CA2792596A1

CA2792596A1 - Vehicle seat assembly

Info

Publication number: CA2792596A1
Application number: CA2792596A
Authority: CA
Inventors: Terrie Ellison; Trenton Hobbs; Derek Shane Lindsay; William J. Gross
Original assignee: Honda Motor Co Ltd
Current assignee: Honda Motor Co Ltd
Priority date: 2010-03-11
Filing date: 2011-03-04
Publication date: 2011-09-15
Also published as: CN102791521B; MX2012010426A; WO2011112462A1; CN102791521A; DE112011100872T5

Abstract

A vehicle seat assembly includes a seat back and a seat base extending forward from a lower end of the seat back. The seat base is formed of a first foam member extending laterally across the seat base to absorb loads and a second foam member formed over the first member to form a seating surface of the seat base.

Description

VEHICLE SEAT ASSEMBLY

BACKGROUND
[0001] The present disclosure generally relates to a vehicle seat assembly, and more particularly relates to a seat cushion having a rigid member anchored to a vehicle body.
[0002] Vehicle seat assemblies typically include a seat cushion fixed to a vehicle body and a seat back extending upwardly from a rearward portion of the seat cushion. In one conventional anti-submarine construction, a forward edge of the seat cushion is raised relative to the rearward edge. For example, a cross member can be provided under the forward edge to elevate it relative to a vehicle floor and the rearward edge of the seat cushion can be mounted directly to the vehicle floor.
In this arrangement, the cross member, which can be formed of sheet metal, can absorb submarine loads imparted to the seat cushion during a vehicle collision event.

[0003] The seat cushion can comprise a wire frame and a foam member molded over the wire frame. It can be the wire frame of the seat cushion that is connected to the forward cross member. A rear portion of the wire frame of the seat cushion can be bolted or otherwise secured to the vehicle's floor panel or brackets mounted to the floor panel.

[0004] Some vehicle manufacturers employ an expanded polypropylene (EPP) foam member in their vehicle seat cushions. However, such seat assemblies often suffer in comfort. This is particularly a problem when minimal space is available between the rear end of the seat cushion and the vehicle body (e.g., the floor panel).
SUMMARY

[0005] According to one aspect, a vehicle seat assembly includes a seat back and a seat base extending forward from a lower end of the seat back. The seat base is formed of a first foam member extending laterally across the seat base to absorb loads and a second foam member formed over the first member to form a seating surface of the seat base. At least one wire frame section is secured to the first foam member and extends rearwardly therefrom toward a rear of the seat base for mounting the seat base to an associated vehicle body.

[0006] According to another aspect, a vehicle seat assembly includes a seat base having a seat back extending upwardly therefrom. The seat base includes a first foam portion extending laterally across the seat base with a wire frame section connected to the first foam portion and extending longitudinally therefrom toward a rear of the seat base where the wire frame section is secured to a vehicle body component. The seat base further includes a second foam portion molded over the first foam portion and extending longitudinally therefrom toward the rear of the seat base to form a seating surface thereof.

[0007] According to a further aspect, a method for constructing a vehicle seat assembly is provided. In the method according to this example, at least one wire frame section is provided for extending from a forward portion of the seat base longitudinally toward a rearward portion of the seat base. A laterally extending first foam member is overmolded on the at least one wire frame section adjacent a forward end of the at least one wire frame section. A second foam member is overmolded on the first foam member and the at least one wire frame section to form a seating portion of the seat base.

[0008] According to still a further aspect, a vehicle seat assembly includes a seat back and a seat base extending forward from the lower end of the seat back.
The seat base is formed of a first foam member extending laterally across the seat base to absorb loads and a second foam member formed over the first member to form a seating surface of the seat base. At least one plate member has one end overmolded by the first foam member and a second, opposite end secured to an associated vehicle body.

[0009] According to another aspect, a vehicle seat assembly includes a seat base having a seat back extending upwardly therefrom. The seat base includes a first foam portion extending laterally across the seat base with a plate member connected to the first foam portion and extending therefrom toward a vehicle body component where the plate member is secured to the vehicle body component. The seat base further includes a second foam portion molded over the first foam portion and extending longitudinally therefrom toward the rear of the seat base to form a seating surface thereof.

[0010] According to still another aspect, a method for constructing a vehicle seat assembly is provided. In the method according to this example, at least one plate member is provided for securing a laterally extending first foam member of a seat cushion to a vehicle body component. The laterally extending first foam member is over molded on a forward end of the at least one plate member. A second foam member is over molded on the first foam member to form a seating portion of the seat base.

[0011] According to a further aspect, a seat assembly includes a seatback and a seat base extending forward from a lower end of the seatback. The seat base is formed of a first foam member extending laterally across the seat base to absorb loads and a second foam member formed over the first member and extending rearwardly therefrom to form a seating surface of the seat base. The first foam member is formed of complementary portions that mate together to form the first foam member.

[0012] According to another aspect, a seat cushion for a seat assembly in a vehicle includes a first foam member having a longitudinal length extending laterally across the seat assembly and a second foam member molded over the first foam member and extending longitudinally rearward therefrom to form a seating surface.
The first foam member is formed of first and second complementary molded halves that meet together along a parting line.

[0013] According to a further aspect, a method of constructing a seat cushion for a vehicle seat assembly is provided. In the method according to this example, a first foam member having complementary portions is molded of a first relatively rigid foam material. The complementary portions are secured together along a parting line. The first foam member is overmolded with a second foam member. The second foam member forms a seating surface extending approximately orthogonally from the first foam member relative to a longitudinal length of the first foam member.

[0014] According to another aspect, a vehicle seat assembly includes a seat back and a seat base extending forward from a lower end of the seat back. The seat base is formed of a first foam member extending laterally across the seat base to absorb loads and a second foam member formed over the first member to form a seating surface of the seat base. The first foam member includes at least one channel for interlocking the first foam member and the second foam member.

[0015] According to still another aspect, a seat cushion for a seat assembly in a vehicle includes a first foam member extending laterally across the seat assembly and a second foam member molded over the first foam member and extending longitudinally rearward therefrom to form a seating surface. At least one channel is formed in the first foam member for receiving the second foam member to interlock the first and second foam members together.

[0016] According to still yet another aspect, a method of constructing a seat cushion for a vehicle seat assembly is provided. In the method according to this example, a first foam member is molded, the first foam member having a longitudinal length and laterally spaced apart channels disposed along the longitudinal length.
The first foam member is overmolded with a second foam member. The second foam member fills the laterally spaced apart channels during overmolding to interlock the second foam member to the first foam member. The second foam member forms a seating surface extending approximately orthogonally from the first foam member relative to the longitudinal length of the first foam member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a perspective cross sectional view of a vehicle seat assembly according to a first exemplary embodiment.

[0018] FIG. 2 is a front elevational view, partially in cross section, of the vehicle seat assembly of FIG. 1.

[0019] FIG. 3 is a cross sectional view of the vehicle seat assembly taken along the line 3-3 of FIG. 2.

[0020] FIG. 4 is a perspective view of a first foam member and wire frame sections secured thereto shown in isolation from the vehicle seat assembly of FIG.
1.

[0021] FIG. 5 is a perspective cross sectional view of a vehicle seat assembly according to a second exemplary embodiment.

[0022] FIG. 6 is a front elevational view, partially in cross section, of the vehicle seat assembly of FIG 5.

[0023] FIG. 7 is a cross sectional view of the vehicle seat assembly taken along the line 7-7 of FIG. 6.

[0024] FIG. 8 is a perspective view of a first foam member and plate members having ends overmolded by the first foam member, both shown in isolation from the vehicle seat assembly of FIG. 5.

[0025] FIG. 9 is a perspective cross-sectional view of a vehicle seat assembly according to a third exemplary embodiment.

[0026] FIG. 10 is a front elevational view, partially in cross-section, of the vehicle seat assembly of FIG. 9.

[0027] FIG. 11 is a cross-sectional view of the vehicle seat assembly taken along the line 11-11 of FIG. 10.

[0028] FIG. 12 is a partial perspective view of a seat base of the vehicle seat assembly of FIG. 9 shown with second foam member removed.

[0029] FIG. 13 is a partial perspective view showing complementary portions of a first foam member of the vehicle seat assembly of FIG. 9 being closed about a longitudinally extending wireframe section and another wireframe.

[0030] FIG. 14 is a perspective cross-sectional view of a vehicle seat assembly according to a fourth exemplary embodiment.

[0031] FIG. 15 is a front elevational view, partially in cross section, of the vehicle seat assembly of FIG. 14.

[0032] FIG. 16 is a cross-sectional view of the vehicle seat assembly taken along the line 16-16 of FIG. 15.

[0033] FIG. 17 is a partial cross-sectional view of the vehicle seat assembly taken along the line 17-17 of FIG. 15.

[0034] FIG. 18 is a partial perspective view of a seat base of the vehicle seat assembly of FIG. 14 shown with the second foam member removed.

DETAILED DESCRIPTION

[0035] Referring now to the drawings, wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting same, FIG. 1 shows a vehicle seat assembly 10 including a seat back 12 and a seat base 14 extending from a lower end of the seat back 12. The seat base 14, which can also be referred to as a seat cushion, includes and is formed of a first portion or member 16 extending laterally across the seat base 14 to absorb loads (e.g., submarine loads) and a second portion or member 18 formed over the first member 16 to form a seating surface 20 of the seat base 14. In particular, the second member 18 extends longitudinally from the first member 16 toward a rear or rear edge 22 of the seat base 14 to form the seating surface 20. A trim cover 42 can be received over the first and second members 16, 18, particularly over the second member 18 which is itself received over the first member 16.

[0036] In one embodiment, the first member 16 is formed of a relatively rigid material, such as a rigid foam, and the second member 18 is formed of a relatively less rigid material, such as a soft or less rigid foam. For example, the relatively rigid material of the first member 16 can be expanded polypropylene (EPP) foam and the relatively less rigid material of the second member 18 can be urethane foam.
Providing the first member 16, which is formed of a more rigid material (e.g., EPP
foam) along a forward portion 24 of the seat base 14 allows the first member 16 to absorb submarine loads and/or child restraint fixture loads, such as might be generated during a vehicle crash event. Providing the first member 16 only locally adjacent to the forward portion 24 allows comfort of the seat base 14 to be maintained through use of the second member 18 being formed of a less rigid material (e.g., urethane foam), while managing loads developed during a crash event.

[0037] As shown in the illustrated embodiment, the first foam member 16 can be an elongated member having a longitudinal length extending laterally across the seat base 14. In particular, the longitudinal length of the first member 16 can correspond closely to a lateral width of the seat base 14, though the first member 16 is slightly shorter. A width of the first member 16, by contrast, can be significantly smaller. For example, as best shown in FIG. 3, the width can be less than fifty percent of the front-to-back dimension of the seat base 14, preferably less than thirty-three percent of the front-to-back dimension, and more preferably approximately twenty-five percent of the front-to-back dimension. A height of the first member 16 can be such that it is nominally shorter than the seat base 14 adjacent the forward portion 24 but higher than the seat base 14 adjacent the rear 22.

[0038] With additional reference to FIGS. 2-4, the vehicle seat assembly 10 further includes at least one wire frame section (e.g., wire frame sections 26 and 28) secured to the first member 16 and extending rearwardly therefrom toward the rear 22 of the seat base 14 for mounting the seat base to an associated vehicle body (e.g., floor panel 30). As described in more detail below, the at least one wire frame section can be laterally disposed at a B-location, which is located centrally along a hip point axis of the seat base 14. This can assist in transferring submarine loads or other loads (e.g., those of a child restraint fixture) from the first member 16 to the associated vehicle body at a location adjacent the rear 22 of the seat cushion or base 14.

[0039] In the illustrated embodiment, the at least one wire frame section of the vehicle seat assembly 10 includes a first wire section 26 and a second wire section 28. Accordingly, a pair of laterally spaced apart wire frame sections 26, 28 are provided, wherein the wire frame sections 26, 28 are connected to the first member 16 and extend longitudinally therefrom toward the rear 22 of the seat base 14 where the wire frame sections 26, 28 can be secured to the vehicle body component (e.g., floor panel 30). In the illustrated embodiment, the wire frame sections 26, 28 are each disposed centrally (i.e., at a B-location) along a respective hip point axis of the seat base 14.

[0040] More particularly, the first wire section 26 is laterally disposed at a location 131 of a first hip point axis Al of the seat base 14 and the second wire frame section 28 is laterally disposed at a B-location B2 of a second hip point axis A2 of the seat base 14. As is known and understood by those skilled in the art, each hip point axis of the seat base 14 is located at a vertical location where an expected seat occupant's hip would be located (i.e., the pivot point between the torso and upper leg portions of a seat occupant's body). As used herein, hip point axis is an axis extending in a direction laterally across the vehicle and each hip point axis has a first lateral end and a second lateral end, the distance between the first and second lateral ends being an approximate width of the expected seat occupant.
As used herein, B-location is a location disposed centrally along each hip point axis (i.e., located centrally between the first and second lateral ends of each hip point axis).

[0041] While the illustrated embodiment includes two wire frame sections 26, 28, it is to be appreciated that the seat base 14 could include only a single wire frame section or could include more than two wire frame sections. For example, in a seat base designed for only one occupant, the seat base would have only a single hip point axis with a single B-location or center location defined therealong.
Accordingly, only a single wire frame section could be used. In a seat base designed for multiple occupants, the seat base could have a hip point axis located where each occupant is expected to be seated and each hip point axis could have its own B-location or center location. In this arrangement, a wire frame section could be provided at each B-location. Also in the illustrated embodiment, the vehicle body or vehicle body component is illustrated as the floor panel 30, however, it is to be appreciated that the wire frame sections 26, 28 could be secured to some other vehicle body component or to some intermediate component or bracket that is itself secured to the vehicle floor panel 30 or some other vehicle body component.

[0042] As shown in the illustrated embodiment, first ends 26a, 28a of the wire frame sections 26, 28 can be secured to the vehicle floor panel 30 adjacent the forward edge 24 of the seat base 14 and second ends 26b, 28b can be secured to the vehicle floor panel 30 adjacent the rearward edge 22 of the seat base 14.
Respective portions 26c, 28c can be secured via overmolding to the first member 16 for transferring submarine loads (or other loads, e.g., child restraint device loads) absorbed thereby to the vehicle floor panel 30. In particular, the portions 26c, 28c can be formed with an inverted U or V-shape that provides for better interlocking by the overmolded first member 16. As best shown in FIG. 3, the rear ends 26b, 28b of the wire frame sections 26, 28 are secured to the vehicle body component or floor panel 30 adjacent the rear end 22 of the seat base 14 and forward ends 26a, 28a are secured to the vehicle body component (e.g., floor panel 30) or another vehicle body component (e.g., a bracket mounted to the floor panel 30) adjacent the forward end 24 of the seat base 14 below the first member 16 in the illustrated embodiment.

[0043] More specifically, in the illustrated embodiment, the floor panel 30 defines receiving apertures 34 in which the forward ends 26a, 28a are received for connecting to the floor panel 30, though this could be another vehicle body component. In particular, grommets 36 can facilitate connection of the forward ends 26a, 28a to the floor panel 30. To facilitate this connecting, the forward ends 26a, 28a can include hooked portions as shown in the illustrated embodiment. The rearward ends 26b, 28b of the wire frame sections 26, 28 can be formed as looped portions for receipt of bolts 38. In particular, bolts 38 can be received through looped end portions 26b, 28b of the wire frame sections 26, 28 for securing the same to the floor panel 30 (or to another vehicle body component) as best shown in FIG. 3. A threaded member, such as nut 39, can be threadedly secured to the bolt 38 thereby connecting the wire frame section 26 or 28 to the floor panel 30.
Of course, other connection means and devices can be used to secure the rearward ends 26b, 28b to the vehicle body component.

[0044] The first member 16 can be overmolded onto the wire frame sections 26, 28. In particular, the first member 16 can be overmolded onto the inverted U-shaped portions 26c, 28c of the wire frame sections 26, 28. These portions 26c, 28c can be shaped (as shown in the illustrated embodiment) to facilitate a secure attachment between the overmolded first member 16 and the wire frame sections 26, 28. The second member 18 can then be overmolded onto at least one of the first member and the wire frame sections 26, 28. In the illustrated embodiment, the second member 18 is overmolded onto both the first member 16 and the wire frame sections 26, 28.

[0045] If desired, the vehicle seat assembly 10, and particularly the seat base 14 thereof, can include another wire frame section 40 which is overmolded by the second member 18. In particular, the wire frame section 40 can be provided about a perimeter of the seat cushion or base 14 and provide a structure on which to overmold the second member 18. Additionally, as best shown in FIG. 3, the longitudinally extending wire frame sections 26, 28 can pass through and interengage the wire frame 40 adjacent the rear end 22 of the seat base 14.

[0046] A plate member 44 can be provided in association with each wire frame section 26, 28. In the illustrated embodiment, each plate member 44 is disposed along a rearward section of the portions 26c, 28c of the wire frame sections 26, 28.
The plate 44 functions to prevent the wire frame section 26 or 28 from tearing or ripping through the first member 16 during a collision event. Each plate 44 can be welded onto the corresponding wire frame section 26, 28 or otherwise secured in position. In the illustrated embodiment, the plate 44 has a first end portion secured to the extending portion of the at least one wire section, a second end portion secured to a base of the inverted U-shaped portion 26c or 28c, and a middle portion secured to leg or rearward section of the inverted U-shaped portion 26c or 28c.
Alternatively, the plate 44 can be overmolded in position by the first member 16 or could be secured to the frame 40.

[0047] A method for constructing a vehicle seat assembly will now be described, such as the vehicle seat assembly 10 of the illustrated embodiment. First, at least one wire frame section is provided for extending from the forward portion of the seat base longitudinally toward a rearward portion of the seat base. In the illustrated embodiment, the wire frame sections 26, 28 are provided and both extend from the forward portion 24 of the seat base 14 longitudinally toward the rearward portion 22 of the seat base 14. Next, a laterally extending first member, such as first foam member 16, is overmolded on the wire frame sections 26, 28, particularly overmolded adjacent forward end 24 of the wire frame sections 26, 28. Plates can be secured to the wire frame sections 26, 28 or otherwise positioned to prevent tearing of the first member 16 during a collision event (i.e. a loading event). Then, the second member 18 is overmolded on the first member 16 and the wire frame sections 26, 28 to form a seating portion of the seat base 14.

[0048] A trim cover 42 can be installed over the first and second members 16, 18.
As already described herein, the first member 16 can be an EPP foam and the second member 18 can be a urethane foam. Additionally, overmolding of the first member 16 can include positioning the wire frame sections 26, 28 at hip point locations of the seat base 14 (i.e., where an occupant's hip points are expected to be on the seat base 14).

[0049] FIG. 5 shows a vehicle seat assembly 100 according to a second exemplary embodiment. The seat assembly 100 includes a seat back 112 and a seat base 114 extending from a lower end of the seat back 112. The seat base 114, which can also be referred to as a seat cushion, includes and is formed of a first portion or member 116 extending laterally across the seat base 114 to absorb loads (e.g., submarine loads) and a second portion or member 118 formed over the first member 116 to form a seating surface 120 of the seat base 114. In particular, the second member 118 extends longitudinally from the first member 116 toward a rear 122 of the seat base 114 to form the seating surface 120. A trim cover 142 can be received over the first and second members 116, 118, particularly over the second member 118 which is itself received over the first member 116.

[0050] In one embodiment, the first member 116 is formed of a relatively rigid material, such as a rigid foam, and the second member 118 is formed of a relatively less rigid material, such as a soft or less rigid foam. For example, the relatively rigid material of the first member 116 can be expanded polypropylene (EPP) foam and the relatively less rigid material of the second member 118 can be urethane foam.
Providing the first member 116, which is formed of a more rigid material (e.g., EPP
foam) along a forward portion 124 of the seat base 114 allows the first member to absorb submarine loads and/or child restraint fixture loads, such as might be generated during a vehicle crash event. Providing the first member 116 only locally adjacent to the forward portion 124 allows comfort of the seat base 114 to be maintained through use of the second member 118 being formed of a less rigid material (e.g., urethane foam), while managing loads developed during a crash event.

[0051] As shown in the illustrated embodiment, the first foam member 116 can be an elongated member having a longitudinal length extending laterally across the seat base 114. In particular, the longitudinal length of the first member 116 can correspond closely to a lateral width of the seat base 114, though the first member 116 is slightly shorter. A width of the first member 116, by contrast, can be significantly smaller. For example, as best shown in FIG. 7, the width can be less than fifty percent of the front-to-back dimension of the seat base 114, preferably less than thirty-three percent of the front-to-back dimension, and more preferably approximately twenty-five percent of the front-to-back dimension. A height of the first member 116 can be such that it is nominally shorter than the seat base adjacent the forward portion 124 but higher than the seat base 114 adjacent a rear 122 of the seat base 114.

[0052] In one known design (not shown), at least one wire frame section can be secured to the first foam member 116 and can extend rearwardly therefrom toward the rear 122 of the seat base 114 for mounting the seat base to an associated vehicle body (e.g., floor panel 130). In particular, each one of the at least one wire frame section can be laterally disposed at a B-location, which is located centrally along a hip point axis of the seat base 114 for assisting in transferring of submarine loads or other loads (e.g., those of a child restraint fixture) from the first member 116 to the associated vehicle body at a location adjacent the rear 122 of the seat cushion or base 114. Specifically, the at least one wire frame section can be bolted to the vehicle floor 130 adjacent the rear 122 of the seat cushion 114. In this arrangement, a metal plate can be used on top of the at least one wire section to prevent the wire frame section from slicing through the first foam member 16 during a loading condition.

[0053] One drawback of this known arrangement is that the first foam member 116 can undesirably shrink during the cooling process, particularly when the first foam member 116 is formed of EPP. As a result, when the first foam member 116 is molded over the at least one wire frame section, the shrinkage can cause the wire frame sections to distort (e.g., ends of the wire frame sections distal relative to the first foam member can converge toward one another) resulting in mounting locations for the seat cushion 114 being outside an acceptable range or tolerance and thus making cushion installation difficult. Shrinkage of the first foam member 116 can also cause the first foam member 116 itself to deform (e.g., it can bow) and thus it does not conform to its intended shape when installed in a vehicle.

[0054] With additional reference to FIGS. 6-8, the vehicle seat assembly 100 of the second exemplary embodiment further includes at least one plate member (e.g., plate members 126 and 128) secured to the first member 116. In particular, the at least one plate member has one end overmolded by the first foam member 116 and a second, opposite end secured to the associated vehicle body (e.g., the floor panel 130). Like the wire frame sections of the known vehicle seat arrangement, each of the plate members can be laterally disposed at the B-location, which is located centrally along a hip point axis of the seat base 114. Also like the wire frame sections of the known vehicle seat arrangement, this positioning of the one or more plate members can assist in transferring submarine loads or other loads (e.g., those of a child restraint fixture) from the first member 116 to the associated vehicle body.

[0055] In the illustrated embodiment, the one or more plate members of the vehicle seat assembly 100 includes first plate member 126 and second plate member 128. Accordingly, a pair of laterally spaced apart plate members 126, are provided, wherein the plate members 126, 128 have their respective first ends 126a, 128a connected to the first member 116. In particular, the first ends 126a, 128a are overmolded by the first foam member 116 for securing the plate members 126, 128 and the first member 116 together. Second, opposite ends 126b, 128b of the plate members 126, 128 can be secured to the vehicle body component (e.g., floor panel 130). In the illustrated embodiment, and similar to the wire frame sections of the above-discussed seat arrangement, the plate members, 126, 128 are each disposed centrally (i.e., at a B-location) along a respective hip point axis of the seat base 114.

[0056] More particularly, the first plate member 126 is laterally disposed at a 13-location 131 of a first hip point access Al of the seat base 114 and the second plate member 128 is laterally disposed at a B-location B2 of a second hip point axis A2 of the seat base 114. As is known and understood by those skilled in the art, each hip point axis of the seat base 114 is located at a vertical location where an expected seat occupant's hip would be located (i.e., the pivot point between the torso and upper leg portions of a seat occupant's body). As used herein, hip point axis is an axis extending in a direction laterally across the vehicle and each hip point axis has a first lateral end and a second lateral end, the distance between the first and second lateral ends being an approximate width of the expected seat occupant.
As used herein, B-location is a location disposed centrally along each hip point axis (i.e., located centrally between the first and second lateral ends of each hip point axis).

[0057] While the illustrated embodiment includes two plate members 126, 128, it is to be appreciated that the seat base 114 could include only a single plate member or could include more than two plate members. For example, in a seat base designed for only one occupant, the seat base would have only a single hip point axis with a single B-location or center location defined therealong.
Accordingly, only a single plate member could be used. In a seat base designed for multiple occupants, the seat base could have a hip point axis located where each occupant is expected to be seated and each hip point axis could have its own B-location or center location. In this arrangement, a plate member could be provided at each B-location. Also in the illustrated embodiment, the vehicle body or vehicle body component is illustrated as the floor panel 130; however, it is to be appreciated that the plate members 126, 128 could be secured to some other vehicle body component or to some intermediate component or bracket that is itself secured to the vehicle floor panel 130 or some other vehicle component.

[0058] As shown in the illustrated embodiment, first ends 126a, 128a of the plate members 126, 128 are overmolded by the first foam member 116 and second or rear ends 126b, 128b are secured to the vehicle body component or floor panel below the seat base 114. In addition, at least in the illustrated embodiment, connecting portions 126c, 128c, which extend between respective first portions 126a, 128a and second portions 126b, 128b, can also be overmolded by the first foam member 116. In the illustrated embodiment, the first portions 126a, 128a are oriented approximately parallel to a horizontal plane, which in the illustrated embodiment is shown parallel to floor panel 130, and the second portions 126b, 128b are oriented approximately parallel to at least a portion of the associated vehicle component (floor panel 130) to which the ends 126b, 128b are secured.
The connecting portions 126c, 128c extend at an angle between the first and second portions 126a, 128a and 126b, 128b. More specifically, as best shown in FIG.
7, the connection portions 126c, 128c extend at obtuse angles relative to the first and second portions 126a, 128a and 126b, 128b (i.e., the connecting portion is not orthogonally or acutely oriented relative to the first and second portions).
Additionally, a section of each of the second portions 126b, 128b adjacent the connecting portions 126c, 128c can also be overmolded by the first foam member 116. By the plate members 126, 128 being overmolded by the first foam member 116, these components are connected to one another for transferring submarine loads (or other loads, e.g., child restraint device loads) absorbed by the first foam member 116 to the vehicle floor panel 130.

[0059] The second ends 126b, 128b of the plate members 126, 128 are secured to the vehicle body component, such as the floor panel 130, rearwardly adjacent the first foam portion 116. That is, the second ends 126b, 128b are secured to the associated vehicle body rearward of and adjacent to the first foam member 116.
Specifically, as shown in the illustrated embodiment, the second ends 126b, 128b can be secured to the associated vehicle body immediately rearwardly of the first foam member 116. As shown, the second ends 126b, 128b define respective apertures 126d, 128d through which bolts 134 can be received. The apertures 126d, 128d can be in registry with apertures 136 defined in the vehicle body component or floor panel 130 (only one shown in FIG. 7) and a threaded member, such as nut 138, can be secured to the bolt 134 thereby connecting the plate member 126 or 128 to the floor panel 130. Of course, other connection means and devices can be used to secure the plate members 126, 128 to the vehicle body component. For example, the second ends 126b, 128b could be connected by welding, grommet-type connections, etc.

[0060] As already mentioned, the first member 116 can be overmolded onto the plate members 126, 128, particularly the first ends 126a, 128a, the connecting portions 126c, 128c and portions of the second ends 126b, 128b. The Z-shape of the plate members 126, 128 can facilitate secure attachment between the overmolded first member 116 and the plate members 126, 128. The second member 118 can be overmolded onto the first member 116.

[0061] If desired, the vehicle seat assembly 100, and particularly the seat base 114 thereof, can include wire frame section 140, which is overmolded by the second member 118. In particular, the wire frame section 140 can be provided about a perimeter of the seat cushion or base 114 and provide a structure on which to overmold the second member 118, though this is not required.

[0062] A method for constructing a vehicle seat assembly will now be described, such as the vehicle seat assembly 100 of the illustrated embodiment. First, at least one plate member is provided for securing a laterally extending first foam member of a seat cushion to a vehicle body component. In the illustrated embodiment, plate members 126, 128 are provided for securing the laterally extending first foam member 116 of the seat cushion 114 to the floor panel 130. Next, the laterally extending first foam member 116 is overmolded on a forward end of the at least one plate member. In the illustrated embodiment, the laterally extending first foam member 116 is overmolded on respective forward ends 126a, 128a of the plate members 126, 128. Then, a second foam member can be overmolded on the first foam member to form a seating portion of the seat base. In the illustrated embodiment, the second foam member 118 is overmolded on the first foam member 116 to form seating portion or surface 120 of the seat base 114. As already mentioned, the first foam member, such as first foam member 116, can be an expanded polypropylene foam and a second foam member, such as second foam member 118, can be a urethane foam. Overmolding of the first foam member 116 onto the plate members 126, 128 can include positioning the plate members 126, 128 in a lateral center of at least one hip point axis of the seat base 114.

[0063] The trim cover 142 can then be installed over the first and second members 116, 118. Next, the seat cushion 114 can then be installed in a vehicle, optionally in conjunction with the seat back 112. More specifically, the second ends 126b, 128b of the plate members 126, 128 can be secured to floor panel 130 via bolts 134 and nuts 138 or some other securing means or device.

[0064] FIG. 9 shows a vehicle seat assembly 200 according to a third exemplary embodiment. The seat assembly 200 includes a seatback 212 and a seat base 214 extended from a lower end of the seatback 212. The seat base 214, which can also be referred to as a seat cushion, includes and is formed of a first portion or member 216 extending laterally across the seat base 214 to absorb loads (e.g., submarine loads) and a second portion or member 218 formed over the first member 216 to form a seating surface 220 of the seat base 214. In particular, the second member 218 extends longitudinally rearward from the first member 216 to form the seating surface 220. A trim cover 250 can be received over the first and second members 216, 218, particularly over the second member 218, which is itself received over the first member 216.

[0065] In one embodiment, the first member 216 is formed of a relatively rigid material, such as rigid foam, and the second member 218 if formed of a relatively less rigid material, such as a soft or less rigid foam. For example, the relatively rigid material of the first member 216 can be expanded polypropylene (EPP) foam and the relatively less rigid material of the second member 218 can be urethane foam.
Providing the first member 216, which is formed of a more rigid material (e.g., EPP
foam) along a forward portion 224 of the seat base 214 allows the first member to absorb submarine loads and/or child restraint fixture loads, such as might be generated during a vehicle crash event. Providing the first member 216 only locally adjacent to the forward portion 224 allows comfort of the seat base 214 to be maintained through use of the second member 218 being formed of a less rigid material (e.g., urethane foam), while managing loads developed during a crash event.

[0066] As shown in the illustrated embodiment, the first foam member 216 can be an elongated member having a longitudinal length extending laterally across the seat base 214. In particular, the longitudinal length of the first member 216 can correspond closely to a lateral width of the seat base 214, though the first member 216 is slightly shorter. A width of the first member 216, by contrast, can be significantly smaller. For example, as best shown in FIG. 11, the width can be less than fifty percent of the front-to-back dimension of the seat base 214, preferably less than thirty percent of the front-to-back dimension, and more preferably approximately twenty-five percent of the front-to-back dimension. A height of the first member 216 can be such that it is nominally shorter than the seat base adjacent the forward portion 224 but higher than the seat base 214 adjacent a rear 222 of the seat base 214.

[0067] With additional reference to FIGS. 10-13, the vehicle seat assembly 200 further includes at least one wireframe section (e.g., wireframe sections 226 and 228) secured to the first member 216 and extending rearwardly therefrom toward the rear 222 of the seat base 214 for mounting the seat base 214 to an associated vehicle body (e.g., floor panel 230). As will be described in more detail below, the at least one wireframe section can be laterally disposed at a B-location, which is located centrally along a hip point axis of the seat base 214. This can assist in transferring submarine loads or other loads (e.g., those of a child restraint fixture) from the first member 216 to the associated vehicle body at a location adjacent the rear 222 of the seat base 214.

[0068] In the illustrated embodiment, the at least one wireframe section of the vehicle seat assembly 200 includes a first wireframe section 226 and a second wireframe section 228. Accordingly, a pair of laterally spaced apart wireframe sections 226, 228 are provided in the illustrated embodiment, wherein the wireframe sections 226, 228 are connected to the first member 216 and extend longitudinally therefrom toward the rear 222 of the seat base 214 where the wireframe sections 226, 228 can be secured to the vehicle body component (e.g., floor a panel 230). In the illustrated embodiment, the wireframe sections 226, 228 are each disposed centrally (i.e., at a B-location) along a respective hip point axis of the seat base 214.

[0069] More particularly, the first wireframe section 226 can be laterally disposed at a B-location 131 of a first hip point axis Al of the seat base 214 and the second wireframe section 228 can be laterally disposed at a B-location B2 of a second hip point axis A2 of the seat base 214. As is known and understood by those skilled in the art, each hip point axis of the seat base 214 is located at a vertical location where an expected seat occupants hip would be located (i.e., the pivot point between the torso and upper leg portions of a seat occupants body). As used herein, hip point axis is an axis extending in a direction laterally across the vehicle and each hip point axis has a first lateral end and a second lateral end, the distance between the first and second lateral ends being an approximate width of the expected seat occupant. As used here, B-location is a location disposed centrally along each hip point axis (i.e., located centrally between the first and second lateral ends of each hip point axis).

[0070] While the illustrated embodiment includes two wireframe sections 226, 228, it is to be appreciated that the seat base 214 could include only a single wireframe section or could include more than two wireframe sections. For example, for a seat base designed for only one occupant the seat base would have only a single hip point axis with a single B-location or center location defined therealong.
Accordingly, only a single wireframe section could be used. In a seat base designed for multiple occupants, the seat base could have a hip point axis located where each occupant is expected to be seated and each hip point axis could have its own B-location or center location. In this arrangement, a wireframe section could be provided at each B-location. Also in the illustrated embodiment, the vehicle body or vehicle body component is illustrated as the floor panel 230; however, it is to be appreciated that the wireframe sections 226, 228 could be secured to some other vehicle body component or to some intermediate component or bracket that is itself secured to the vehicle floor panel 230 or some other vehicle body component.

[0071] As shown in the illustrated embodiment, first ends 226a, 228a of the wireframe sections 226, 228 can be secured to the vehicle floor panel 230 adjacent the forward edge 224 of the seat base 214 and second ends 226b, 228b can be secured to the vehicle floor panel 230 adjacent the rearward edge 222 of the seat base 214. Respective portions 226c, 228c can be secured to the first member as will be described in more detail herein below for transferring submarine loads (or other loads, e.g., child restraint device loads) absorbed thereby to the vehicle floor panel 230. In particular, portions 226c, 228c can be formed with an inverted U
or V-shape that provides for better interlocking by the first member 216. Extending portions 226d, 228d of the wireframe sections 226, 228 extend from the inverted U-shaped sections 226c, 228c to the rear end 222 of the seat base 214. As best shown in FIG. 11 with respect to rear end 228b, the rear ends 226b, 228b of the wireframe sections 226, 228 can be secured to the vehicle body component or floor panel 230 adjacent the rear end 222 of the seat base 214. Forward ends 226a, 228a can be secured to the vehicle body component (e.g., floor panel 230) or another vehicle body component (e.g., a bracket mounted to the floor panel 230) adjacent the forward end 224 of the seat base 214 below the first member 216 in the illustrated embodiment.

[0072] More specifically, in the illustrated embodiment, the floor panel 230 defines receiving apertures 234 in which the forward ends 226a, 228a are received for connecting to the floor panel 230, though this could be another vehicle body component. In particular, grommets 236 can facilitate connection of the forward ends 226a, 228a to the floor panel 230. To facilitate this connection, the forward ends 226a, 228a can include hooked portions as shown in the illustrated embodiment. The rearward ends 226b, 228b of the wireframe sections 226, 228 can be formed as looped portions for receipt of bolts 238. In particular, bolts 238 can be received through looped ends portions 226b, 228b of the wireframe sections 226, 228 and then into apertures 240 defined in the floor panel 230 for securing the wire frame sections 226, 228 to the floor panel 230 (or to another vehicle body component) as best shown with respect to rearward end 228b in FIG. 11. A
threaded member, such as nut 239, can be threadedly secured to each of the bolts 238 thereby securing the connection of the wireframe sections 226, 228 to the floor panel 230. Of course, other connection means and devices can be used to secure the rearward ends 226b, 228b to the vehicle body component.

[0073] As will be described in more detail below, the first member 216 can be secured onto the wireframe sections 226, 228, particularly onto the inverted U-shaped portions 226c, 228c of the wireframe sections 226, 228. The second member 218 can then be overmolded onto at least one of the first member 216 and the wireframe sections 226, 228. In the illustrated embodiment, the second member 218 is over-molded onto both the first member 216 and the wireframe sections 226, 228 as will be described in further detail below.

[0074] If desired, the vehicle seat assembly 200, and particularly the seat base 214 thereof, can include another wireframe section 242, which is also overmolded by the second member 218. In particular, the wireframe section 242 can be provided about a perimeter of the seat cushion or base 214 and provide a structure on which to overmold the second member 218. Additionally, as best shown in FIG. 11, the longitudinally extending wireframe sections 226, 228 can pass through and inter-engage the wireframe 242 adjacent the rear end 222 of the seat base 214.

[0075] A plate member 244 can be provided in association with each wireframe section 226, 228. In the illustrated embodiment, each plate member 244 is disposed along a rearward section of the portions 226c, 228c of the wireframe sections 226, 228. The plates 244 function to prevent the wireframe sections 226, 228 from tearing or ripping through the first member 216 during a collision event. In the illustrated embodiment, each plate 244 is secured to the frame 242, such as by welding, though other arrangements are possible. For example, each plate 244 could be welded onto the corresponding wireframe section 226, 228 or otherwise secured in position.

[0076] In one known design (not shown), the first member 216 is overmolded onto the wireframe sections 226, 228 for connecting the first member 216 and the wireframe sections 226, 228 together. While this creates a secure connection between the wireframe sections 226, 228 and the first member 216, overmolding the first member 216 onto the wireframe sections 226, 228 can cause deformation of the wireframe sections 226, 228. In particular, as the first member 216 shrinks after such overmolding, particularly when the first member 216 is formed from EPP, the wireframe sections 226, 228 deform from the force of contraction of the first member 216. As a result, the forward ends 226a, 228a of the wireframe sections 226, end up being spaced closer together and the rear ends 226b, 228b of the wireframe sections 226, 228 end up being spaced further apart. This can make installation of the seat base 214 in a vehicle difficult as the forward ends 226a, 228a of the wireframe sections 226, 228 may not line up with the apertures 234 in the floor panel 230 and/or the rear ends 226b, 228b may not line up with the apertures 240 in the floor panel 230. Moreover, predicting the exact amount of shrinkage in the first member 216 and the corresponding amount of deformation at the forward ends 226a, 228a and/or the rear ends 226b, 228b is difficult.

[0077] Accordingly, in part to address this problem, the first foam member 216 of the illustrated embodiment is formed of complementary molded portions or halves that mate together along a parting line to form the first foam member 216. In particular, with specific reference to FIG. 12, the first foam member 216 of the illustrated embodiment is formed of first and second complementary molded portions or halves 260, 262 that are connected to one another by an integrally molded or formed hinge 264 and mate together along a parting line 266. Being connected to one another by the integrally molded hinge 264, which can be a living hinge, allows the portions 260, 262 to be molded together as a single molded piece. As already described herein, the first member 216 can be formed of a relatively rigid material and thus the complementary portions 260, 262 can likewise be formed of a relatively rigid material (e.g., EPP).

[0078] The complementary portions 260, 262, which include lower portion 260 and upper portion 262 in the illustrated embodiment, mate together around the wireframe sections 226, 228 to secure the first foam member 216 thereto. In particular, in the illustrated embodiment, each of the wireframe sections 226, includes a non-linear section (e.g., portions 226c and 228c) about which the complementary portions 260, 262 are received. In the illustrated embodiment, these non-linear sections are the inverted U-shaped sections 226c, 228c adjacent the forward ends 226a, 228a of the wireframe sections 226, 228. Each of the complementary portions 260, 262 can have a mating surface 260a, 262a that, respectively, conforms to the non-linear sections 226c, 228c of the wireframe sections 226, 228 and to the other of the complementary portions or halves 260, 262 (i.e., mating surface 260a of the lower portion 260 conforms to the non-linear sections 226c, 228c and to the upper portion 262; likewise, the mating surface 262a conforms to the non-linear sections 226c, 228c and to the lower portion 260).
This arrangement results in the parting line 266 being non-linear.

[0079] More specifically, the lower portion 260 can have a ridge 268 extending upward from mating surface 260a thereof. The upper portion 262 can have a recess 270 defined in mating surface 262a of the upper portion 262 for receiving the ridge 268 when the lower and upper portions are assembled together as shown in FIG.
12. As shown, the ridge 268 can be received in the inverted U-shaped sections 226c, 228c, and in the recess 270 of the upper portion 262, and recess 270 of the upper portion 262 can receive an apex or apex portion of the inverted U-shaped sections 226c, 228c and the ridge 268 of the lower portion 260. The lower portion 60 can also include apertures 282 that allow respective wireframe sections 226, 228 to pass through the lower portion 260 to the floor panel 230.

[0080] The complementary portions 260, 262 can include at least one integrally molded connector for locking the molded portions 260, 262 together. In the illustrated embodiment, each of the complementary portions 260, 262 have at least one integrally molded connector 274 for locking the complementary portions 260, 262 together when folded together about the hinge 264. For receipt of the integrally molded connector, at least one of the complementary portions 260, 262 can include a recess 276 formed therein for receiving the at least one integrally molded connector 274. In the illustrated embodiment, each of the molded portions, 260, 262 includes an integrally molded connector 274 and each includes a recess 276 for accommodating the integrally molded connector of the other of the molded portions 260 or 262.

[0081] In the illustrated embodiment, the integrally molded connector 274 specifically connects to the plates 244 of each of the wireframe sections 226, 228.
Accordingly, the plates 244 are fixed to the respective wireframe sections 226, 228 along respective lengths or portions thereof that have the complementary portions 260, 262 mated therearound. The complementary portion 260, 262 have the integrally molded connector 274 locking the complementary portions 260, 262 to the plates 244. More specifically, each of the plates 244 defines apertures 278 therein and each of the complementary portions 260, 262 has its integrally molded connector 274 received through a corresponding one of the apertures 278 to lock the complementary portions 260, 262 to the plate 244. As shown in the illustrated embodiment, a lower portion 280 of the plate 244 can have two spaced apart apertures 278, one for receiving connector 274 of the lower portion 260 and one for receiving the connector 274 of the upper portion 262. Of course, it should be appreciated by those skilled in the art that other types of connectors and arrangements are possible and should be considered within the scope of the present disclosure.

[0082] A method for constructing a vehicle seat assembly, and particularly a seat cushion for a vehicle seat assembly, will now be described, such as the vehicle seat assembly 200 of the illustrated embodiment and its seat cushion 214. First, a first foam member having complementary portions is molded of a first relatively rigid foam material. In the illustrated embodiment, the first foam member 216 has the complementary portions 260, 262 and can be molded of a relatively rigid material, such as EPP foam. Next, the complementary portions are secured together along a parting line. In the illustrated embodiment, the complementary portion 260, 262 are secured to one another along the parting line 266, which can be a non-linear parting line. Next, the first foam member is overmolded with a second foam member. In the illustrated embodiment, the first foam member 216 is overmolded with the second foam member 218. As already described herein, the second foam member 218 forms the seating surface 220 extending approximately orthogonally from the first foam member 216 relative to a longitudinal length of the first foam member 216.

[0083] Securing the complementary portions together can include securing the complementary portions to at least one wireframe section extending approximately normal relative to the longitudinal length of the first foam member for transferring loads from the first foam member to a rear of the seat cushion. In the illustrated embodiment, the complementary portion 260, 262 can be secured to the wireframe sections 226, 228 that extend approximately normal relative to the longitudinal length of the first member 216 for transferring loads from the first member 216 to a rear 222 of the seat cushion 214. As already discussed herein, one or both of the complementary portions 260, 262 can be molded with integral connectors, such as connector 274, for interlocking the complementary portions 260, 262 together.

[0084] FIG. 14 shows a vehicle seat assembly 300 according to a fourth exemplary embodiment. The seat assembly 300 includes a seat back 312 and a seat base 314 extending from a lower end of the seat back 312. The seat base 314, which can also be referred to as a seat cushion, includes and is formed of a first portion or member 316 extending laterally across the seat base 314 to absorb loads (e.g., submarine loads) and a second portion or member 318 formed over the first member 316 to form a seating surface 320 of the seat base 314. In particular, the second member 318 extends longitudinally from the first member 314 toward a rear or rear edge 322 of the seat base 314 form the seating surface 320. A trim cover 342 can be received over the first and second members 316, 318, particularly over the second member 318 which is itself received over the first member 316.

[0085] In one embodiment, the first member 316 is formed of a relatively rigid material, such as rigid foam, and the second member 318 is formed of a relatively less rigid material, such as a soft or less rigid foam. For example, the relatively rigid material of the first member 316 can be expanded polypropylene (EPP) foam and the relatively less rigid material of the second member 318 can be urethane foam.
Providing the first member 316, which is formed of a more rigid material (e.g., EPP
foam) along a forward portion 324 of the seat base 314 allows the first member to absorb submarine loads and/or child restraint fixture loads, such as might be generated during a vehicle crash event. Providing the first member 316 only locally adjacent to the forward portion 324 allows comfort of the seat base 314 to be maintained through use of the second member 318 being formed of a less rigid material (e.g., urethane foam), while managing loads developed during a crash event.

[0086] As shown in the illustrated embodiment, the first foam member 316 can be an elongated member having a longitudinal length extending laterally across the seat base 314. In particular, the longitudinal length of the first member 316 can correspond closely to a lateral width of the seat base 314, though the first member 316 is slightly shorter. A width of the first member 316, by contrast, can be significantly smaller. For example, as best shown in FIG. 16, the width can be less than fifty percent of the front-to-back dimension of the seat base 314, preferably less than thirty-three percent of the front-to-back dimension, and more preferably approximately twenty-five percent of the front-to-back dimension. A height of the first member 316 can be such that it is nominally shorter than the seat base adjacent the forward portion 324 but higher than the seat base 314 adjacent a rear 322 of the seat base 314.

[0087] With additional reference to FIGS. 15-18, the vehicle seat assembly 300 further includes at least one wire frame section (e.g., wire frame sections 326 and 328) secured to the first member 316 and extending rearwardly therefrom toward the rear 322 of the seat base 314 for mounting the seat base to an associated vehicle body (e.g., floor panel 330). As will be described in more detail below, at least one wire frame section can be laterally disposed at a B-location, which is located centrally along a hip point axis of the seat base 314. This can assist in transferring submarine loads or other loads (e.g., those of a child restraint fixture) from the first member 316 to the associated vehicle body at a location adjacent the rear 322 of the seat base 314.

[0088] In the illustrated embodiment, the at least one wire frame section of the vehicle seat assembly 300 includes a first wire section 326 and a second wire section 328. Accordingly, a pair of laterally spaced apart wire frame sections 326, 328 are provided in the illustrated embodiment, wherein the wire frame sections 326, 328 are connected to the first member 316 and extend longitudinally therefrom toward the rear 322 of the seat base 314 where the wire frame sections 326, can be secured to the vehicle body component (e.g., floor panel 330). In the illustrated embodiment, the wire frame sections 326, 328 are each disposed centrally (i.e., at a B-location) along a respective hip point axis of the seat base 314.

[0089] More particularly, the first wire section 326 can be laterally disposed at a B-location 131 of a first hip point axis Al of the seat base 314 and the second wire frame section 328 can be laterally disposed at a B-location B2 of a second hip point axis A2 of the seat base 314. As is known and understood by those skilled in the art, each hip point axis of the seat base 314 is located at a vertical location where an expected seat occupant's hip would be located (i.e., the pivot point between the torso and upper leg portions of a seat occupant's body). As used herein, hip point axis is an axis extending in a direction laterally across the vehicle and each hip point axis has a first lateral end and a second lateral end, the distance between the first and second lateral ends being an approximate width of the expected seat occupant.
As used herein, B-location is a location disposed centrally along each hip point axis (i.e., located centrally between the first and second lateral ends of each hip point axis).

[0090] While the illustrated embodiment includes two wire frame sections 326, 328, it is to be appreciated that the seat base 314 could include only a single wire frame section or could include more than two wire frame sections. For example, in a seat base designed for only one occupant the seat base would have only a single hip point axis with a single B-location or center location defined therealong.
Accordingly, only a single wire frame section could be used. In a seat base designed for multiple occupants, the seat base could have a hip point axis located where each occupant is expected to be seated and each hip point axis could have its own B-location or center location. In this arrangement, a wire frame section could be provided at each B-location. Also in the illustrated embodiment, the vehicle body or vehicle body component is illustrated as the floor panel 330; however, it is to be appreciated that the wire frame sections 326, 328 could be secured to some other vehicle body component or to some intermediate component or bracket that is itself secured to the vehicle floor panel 330 or some other vehicle body component.

[0091] As shown in the illustrated embodiment, first ends 326a, 328a of the wire frame sections 326, 328 can be secured to the vehicle floor panel 330 adjacent the forward edge 324 of the seat base 314 and second ends 326b, 328b can be secured to the vehicle floor panel 330 adjacent the rearward edge 322 of the seat base 314.
Respective portions 326c, 328c can be secured via overmolding to the first member 316 for transferring submarine loads (or other loads, e.g., child restraint device loads) absorbed thereby to the vehicle floor panel 330. In particular, portions 326c, 328c can be formed with an inverted U or V-shape that provides for better interlocking by the overmolded first member 316. As best shown in FIG. 16 with respect to rear end 328b, the rear ends 326b, 328b of the wire frame sections 326, 328 can be secured to the vehicle body component or floor panel 330 adjacent the rear end 322 of the seat base 314. Forward ends 326a, 328a can be secured to the vehicle body component (e.g., floor panel 330) or another vehicle body component (e.g., a bracket mounted to the floor panel 330) adjacent the forward end 324 of the seat base 314 below the first member 316 in the illustrated embodiment.

[0092] More specifically, in the illustrated embodiment, the floor panel 330 defines receiving apertures 334 in which the forward ends 326a, 328a are received for connecting to the floor panel 330, though this could be another vehicle body component. In particular, grommets 336 can facilitate connection of the forward ends 326a, 328a to the floor panel 330. To facilitate this connecting, the forward ends 326a, 328a can include hooked portions as shown in the illustrated embodiment. The rearward ends 326b, 328b of the wire frame sections 326, 328 can be formed as looped portions for receipt of bolts 338. In particular, bolts 338 can be received through looped end portions 326b, 328b of the wire frame sections 326, 328 for securing the same to the floor panel 330 (or to another vehicle body component) as best shown with respect to rearward end 328b in FIG. 16. A
threaded member, such as nut 339, can be threaded onto the bolt 338 thereby connecting the wire frame section 326 or 328 to the floor panel 330. Of course, other connection means and devices can be used to secure the rearward ends 326b, 328b to the vehicle body component.

[0093] The first member 316 can be overmolded onto the wire frame sections 326, 328. In particular, the first member 316 can be overmolded onto the inverted U-shaped portions 326c, 328c of the wire frame sections 326, 328. These portions 326c, 328c can be shaped (as shown in the illustrated embodiment) to facilitate a secure attachment between the overmolded first member 316 and the wire frame sections 326, 328. The second member 318 can then be overmolded onto at least one of the first member 316 and the wire frame sections 326, 328. In the illustrated embodiment, the second member 318 is overmolded onto both the first member 316 and the wire frame sections 326, 328 as will be described in further detail below.

[0094] If desired, the vehicle seat assembly 300, and particularly the seat base 314 thereof, can include another wire frame section 340 which is overmolded by the second member 318. In particular, the wire frame section 340 can be provided about a perimeter of the seat cushion or base 314 and provide a structure on which to overmold the second member 318. Additionally, as best shown in FIG. 16, the longitudinally extending wire frame sections 326, 328 can pass through and inter-engage the wire frame 340 adjacent the rear end 322 of the seat base 314.

[0095] A plate member 344 can be provided in association with each wire frame section 326, 328. In the illustrated embodiment, each plate member 344 is disposed along a rearward section of the portions 326c, 328c of the wire frame sections 326, 328. The plates 344 function to prevent the wire frame sections 326, 328 from tearing or ripping through the first member 316 during a collision event. In the illustrated embodiment, each plate 344 is secured to the frame 340, such as by welding, though other arrangements are possible. For example, each plate 344 could be welded onto the corresponding wire frame section 326, 328 or otherwise secured in position. Another example would include simply overmolding the plates 344 in their respective positions by the first member 316.

[0096] In one known design (not shown), bonding of the second member 318 to the first member 316 occurs through overmolding of the second member 318 to the first member 316. Specifically, the second member 318 is molded around front, top and rear sides of the first member in this known design. While this creates a physical bond between the second member 318 and the first member 316, particularly when the second member 318 is formed of urethane and the first member 316 is formed of EPP foam, the physical bond is not very strong and thus it is relatively easy to separate the two members 316, 318. Of course, such separation between the second member 318 and the first member 316 is not desired in the assembled vehicle seat assembly 300.

[0097] Accordingly, the first foam member 316 of the illustrated embodiment includes at least one channel (e.g., channels 350) for interlocking the first member 316 and the second member 318. As already mentioned, the second member 318 is overmolded onto the first member 316. During such overmolding, the channel or channels of the first member 316 receive the second member 318 to interlock the first member 316 and the second member 318 together. According to this construction, the channel or channels formed in the first member 316 are specifically provided for receiving the second member 318 to interlock the first and second members 316, 318 together.

[0098] In the illustrated embodiment, a plurality of laterally spaced apart channels 350 is disposed along the longitudinal length of the first member 316. In addition, though not required, the channels 350 can include partial channels 350a laterally disposed at each longitudinal end of the first member 316. In the illustrated embodiment, the plurality of laterally spaced apart channels 350 is disposed on an underside 352 of the first member 316. Each channel 350 of the illustrated embodiment allows the second member 318 to surround the first member 316. That is, the second member 318 surrounds the first member 316 at each of the channels 350. Accordingly, a lateral profile of the second member 318, as illustrated in FIG.
16, fully encapsulates a lateral profile of the first member 316 at each channel 350.
An advantage of this arrangement is that the second member 318 is allowed to flow and fully envelope around the first member 316 locally at each of the channels 350.

[0099] As best shown in FIGS. 15 and 16, portions 356 of the second member 318 are received in the channels 350 along the underside 352 of the first member 316. By this arrangement, the first member 316, and particularly portions 358 thereof, contacts the vehicle body component (e.g., floor panel 330) at locations between the channels 350 and the second foam member 318, and particularly portions 356 thereof received in the channels 350, contacts the vehicle body component at locations in registry with the channels 350. Advantageously, reduced contact by the first member 316 and/or increased contact by the second member 318 has the effect of improving noise performance. In particular, undesirable noises, such as squeaks, between the second base 314 and the floor panel 330 are reduced when less of the first member 316 contacts the floor panel 330.

[0100] A method for constructing a vehicle seat assembly, and particularly a seat cushion for a vehicle seat assembly, will now be described, such as the vehicle seat assembly 300 of the illustrated embodiment and its seat cushion 314. First, a first foam member is molded having a longitudinal length and laterally spaced apart channels disposed along the longitudinal length. In the illustrated embodiment, the first foam member 316 is molded having its longitudinal length and the laterally spaced apart channels 350 disposed along the longitudinal length. Next, the first foam member is overmolded with a second foam member. In the illustrated embodiment, the first foam member 316 is overmolded with second foam member 318. As already described herein, the second foam member 318 can fill the laterally spaced apart channels 350 during overmolding to interlock the second member to the first member 316. The second member 318 forms the seating surface 320 extending approximately orthogonally from the first member 316 relative to the longitudinal length of the first member 316.

[0101] Molding of the first member 316 can include overmolding at least one wire frame section, such as wire frame sections 326 and 328 in the illustrated embodiment, which extend approximately normal relative to the longitudinal length of the first member 316 for transferring loads from the first member to the rear 322 of the seat cushion 314. A trim cover 342 can be installed over the first and second member 316, 318. As already described herein, the first member 316 can be an EPP foam and the second member 318 can be a urethane foam. Also as already described herein, molding of the first member 316 with the laterally spaced apart channels 350 can include forming the laterally spaced apart channels 350 on the underside 352 of the first member 316 such that the second member 318 fully encases the first members 316 at lateral locations corresponding to the laterally spaced apart channels 350.

[0102] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

1. A vehicle seat assembly, comprising:
a seat back; and a seat base extending forward from a lower end of said seat back, said seat base formed of a first foam member extending laterally across said seat base to absorb loads and a second foam member formed over said first member to form a seating surface of said seat base.

2 The vehicle seat assembly of claim 1 further including at least one wire frame section secured to said first foam member and extending rearwardly therefrom toward a rear of said seat base for mounting said seat base to an associated vehicle body.

3. The vehicle seat assembly of claim 2 wherein said at least one wire includes a first end secured to said associated vehicle body adjacent a forward edge of said seat base and a second end secured to said associated vehicle body adjacent a rearward edge of said seat base, said at least one wire section transferring submarine loads absorbed by said first foam member to said associated vehicle body.

4. The vehicle seat assembly of claim 3 wherein the associated vehicle body is a floor panel and said second end of said at least one wire section is bolted to said floor panel.

5. The vehicle seat assembly of claim 2 wherein said first foam member is overmolded onto said at least one wire frame.

6. The vehicle seat assembly of claim 5 wherein said second foam member is overmolded onto at least one of said first foam member and said at least one wire frame.

7. The vehicle seat assembly of claim 2 wherein each of said at least one wire frame section includes a forward end secured to said associated vehicle body under a front end of said seat base, an inverted U-shaped section adjacent said forward end embedded in said first foam member, an extending portion extending from said first foam member to a rear end of said seat base, and a rear end secured to said associated vehicle body rearwardly of said seat base.

8. The vehicle seat assembly of claim 2 wherein a plate is fixedly secured to said inverted U-shaped section.

9. The vehicle seat assembly of claim 8 wherein said plate has a first end portion secured to said extending portion, a second end portion secured to a base of said inverted U-shaped section and a middle portion secured to a leg of said inverted U-shaped section.

10. The vehicle seat assembly of claim 2 wherein a plate is secured to said at least one wire frame section for preventing the at least one wire frame section from ripping through said first foam member during a collision event.

11. The vehicle seat assembly of claim 2 further including another wire frame section overmolded by said second foam member.

12. The vehicle seat assembly of claim 2 wherein said seat base has at least one hip point axis with a first lateral end and a second lateral end, said at least one wire frame section is laterally disposed at a B-location of each of said at least one hip point axis.

13. The vehicle seat assembly of claim 12 wherein said at least one wire frame section includes a first wire section and a second wire section, and wherein said at least one hip point axis includes a first hip point axis and a second hip point axis, said first wire section laterally disposed at a B-location of said first hip point axis and said second wire section laterally disposed at a B-location of said second hip point axis.

14. The vehicle seat assembly of claim 1 further including:
at least one plate member having one end overmolded by said first foam member and a second, opposite end secured to an associated vehicle body.

15. The vehicle seat assembly of claim 14 wherein said second end is secured to the associated vehicle body below said seat base.

16. The vehicle seat assembly of claim 14 wherein said second end is secured to the associated vehicle body rearward of and adjacent to said first foam member.

17. The vehicle seat assembly of claim 16 wherein said second end is secured to the associated vehicle body immediately rearwardly of the first foam member.

18. The vehicle seat assembly of claim 14 wherein each of said at least one plate member includes a first portion formed at said first end oriented approximately parallel to a horizontal plane, a second portion formed at said second end oriented approximately parallel to at least a portion of the associated vehicle component to which said second end is secured, and a connecting portion extending at an angle between said first portion and said second portion.

19. The vehicle seat assembly of claim 14 wherein the associated vehicle body is a floor panel and said second end of said at least one plate member is bolted to said floor panel.

20. The vehicle seat assembly of claim 14 wherein said seat base has at least one hip point axis with a first lateral end and a second lateral end, said at least one plate member is laterally disposed at a B-location of each of said at least one hip point axis.

21. The vehicle seat assembly of claim 20 wherein said at least one plate member includes a first plate member and a second plate member, and wherein said at least one hip point axis includes a first hip point axis and a second hip point axis, said first plate member laterally disposed at a B-location of said first hip point axis and said second plate member laterally disposed at a B-location of said second hip point axis.

22. The vehicle seat assembly of claim 14 further including a wire frame section overmolded by said second foam member.

23. The vehicle seat assembly of any one of claims 1-22 wherein said first foam member is formed of a relatively rigid material and said second foam member is formed of a relatively less rigid material.

24. The vehicle seat assembly of claim 23 wherein said relatively rigid material is expanded polypropylene foam and said relatively less rigid material is urethane foam.

25. The vehicle seat assembly of any one of claims 1-22 wherein said second foam member is overmolded onto said first foam member.

26. The vehicle seat assembly of any one of claims 1-22 wherein said first foam member is formed of complementary portions that mate together to form said first foam member.

27. The vehicle seat assembly of claim 26 wherein said complementary portions include a first portion and a second portion connected to one another by an integrally formed hinge.

28. The vehicle seat assembly of claim 27 wherein said complementary portions are formed of a relatively rigid material and said integrally formed hinge is a living hinge, said second foam member formed of a relatively less rigid material.

29. The vehicle seat assembly of claim 28 wherein said relatively rigid material is expanded polypropylene and said relatively less rigid material is a urethane foam.

30. The vehicle seat assembly of claim 26 wherein said first foam member is secured to at least one wire frame section that extends rearwardly from said first foam member toward a rear of said seat base for mounting said seat base to an associated vehicle body, said complementary portions mating together around said at least one wire frame section to secure said first foam member thereto.

31. The vehicle seat assembly of claim 30 further including:
a plate fixed to said at least one wire frame section along a length thereof that has said complementary portions mated therearound, said complementary portions having at least one integrally molded connector locking said complementary portions to said plate.

32. The vehicle seat assembly of claim 31 wherein said plate defines apertures and each of said complementary portions has at least one integrally molded connector received through a corresponding one of said apertures to lock said complementary portions to said plate.

33. The vehicle seat assembly of claim 30 wherein each of said at least one wire frame section includes a nonlinear section about which said complementary portions are received, each of said complementary portions having a mating surface that conforms to said nonlinear section and the other of said complementary portions.

34. The vehicle seat assembly of claim 33 wherein said nonlinear section is an inverted U-shaped section adjacent a forward end of said at least one wire frame section, a first lower one of said complementary portions having a complementary ridge received in said inverted U-shaped section and a second upper one of said complementary portions having a recess receiving an apex of said inverted U-shaped section and said ridge of said first lower one.

35. The vehicle seat assembly of claim 34 wherein said forward end of said at least one wire frame section is secured to an associated vehicle body under a front end of said seat base, and an extending portion of said at least one wire frame section extends from said inverted U-shaped section to a rear end of said seat base, and a rear end of said at least one wire frame section is secured to said associated vehicle body rearwardly of said seat base.

36. The vehicle seat base of claim 26 wherein said complementary portions include a lower portion having a ridge extending upward from a mating surface of said lower portion, and an upper portion having a recess defined in a mating surface of said upper portion for receiving said ridge when said lower and upper portions are assembled together.

37. The vehicle seat assembly of claim 26 wherein said complementary portions have at least one integrally molded connector for locking said complementary portions together when folded together about said integrally formed hinge.

38. The vehicle seat assembly of claim 37 wherein at least one of said complementary portions has said at least one integrally molded connector and at least the other of said complementary portions has a recess formed therein for receiving said at least one integrally molded connector.

39. The vehicle seat assembly of claim 26 further including a wire frame overmolded by said second foam member.

40. The vehicle seat assembly of any one of claims 1-22 wherein said first foam member includes at least one channel for interlocking said first foam member and said second foam member.

41. The vehicle seat assembly of claim 40 wherein said second foam member is overmolded onto said first foam member and said at least one channel receives said second foam member to interlock said first foam member and said second foam member together.

42. The vehicle seat assembly of claim 41 wherein a lateral profile of said second foam member fully encapsulates a lateral profile of said first foam member at each of said at least one channel.

43. The vehicle seat assembly of claim 42 wherein said at least one channel includes a plurality of laterally spaced apart channels disposed on an underside of said first foam member.

44. The vehicle seat assembly of claim 43 wherein said first foam member contacts a vehicle body component at locations between said channels and said second foam member contacts said vehicle body component at locations in register with said plurality of channels.

45. The vehicle seat assembly of claim 41 wherein said first foam member is formed of a relatively rigid material and said second foam member is formed of a relatively less rigid material.

46. The vehicle seat assembly of claim 45 wherein said relatively rigid material is expanded polypropylene foam and said relatively less rigid material is urethane foam.

47. A vehicle seat assembly, comprising:
a seat base having a seat back extending upwardly therefrom, said seat base including a first foam portion extending laterally across said seat base and a second foam portion molded over said first foam portion and extending longitudinally therefrom toward said rear of said seat base to form a seating surface thereof.

48. The vehicle seat assembly of claim 47 further including a wire frame section connected to said first foam portion and extending longitudinally therefrom toward a rear of said seat base where said wire frame section is secured to a vehicle body component.

49. The vehicle seat assembly of claim 48 wherein said seat base includes at least one hip point axis and said wire frame section is disposed centrally along each of said at least one hip point axis of said seat base.

50. The vehicle seat assembly of claim 49 wherein said seat base includes at least two hip point axes each having a first lateral end and a second lateral end, center points of said at least two hip point axes spaced apart from one another.

51. The vehicle seat assembly of claim 48 wherein said wire frame section has a rear end secured to said vehicle body component adjacent a rear end of said seat base and a forward end secured to said vehicle body component or another vehicle body component adjacent a forward end of said seat base below said first foam portion.

52. The vehicle seat assembly of claim 48 wherein a plate is fixedly secured to said rear end of said wire frame section.

53. The vehicle seat assembly of claim 47 further including a plate member connected to said first foam portion and extending therefrom toward a vehicle body component where said plate member is secured to said vehicle body component.

54. The vehicle seat assembly of claim 53 wherein said seat base includes at least one hip point axis and said plate member is disposed centrally along each of said at least one hip point axis of said seat base.

55. The vehicle seat assembly of claim 54 wherein said seat base includes at least two hip point axes each having a first lateral end and a second lateral end, center points of said at least two hip point axes spaced apart from one another.

56. The vehicle seat assembly of claim 53 wherein said plate member has a rear end secured to said vehicle body component rearwardly adjacent said first foam portion.

57. The vehicle seat assembly of any one of claims 47-56 wherein said first foam portion is formed of a rigid foam and said second foam portion is formed of a less rigid foam.

58. A method for constructing a vehicle seat assembly, comprising:
providing at least one wire frame section for extending from a forward portion of a seat base longitudinally toward a rearward portion of said seat base;
overmolding a laterally extending first foam member on said at least one wire frame section adjacent a forward end of said at least one wire section; and overmolding a second foam member on said first foam member and said at least one wire frame section to form a seating portion of said seat base.

59. The method of claim 58 wherein said overmolding of said first foam member includes positioning said at least one wire frame section in a lateral center of at least one hip point axis of said seat base.

60. A method for constructing a vehicle seat assembly, comprising:
providing at least one plate member for securing a laterally extending first foam member of a seat cushion to a vehicle body component;
overmolding said laterally extending first foam member on a forward end of said at least one plate member; and overmolding a second foam member on said first foam member to form a seating portion of said seat base.

61. The method of claim 60 wherein said overmolding of said first foam member includes positioning said at least one plate in a lateral center of at least one hip point axis of said seat base.

62. The method of any one of claims 58-61 further including:
installing a trim cover over said first and second foam members.

63. The method of claim 62 wherein said first foam member is an expanded polypropylene foam and said second foam member is a urethane foam.

64. A seat cushion for a seat assembly in a vehicle, comprising:
a first foam member having a longitudinal length extending laterally across the seat assembly; and a second foam member molded over said first foam portion and extending longitudinally rearward therefrom to form a seating surface, wherein said first foam member is formed of first and second complementary molded halves that mate together along a parting line.

65. The seat cushion of claim 64 wherein said first and second complementary molded halves are connected to one another by an integrally molded hinge, said first and second complementary molded halves molded together as a single molded piece.

66. The seat cushion of claim 64 wherein said complementary molded halves include at least one integrally molded connector for locking said molded halves together.

67. The seat cushion of claim 64 wherein said parting line is nonlinear.

68. A seat cushion for a seat assembly in a vehicle, comprising:
a first foam member having a longitudinal length extending laterally across the seat assembly;
a second foam member molded over said first foam portion and extending longitudinally rearward therefrom to form a seating surface; and at least one channel formed in said first foam member for receiving said second foam member to interlock said first and second foam members together.

69. The seat cushion of claim 68 wherein said second foam member surrounds said first foam member at said at least one channel.

70. The seat cushion of claim 69 wherein said at least one channel is a plurality of laterally spaced apart channels disposed along said longitudinal length of said first foam member.

71. The seat cushion of claim 68 further including:
a wire frame section connected to said first foam portion and extending longitudinally therefrom toward a rear of said second foam member where said wire frame section is secured to a vehicle body component, said wire frame section disposed centrally along each hip point axis of said seat base, said wire frame section having a rear end secured to said vehicle body component adjacent said rear of said second foam member.

72. The seat cushion of any one of claims 64-71 wherein said first foam member is formed of a rigid foam and said second foam member is formed of a less rigid foam.

73. A method of constructing a seat cushion for a vehicle seat assembly, comprising:
molding a first foam member having complementary portions of a first relatively rigid foam material;
securing said complementary portions together along a parting line; and overmolding said first foam member with a second foam member, said second member forming a seating surface extending approximately orthogonally from said first foam member relative to a longitudinal length of said first foam member.

74. The method of claim 73 wherein securing said complementary portions together includes securing said complementary portions to at least one wire frame section extending approximately normal relative to said longitudinal length for transferring loads from said first foam member to a rear of the seat cushion.

75. The method of claim 73 wherein said one or both of said complementary portions are molded with integral connectors for interlocking said complementary portions together.

76. A method of constructing a seat cushion for a vehicle seat assembly, comprising:
molding a first foam member having a longitudinal length and laterally spaced apart channels disposed along said longitudinal length; and overmolding said first foam member with a second foam member, said second foam member filling said laterally spaced apart channels during overmolding to interlock said second foam member to said first foam member, and said second foam member forming a seating surface extending approximately orthogonally from said first foam member relative to said longitudinal length of said first foam member.

77. The method of claim 76 wherein said molding of said first foam member includes overmolding at least one wire frame section extending approximately normal relative to said longitudinal length for transferring loads from said first foam member to a rear of the seat cushion.

78. The method of claim 76 wherein said laterally spaced apart channels are formed on an underside of said first foam member and said second foam member fully encases said first foam member at lateral locations corresponding to said laterally spaced apart channels.

79. The method of any one of claims 73-78 further including:
installing a trim cover over said first and second foam members.

80. The method of any one of claims 73-78 wherein said first foam member is an expanded polypropylene foam and said second foam member is a urethane foam.