat support 22 is molded from expanded polypropylene and has
a density in the range of 5 to 10 pounds per cubic foot so as to
have sufficient rigidity to provide structural support. The seat
component 14 as described can be totally recycled unlike most
commercial vehicle seats which use polyurethane foam that cannot be
recycled.
[0030] In the preferred construction of the seat component 14, the
seating portion 20 and the seat support 22 have a molded interface
24 with each other in a manner that is provided by the molding
apparatus 26 illustrated in FIG. 4 as is hereinafter more fully
described.
[0031] With reference to FIG. 2, in one construction the seating
portion 20 is made from expanded polymeric pellets 28 that are
fused to each other during the molding as is hereinafter more fully
described. Furthermore, the seat support 22 is made from expanded
polypropylene pellets 30 that are also fused to each other during
molding. The fused pellets have engaged surfaces with each other so
as to have an appearance of having no voids.
[0032] As illustrated in FIG. 3, another construction of the seat
component 14a has the seating portion 20 made from extruded
polymeric tubes that are expanded as identified by 34 and then
fused to each other during the molding. Such fused tubes have
interior voids that promote softness of the seating portion.
Furthermore, this construction of the seat component like the other
construction has the seat support 24 made from expanded
polypropylene pellets 30 that are fused to each other during the
molding.
[0033] With reference to FIG. 1, the vehicle seat cushion component
14 illustrated is most normally also provided with a cover 36 of
any conventional seating material. Furthermore, as illustrated in
FIGS. 5-7, an alternate embodiment of the seat 10' has the vehicle
seat cushion component 14' provided with a cover 36' that is molded
to the softer seating portion 20 as is hereinafter described in
connection with the molding apparatus 26' illustrated in FIG.
8.
[0034] As shown in FIGS. 6 and 7, the seating portion 20 of seat
10' is illustrated as having vent passages 38 through which air
passes to provide cooling to the seat. The seat also includes a fan
40 mounted by the seat support 22 to supply air to the vent
passages 38 of the seating portion. More specifically, the seat
support 22 includes a vent opening 42 in which the fan 40 is
mounted to supply the air to the vent passages 38 of the seating
portion.
[0035] With reference to FIG. 4, the vehicle seat component 14 is
molded within the mold apparatus 26 illustrated by first injecting
either pellets or tubes of an expanded polymer of either
polyethylene or polypropylene into a mold 44 whose mold portions 46
are shown in a closed position to define a mold cavity 48. This
introduction of the expanded polymer is provided into the mold from
a source 50 of the expanded polymer through a control valve 52 to
mold inlets 54. Steam is introduced from a source 55 through a
plurality of inlets 56 to fuse the expanded pellets or expanded
tubes to each other and provide the molding of the seating portion
with, as previously mentioned, the density in the range of 0.3 to
2.8 pounds per cubic foot so as to have softness to provide seating
comfort. As the molding takes place, the steam exits the mold
through outlet vents 58 spaced over the surface of the mold cavity
48.
[0036] After the molding of the seating portion 20, pellets of
expanded polypropylene are injected from a source 60 under the
control of valve 52 through the inlets 56 into the mold and the
steam is injected from the source 54 through the inlets 56 to
provide the fusing of the expanded polypropylene pellets to each
other before the steam then exits the mold through outlet vents 58.
The seat support 22 is thus molded as previously described with a
density in the range of 5 to 10 pounds per cubic foot so as to have
sufficient rigidity to provide structural support.
[0037] It should be appreciated that the seating portion 20 and the
seat support 22 can be molded in different molds and then
subsequently secured to each other in any suitable manner such as
by an adhesive or other type of securement. However, the sequential
molding of the seating portion 20 and the seat support 22 within
the same mold provides the molded interface 24 of the seating
portion to the seat support without requiring any post molding
securement processing.
[0038] The molding can be performed as previously described in
connection with either the seat component 14 of FIG. 2 or the seat
component 14a in FIG. 3. More specifically, the seating portion 20
can be made from expanded polymeric pellets 28 that are fused to
each other during the molding, and the seat support 22 can be made
from expanded polypropylene pellets 30 that are molded to each
other as illustrated in FIG. 2. Furthermore, the seating portion 20
can be made from extruded and expanded polymeric tubes 34 that are
fused to each other during the molding, and the seat support 22 can
be made from expanded polypropylene pellets 30 that are fused to
each other during the molding as illustrated in FIG. 3.
[0039] With reference to FIGS. 5-8, the method for making the
vehicle seat component 14' with the molded cover 36' is performed
in the same manner as described in FIG. 4 except that the mold
apparatus 26' of FIG. 8 utilized has provision for securing the
cover 36' within the mold cavity 48 before the expanded polymer is
introduced into the mold to provide the seating portion. As such,
the seating portion 20 is molded to the cover 36' during the
molding provided by the steam heating before the steam exits
through the outlet vents 58. Actually, the edges of the seat
support 22 are also molded to the cover 36'. Furthermore, the vent
passages 38 are provided in the seating portion during the molding
in any conventional manner and the vent opening 42 is likewise
provided in the seat support 22 in a conventional manner.
[0040] After the molding of the seat component either as in FIG. 4
without a cover or as in FIG. 8 with a cover, the associated mold
44 is opened by relative movement of the mold portions 46 away from
each other to permit removal of the molded component for further
assembly and eventual use.
[0041] While the preferred practice for carrying out the invention
has been described in detail, those familiar with the art to which
this invention relates will recognize various alternative ways of
carrying out the invention as described by the following
claims.
* * * * *