GB2574788A

GB2574788A - Trim assembly and support structure for vehicle seats

Info

Publication number: GB2574788A
Application number: GB201802922A
Authority: GB
Inventors: Cook Ben; Robinson Andrew; Brown Christopher; Taylor Benjamin
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2018-02-23
Filing date: 2018-02-23
Publication date: 2019-12-25
Anticipated expiration: 2038-02-23
Also published as: GB201802922D0; GB2574788B

Abstract

A trim assembly 201, (201’, figures 10A, 10B) for a vehicle, wherein the vehicle comprises a carpet 234 and a support structure 104 (e.g. for a rear seat bench) defining a storage cavity 106, (106’) e.g. under seat pocket at or near floor level. The trim assembly comprises a base trim component 208, (208’) for mounting to the support structure. The base trim component is configured to secure the carpet 234 (e.g. carpet edge) in position within the vehicle, e.g. via studs, flange 232, carpet retention ledge 236, or cover clip (238). The trim assembly also comprises an item retention feature 206, (206’) e.g. retaining ledge for preventing stowed personal items from falling out of the storage cavity, e.g. during braking. Also disclosed a support structure 104 for a vehicle seat. The support structure comprises an integrated storage cavity 106, (106’) e.g. for storing umbrellas, tablet, laptop, mobile phones, newspapers, documents. The support structure comprises a reinforcement structure (150, figure 3), e.g. metal wireframe, located at least partially within a moulding (152, figure 4), e.g. thermoplastic polymer molding. The support structure comprises a trim assembly 201, (201’, figures 10A, 10B) securing carpet 234 against the moulding adjacent storage cavity opening.

Description

TRIM ASSEMBLY AND SUPPORT STRUCTURE FOR VEHICLE SEATS

TECHNICAL FIELD

The present invention relates to a vehicle internal trim assembly, in particular, but not exclusively, for pockets and other storage cavities provided in vehicles at or near floor level in the vehicle. The invention also relates to support structures for vehicle seats, such as for second and third row seats. Aspects of the invention relate to a support structure for a vehicle seat incorporating such trim and bracket, to a system and to a vehicle.

BACKGROUND

Storage cavities are frequently provided in vehicles and sometimes these are near flooring level where carpeting or other floor covering is terminated at the opening of the cavity. A means of retaining items in storage cavities, particularly ones that have a horizontal aspect is desirable. It is an object of the invention to provide a trim assembly for a vehicle storage cavity.

Conventional seating arrangements for rear (e.g. second or third row) seats of vehicles comprise a cushion having a sheet metal base with a padded portion mounted thereon. The cushion is conventionally mounted to an appropriate location on the vehicle body so as to form an approximately, although usually not exactly, horizontal bench portion of the rear seats, on which the rear passengers may sit.

It is also known to provide a support structure between the vehicle body and the cushion, for example to provide a higher seating position. Such a support structure may be mountable to the vehicle body and may define a location at which the base of the cushion may be mounted to the support structure.

Known support structures are provided solely to provide an appropriate location for mounting the cushion.

It is an object of embodiments of the invention to address disadvantages associated with the prior art, and optionally to address the issues just mentioned.

SUMMARY OF THE INVENTION

According to an aspect of the invention for which protection is sought there is provided a trim assembly for a vehicle, wherein the vehicle comprises a carpet and a support structure defining a storage cavity, the trim assembly comprising:

a base trim component for mounting to the support structure wherein the base trim component is configured to secure the carpet in position within the vehicle; and an item retention feature configured to retain items within the storage cavity.

In one embodiment, the item retention feature is disposed on the base trim component. In another embodiment, the item retention feature is disposed on a separate outer trim component configured to be mounted on the base trim component.

The base trim component may comprise:

a carpet holding means;

a fastening mechanism for releasably securing the base trim component to a wall of the support structure adjacent to an opening of the storage cavity; and a first retention mechanism for mounting of the outer trim component. The carpet holding means may comprise one or more studs or a flange. The fastening mechanism may be configured to releasably secure the base trim component to a wall of the support structure outside the storage cavity.

The outer trim component may comprise:

a second retention mechanism for engagement with a first retention mechanism of the base trim component.

The outer trim component may further comprise a first edge, for engaging the support structure or base trim component to provide a close joint against the support structure or base trim component.

Optionally, the outer trim component comprises a second edge, for engaging the carpet or base trim component to provide a close joint against the carpet or base trim component; and a clean surface between said first and second edges.

Optionally, the fastening mechanism comprises a series of bosses formed along the length of the base trim component to receive screws or bolts for engagement with the support structure which, when tightened causes the base trim component to press the carpet holding means into holding engagement with the carpet.

In an embodiment, the carpet holding means serves also to stiffen the base trim component along its length.

In an embodiment, the first retention mechanism comprises a slot in the base trim component and the second retention mechanism comprises a tab on the outer trim component, which tab is adapted to snap into engagement with the slot in the base trim component. Optionally, the direction of insertion of the tab in the slot is transverse the direction of said clean surface. Further optionally, a tool inserted behind said surface enables the outer trim component to be levered away from said base trim component in said transverse direction to spring said tab out of engagement with said slot. The direction of insertion of the tab in the slot may be substantially parallel the direction of said clean surface, the tab comprising a hook to engage with a latch on the base trim component, and a tool inserted behind said base trim component may enable the tab to be released from the latch and the outer trim component to be lifted away from said base trim component in said direction.

Optionally, the item retention feature is disposed on the outer trim component. Alternatively, item retention feature may be disposed on the base trim component.

“Carpet” as used herein is includes any floor covering that is the topmost covering of the floor and rising surfaces of the vehicle against which users of the vehicle engage when carried in the vehicle.

A “close joint” is one which transitions between the components in question to exclude gaps between them that might allow small items to fall between the components.

A “clean surface” is one which provides an acceptable external appearance for the interior of a vehicle and therefore lacks functional elements not relevant to a passenger of the vehicle who is using the vehicle in normal manner.

In an embodiment, the trim assembly is employed with a support structure for a vehicle seat, the support structure comprising a moulding and a reinforcement structure, the reinforcement structure being located at least partially within the moulding, wherein a storage cavity is provided in the support structure.

Thus, the present invention in this embodiment provides an edge trim at a carpet termination that not only secures the carpet/floor covering, but also terminates the edge neatly and without gaps. Sometimes, the cavity may be formed by a moulding process, whereby the core of a mould forms the cavity. In that event, a closure or item retention device is needed for when items are stored in the cavity and to prevent them from being easily dislodged from the storage cavity. This is particularly true in the case where the cavity, or rather its floor, is substantially horizontally arranged in the vehicle.

Furthermore, it may be desirable that any such finish/termination is selectively releasable, should it be necessary to access serviceable parts of the vehicle under the seat and behind the carpet.

The present invention in this embodiment applies to any storage cavity of a vehicle, but especially to those described above associated with an under-seat storage cavity which will be near floor level and have a horizontal aspect

According to another aspect of the invention for which protection is sought there is provided a support structure for a vehicle seat, the support structure comprising a moulding and a reinforcement structure, the reinforcement structure being located at least partially within the moulding, wherein a storage cavity is provided in the support structure. Advantageously, such a support structure is able to provide a convenient location for a vehicle user to store personal items, without compromising crash performance of a seating arrangement in which is installed.

In an embodiment, the reinforcement structure comprises a metal wireframe. Such a wireframe may provide a lightweight structure that significantly increases the compression stiffness and strength of the support structure.

In an embodiment, the moulding comprises expanded polypropylene (EPP), optionally EPP with a density of 40-80 kg/m³, preferably EPP with a density of 5560kg/m³. This may provide a good balance between light weight and high strength and stiffness.

In an embodiment, the reinforcement structure comprises at least one bracket located outside the moulding. The at least one bracket may comprise a first bracket configured to be connected to a body of the vehicle. Alternatively or in addition, the at least one bracket may comprise a second bracket configured to be connected to a portion of the vehicle seat. Such brackets may ensure that a vehicle seat that is supported by the support structure is secured relative to the vehicle body, so that relative movement between the seat and the vehicle body does not occur during a crash. Optionally, the at least one bracket is connected to the reinforcement structure. This may ensure that the connection between the bracket and the support structure is strong. Indeed, in some embodiments the bracket and the reinforcement structure may be integrally formed with each other.

In an embodiment, the reinforcement structure comprises at least one thin-walled portion. A portion may be considered to be thin-walled if it has a thickness that is not more than 25%, preferably not more than 10%, of the width and length of the portion.

In an embodiment one or more apertures are formed in the thin-walled portion. Advantageously, the one or more apertures allow the material of the moulding to pass through the thin-walled portions, thereby ensuring that a strong connection is provided between the moulding and the reinforcement structure.

Optionally, the thin-walled portion comprises a first planar section located within the moulding near an upper surface of the moulding and a second planar section located within the moulding near a lower surface of the moulding, and a connecting portion between the first and second planar sections. The thin-walled portion may comprise a C-shaped bracket. Advantageously, such a thin-walled portion may increase the stiffness and strength of the support structure, especially when the support structure is subjected to large loads as would be the case when the support structure is supporting an occupied seat during a crash.

In an embodiment, the support structure comprises a plurality of thin-walled portions.

In an embodiment, the reinforcement structure comprises at least one compression portion, the compression portion being contained within the moulding, wherein the compression portion is arranged to be compressed between the body of the vehicle and the seat cushion if the seat cushion is compressed towards the body of the vehicle by more than a predetermined amount. Such a compression portion may increase the strength and stiffness of the support structure. Optionally the compression portion comprises a thin-walled portion.

In an embodiment, the cavity has first and second transverse ends and one of said compression portions is located in the moulding proximate each of the first and second transverse ends.

In an embodiment, the storage cavity has a maximum length of at least 90cm, preferably at least 95cm. Optionally, the storage cavity has a depth of at least 15cm. Advantageously, this may allow the storage cavity to be used for storage of relatively long personal items, for example umbrellas.

In an embodiment, the storage cavity comprises a front portion and at least one rearward portion, the front portion being located between an opening of the storage cavity and the rearward portion. Optionally the front portion may have a maximum length of at least 90cm, preferably at least 95cm, and the maximum length of the rearward portion may be less than the maximum length of the front portion. The front and rearward portions may be suitable for storing different items.

In an embodiment, the storage cavity comprises at least two of said rearward portions. Advantageously, a dividing wall between said rearward portions may provide increase the stiffness and strength of the support structure. Furthermore, providing two separate rearward cavities may enable vehicle users sat in different seats to each use their own storage cavity. In an embodiment one of said compression portions is located in the moulding between said rearward portions.

According to another aspect of the invention for which protection is sought there is provided a system comprising a support structure as described above, optionally with a trim assembly as described above, and a vehicle seat cushion.

In an embodiment, the vehicle seat cushion comprises a sheet metal base portion.

According to another aspect of the invention for which protection is sought there is provided a vehicle comprising a system as described above. In an embodiment, the system forms a bench portion of a second or third row seating arrangement.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example only, with reference to the accompanying figures, in which:

Figure 1 shows a vehicle seating arrangement in an embodiment of the present invention;

Figures 2A-C show different views of a support structure for a vehicle seat in an embodiment of the present invention;

Figure 3 shows a reinforcement structure for a support structure in an embodiment of the present invention;

Figure 4 shows the location of the reinforcement structure shown in Figure 3 within the support structure shown in figures 2A-C;

Figures 5A-B show a support structure attached to a cushion of a vehicle seat in an embodiment of the present invention;

Figure 6 shows an interior floor of the rear portion of a vehicle, into which a support structure in an embodiment of the present invention may be mounted;

Figure 7 shows an underseat area including a trim assembly being an embodiment of a different aspect of the present invention;

Figures 8A and 8B show an arrangement of a base trim component and an outer trim component in the trim assembly visible in Figure 7;

Figure 9 shows a section through the trim assembly on the line l-l in Figure 7;

Figures 10A, B and C show sections through an alternative arrangement of a trim assembly in accordance with the present invention, the sections being along the lines A-A and B-B respectively as shown in Figure 10C; and

Figure 11 shows a vehicle into which a support structure and/or trim assembly in an embodiment of the present invention may be mounted.

DETAILED DESCRIPTION

Figure 1 shows a vehicle seating arrangement 100 of an embodiment of the present invention. It will be understood that the seating arrangement 100 may be incorporated into a vehicle 700 as shown in Figure 11.

The seating arrangement 100 comprises a cushion 102 having an upper surface 102A that is approximately horizontal so as to allow a passenger to be able to sit on it. The seating arrangement 100 also comprises a seat back portion 112 on which a passenger may rest their back when sitting on the cushion 102. As can be seen in Figure 1, the cushion 102 is mounted on a support structure 104 that includes a storage cavity 106. The support structure 104 is in turn mounted onto the rear floor 108 of the vehicle body, so that the cushion 102 is firmly held in place. In Figure 1 the support structure 104 is partially covered by a decorative trim 110.

The storage cavity 106 advantageously provides a convenient location in which a vehicle user may store personal items such as, for example, tablet or laptop computers, mobile phones, newspapers, documents or umbrellas. Indeed, as best seen in Figure 5B, the storage cavity of the illustrated embodiment has a front portion 106F. The front portion 106F comprises an uninterrupted length (i.e. a distance between transverse ends 106RE and 106LE) of, for example, approximately 1m (e.g. 94.8cm), a depth of, for example, approximately 5cm (e.g. 5.3cm) and a height of, for example, approximately 10cm (e.g. 8.1cm). Accordingly, the front portion 106F is large enough to accommodate a standard full-length umbrella in its folded configuration. Such an umbrella may have a length of approximately 80-95cm and a diameter of approximately 5cm.

The storage cavity of the illustrated embodiment also comprises two side portions 106L, 106R behind the front portion 106F. Each of the side portions 106R, 106L may have a depth of, for example, approximately 15-20cm (e.g. 16.7cm), an uninterrupted width of, for example, approximately 30cm (e.g. 28.8cm) and a height that tapers from, for example, approximately 8cm at the opening of the side portion 106R, 106L to, for example, approximately 5cm at a distal end of the side portion 106R, 106L. Accordingly, the side portions 106L, 106R may provide a convenient location in which documents, newspapers, tablet computers or laptop computers may be stored. It will be understood that items stored in the side portions 106R, 106L may protrude into the front portion 106F, as there is no physical barrier at the front of the side portions 106R, 106L.

It will be appreciated that the configuration and dimensions described above are not definitive, and the storage cavity may be provided with various different configurations and dimensions as desired in alternative embodiments.

Figures 2A and 2B show views of the support structure 104 including a top surface 104T on which the cushion 102 is supported. In the illustrated embodiment, mounting brackets 114 are provided on the top surface 104T to connect to a base of cushion 102. The mounting brackets 114 may be arranged to connect to the cushion 102 in any appropriate manner, as will be well understood by the skilled person. The support structure 104 of the illustrated embodiment is also provided with fixing brackets 116 through which the support structure 104 may be bolted to, for example, the heel board of the vehicle body and fixing brackets 118 through which the support structure 104 may be bolted to, for example, the rear floor of the vehicle body.

As best seen in Figure 2A, the support structure 104 of the illustrated embodiment is provided with a plurality of recesses 120, into which protrusions of decorative trim 110 may be inserted to effect a releasable connection between the support structure 104 and the decorative trim 110.

The top surface 104T of the support structure 104 may also be provided with a cap 122 which can be opened to provide access through the support structure 104 via through hole 124 (as best seen in Figure 2C). This may provide access to a switch which may only require access when the vehicle 700 is being serviced. In the illustrated embodiment the cap 122 provides access to an isolation switch of an electric vehicle, but it will be understood that a cap 122 could be used to provide access to other vehicle controls.

In the illustrated embodiment, the support structure 104 is also provided with an opening 126 in a central region of the base of the storage cavity. In use the opening 126 may be covered by a door 128, as shown in Figure 1. The opening 126 can provide access to a vehicle component cavity 168 which is arranged to house any component that does not require regular access, but that it may be necessary for the vehicle users to periodically access. For example, the opening 126 may provide access to the passenger junction box (PJB) 302 illustrated in Figure 6.

As the support structure 104 is to be positioned between the seat cushion 102 and the vehicle body floor 108 it is necessary to ensure that the support structure 104 does not collapse or move significantly under the loading that occurs during a crash event, as movement or collapse of the support structure 104 during a crash event could cause the phenomenon known as “submarining” to occur. As will be well understood by the skilled person, submarining occurs when the loading during a crash causes the seat a user is sat on to move or collapse so that the user moves in a downward direction relative to the vehicle body. This causes the user’s seatbelt to ride up to a higher position on the user, which can increase the likelihood of the user being injured.

Furthermore, as there is a requirement to make vehicles more energy efficient it is desirable that the support structure 104 should be as light as possible without compromising crash safety.

To achieve the required combination of lightness and strength the support structure 104 comprises a moulding and a reinforcement structure, the reinforcement structure being located at least partially within the moulding. Figure 3 shows an example of the reinforcement structure 150, and Figure 4 shows an example of the support structure 104 within the moulding 152 in ghost outline such that the location of the reinforcement structure 150 within the moulding 152 can be seen.

The moulding 152 may be made from a thermoplastic polymer such as, for example, expanded polypropylene (EPP) having a density of, for example, 55-60kg/m³. However, it will be understood that EPP with a different density or different materials would also be suitable.

The reinforcement structure 150 may be made from, for example, steel and in the illustrated embodiment comprises a wireframe with a plurality of thin-walled portions 154, 156, 158, 160 connected thereto. It will be understood that other materials, especially other metals, and alternative structural configurations would also be suitable for use in the manufacture of the reinforcement structure 150.

In the illustrated embodiment, each of the thin-walled portions 154, 156, 158, 160 is provided with a plurality of through holes 162, which holes 162 are provided to allow the EPP to pass through the thin-walled portions 154, 156, 158, 160 during the moulding process, thereby enhancing the adhesion between the moulding 152 and the thin-walled portions 154, 156, 158, 160 of the reinforcement structure 150.

A particular advantage of providing a metal reinforcement structure 150 within a moulding 152 is that it allows the parts that are used in connecting the support structure 104 to other components, such as to a seat cushion 102 or vehicle body, to be formed on the reinforcement structure 150. In the illustrated embodiment the fixing brackets 116, 118 and mounting brackets 114 are all formed as parts of the reinforcement structure 150 that are arranged to protrude outside the moulding 152 when the support structure 104 is formed. As the fixing brackets 116, 118 and the mounting brackets 114 are formed as part of the support structure 104, which is partially contained within the moulding 152, a strong connection between the fixing brackets and mounting brackets and support structure 104, including the moulding 152, is provided.

It will be understood that the reinforcement structure 150 increases the stiffness and strength of the support structure 104. Although the wireframe and thin-walled portions 154, 156, 158, 160 are relatively thin, and therefore do not add a significantly amount to the weight of the support structure 104, they are resistant to buckling under normal or crash loading because of the presence of the moulding 152 around them, which provides them with additional support to resist buckling.

The thin-walled portions 154, 156, 158, 160 may be especially important in ensuring that the support structure 104 is capable of withstanding crash loading without allowing “submarining” of vehicle users sat on a cushion 102 supported by the support structure 104.

In the illustrated embodiment, thin-walled portions 154 and 160 comprise C-shaped fixing brackets located in the moulding 152 close to the respective transverse ends 106LE, 106RE of the front portion 106F of the cavity. Thin-walled portions 154, 160 each have an upper planar section 154U, 160U a lower planar section 154L, 160L and a connecting portion 154C, 160C. As can be seen in Figure 4, the upper portions 154U, 160U, the lower portions 154L, 154U and the connecting portions 154C, 160C are all located within the moulding 152, with the upper and lower portions located close to the upper and lower surfaces of the support structure 104. Accordingly, when the support structure 104 is subjected to a large compressive force, as is typically the case during a crash event when a user is sat on a seat supported by the support structure 104, the upper and lower portions 154U, 160U, 154L, 160L are urged against the base of the cushion 102 and the vehicle body floor 108, respectively. Under such high loading the compression resistance of the portion of the EPP moulding is relatively low, so a substantial proportion of the load is transmitted via the thin-walled portions 154, 160, which have higher stiffness and strength than the EPP moulding per se. It will be understood that under normal loading conditions the EPP moulding itself may be sufficiently strong to transmit the loads occurring as a result of a user sitting on the seat 102 to the vehicle body without undergoing significant deformation. Accordingly, the thin-walled portions may not transmit a significant proportion of the load under normal loading conditions.

The reinforcement structure 150 also comprises thin-walled portions 156, 158, located in the moulding 152 between the rearward portions 106R, 106L of the cavity 168. The thin-walled portions 156, 158 are each provided with lower planar portions 156L, 158L, which lower planar portions are located within the moulding 152 near a lower surface of the support structure 104. The lower planar portions 156L, 158L are each connected to respective centrally located mounting brackets 114 via connecting portions 156C. Accordingly, when the support structure 104 is subjected to a high compressive load as is likely to be the case during a crash event when a user is sat on a cushion that is supported by the support structure 104, the lower planar portions 156L, 158L are urged against (directly or via a part of the moulding) the vehicle body floor 108, whilst the centrally located mounting brackets 114 are urged against the base of the cushion 102. As the resistance to compression of the material that the moulding 152 is made from may be too low to withstand the compressive loads that are present during crashes, a significant proportion of the load that exists between the seat cushion 102 (which is directly connected to the thin-walled portions 156, 158 via the centrally located mounting brackets 114) is transmitted via the thin-walled portions 156, 158 to the vehicle body floor.

Although a large proportion of any large compressive load is transmitted via the thinwalled portions in the illustrated embodiment, it will be understood that it would also be possible to provide other parts within the reinforcement structure 150 for bearing large compressive loads and therefore preventing collapse of the support structure 104 under crash loading. Parts for bearing large compressive loads may be referred to as “compression portions”, and such compression portions may be located within the moulding 152 with ends close to the upper and lower surfaces of the moulding 152. This may allow the compression portion to be compressed between the body of the vehicle and the seat cushion 102 when the support structure 104 is subjected to large compressive loads.

Moving on to figures 5A and 5B, it can be seen that the seat cushion 102 may be secured to the support structure 104 via mounting brackets 114, which may subsequently be connected to the vehicle body via fixing brackets 116, 118. It will be understood that fixing brackets 116 may not be placed under tension when the support structure 104 is first connected to the vehicle body. Instead, the fixing brackets 116 may only be subjected to tension when the seat cushion 102 is subjected to high loads as would be the case during a crash. In this way the fixing brackets 118 may prevent the seat cushion 102 from sliding forward during a crash. It will be understood that the seat cushion 102 sliding forward during a crash may lead to “submarining” of an occupant of the seat, as described above.

Figure 6 shows the location 300 within a vehicle body where the support structure 104 may be attached to a vehicle 700. The fixing brackets 116 may be attached to the heel board 306 at mounting points 304, and the fixing brackets 118 may be attached to the vehicle body floor via mounting points 308. When the support structure 104 is attached to the vehicle body the PJB 302 is located within vehicle component cavity 168.

It will be understood that the support structure 104 of the present invention may be manufactured by known moulding techniques, for example injection moulding or compression steam chest moulding. The reinforcement structure 150 may be placed in the mould before the material of the moulding (e.g. EPP) is introduced to the mould, thereby to form a final part having a reinforcement structure at least partially located within a moulding.

Turning to Figure 7, that shows an underseat area 200 incorporating an embodiment of a different aspect of the present invention. It will be understood that the underseat area 200 may be incorporated into a vehicle 700 as shown in Figure 11 and be substantially as described above. Nevertheless, this aspect of the invention applies to any storage cavity having a horizontal aspect and being located near a floor of a vehicle where floor carpeting may be present.

The cushion support structure 104 shown in Figures 7 to 9 may or may not be the same as described above with reference to Figures 1 to 6. A cushion clip 202 may be located at the top of the support structure 104. Cushion clips 202 may be arranged to attach the support structure 104 to a vehicle cushion 102 (not shown in Figure 7) for example via a mounting bracket 114 of the support structure 104.

The support structure 104 includes, as described above, a storage cavity 106 that is designed to provide a stowage area for small personal items. A front, lower, portion 105 (as shown in Figures 8b and 9) of the support structure 104 adjacent the storage cavity 106 has connected to it a trim assembly 201 comprising an outer trim component 204 and a base trim component 208 (seen in Figure 8A and 9).

In the embodiments of Figures 7 to 9, an item retention ledge 206 is provided on the base trim component 208.

The outer trim component 204 is mounted on the base trim component 208, and is part of the mechanism arranged to both preserve carpet location and to prevent objects contained in the storage cavity 106 from falling or sliding out of it. The item retention ledge 206, as best seen in Figures 8A and 9, is arranged to protrude upwards from the storage cavity 106 in order to prevent small items from dislodging, when the trim assembly 201 is fitted to the storage cavity 106.

A retention ledge is necessary because the storage cavity has a horizontal aspect, and typically its opening is facing forwardly of the vehicle so that objects in it would tend to slide forwardly under vehicle braking and would otherwise be ejected from the cavity. A ledge is difficult to form on a moulding such as the support structure 104 since a core of a mould (not shown) forming the storage cavity 106 must be capable of being retracted once the moulded component within it has solidified.

The cushion support structure 104 may be moulded from expanded polypropylene (EPP) as per requirements of weight and rigidity, whereas the outer trim component 204 and base trim component 208 of the trim assembly 201 may also be moulded components, formed from any of various polymers or composites, and in the case of the outer trim component 204 in order to provide a premium finish to its outer surface 207 which is normally exposed to user view during use of the vehicle.

Figure 8A is a view of the underseat area 200 when the outer trim component 204 is dismounted and presented separately. The base trim component 208 comprises a side portion 210 and a front portion 212 and has a fastening mechanism to permit releasable connection of the base trim component 208 to the support structure 104. Although it is not visible in Fig 8A, it will be understood that another side portion 210 is present on the opposite side of the underseat area 200. The fastening mechanism may comprise the side portion 210 having a boss 211, (possibly with a screw (not shown) inside) to mount the base trim component 208 to the EPP cushion support structure 104, and a plurality of further bosses 214 provided along the front portion 212, which may also be configured to receive screws or other fixings in order to secure the base trim component 208 to the support structure 104. The bosses 211, 214 have a structure as described below with reference to Figure 9.

Between the base and outer trim components 208, 204 is a retention arrangement which comprises a first retention mechanism on the base trim component 208 in the form of a plurality of fixing points 216, and second retention mechanism on the outer trim component 204 in the form of a corresponding plurality of lugs 220 on the inside of the outer trim component 204. Inter-engagement of the lugs 220 with the fixing points 216 releasably connects the outer trim component 204 to the base trim component 208. Each lug 220 may comprise a spring metal clip 223 (see Figure 8B) retained on an upstanding flange 221 formed as part of the outer trim component and the fixing points 216 may comprise a slot 216A into which the metal clip can be snapfitted.

As described above, the lower portion of the cushion support structure 104 comprises a plurality of fixing brackets 116 through which the cushion support structure 104 may be fixed to a vehicle body floor.

The item retention ledge 206 at the top front portion of the base trim component is supported by a plurality of fillets 218 that are used to enhance the resistance and improve item retention functionality of the ledge 206 if heavier or bulky items are stored in the storage cavity 106.

A middle portion of the outer trim component 204 may also include a moulded cover mounting clip 224 that may be connected to the mounting clip slot 226 in a middle portion of the base trim component 208.

The edges of the outer trim component 204 may comprise a rim 222 that aligns with the edge of the retention ledge 206 when the base and the outer trim components 204, 208 are assembled together.

Figure 9 shows a cross sectional view of the trim assembly 201 on the line l-l in Figure 7. A top portion of the base trim component 204 comprises the item retention ledge 206 that protrudes upwards from the storage cavity 106. A rear edge 209 of the base trim component 204, 208 forms a close joint with a shoulder formed on the edge of the support structure 104 at the front/bottom edge of the storage cavity 106. This ensures that small items in the storage cavity 106 do not fall behind the base trim component 208.

A middle portion of the base trim component comprises one of the bosses 214 that hosts a threaded screw or bolt 230 that protrudes into the cushion support structure in order to secure the base trim component to the cushion support structure. An insert 228 is moulded or otherwise fixed within the matrix of the moulding that comprises the support structure 104 and is adapted to receive the screw 230.

Middle and lower middle portions of the base trim component 208 further comprise carpet holding means. In the illustrated embodiment the carpet holding means comprise flanges 232 that are pressed against the carpet 234 or other floor covering when the screws 230 are tightened. This provides engagement between the carpet 234 and the flanges 232 and results in the retaining of the carpet 234 in position. The lower part of the base trim component comprises 208 a carpet retention ledge 236 that further secures the carpet 234 to the vehicle body. The flange 232 runs substantially along the length of the base trim component 208 and serves to stiffen that component.

The outer trim component 204 has top 205 and bottom 235 edges that engage either with the storage cavity 106 (see Figure 10) and/or with the base trim component 208 to provide a close joint between them. A first edge 205 is located at the top portion of the outer trim component 204 for engaging with item retention ledge 206 to provide a close joint with it so as to prevent small items from falling between the outer and base trim components 204, 208. A second edge 235 is located at the bottom portion of the outer trim component 204 engages with the carpet retention ledge 236, or with the carpet 234 itself. Between the edges 205,235, the outer trim component 204 presents a clean surface 277 free of functional items or features that a user of the vehicle 700 would not normally engage in normal use of the vehicle 700 in which the trim assembly 201 is deployed. The outer trim component 204 serves to hide the functional aspects of the base trim component 208.

Disassembly of the outer trim component 204 from the base trim component 208 is achieved by judicial application of a tool from under bottom edge 235 and levering the outer trim component 204 away from the base trim component 208, in a direction transverse to the direction of the surface 277 and springing the lugs 220 away from, and out of engagement with, the reception slots 216A.

Figures 10A, B and C show, (in section in Figures 10A and B, and in plan view in Figure 10C) another possible arrangement of a trim assembly 201’, where the item retention feature 206’ is located on the outer trim component 204’ instead of on the base trim component 208 as described previously. In the embodiment, the top portion of the outer trim component 204’ comprises an item retention ledge 206’ that may protrude upward and in the direction of the storage cavity 106 to prevent the stored items from falling out. The middle portion of the base trim component 208’ comprises stiffening ribs 232’ that further secure the carpet location.

The outer trim component 204’ engages with the base trim component 208’ by means of a first retention mechanism on the base trim component 208’ comprising a retention slot 252 in a top surface 208T of the base trim component 208’ and downwardly depending latch tab 254 from the underside of the top surface adjacent the slot 252. A second retention mechanism on the outer trim component 204’ comprises a hook tab 256 which, when inserted into the slot 252 from above snaps into engagement with the latch tab 254 holding the two components together. At the same time, cover clip 238 on the outer trim component 204’ also snaps into engagement around the edge 236 of the base trim component 208’ to press against the carpet 234, providing a close joint against the carpet 234 (see Figure 10A). However, aligned with the tabs 256 are slots 238S in the cover clip 238. Extensions 236E of the base trim component extend into the slots 238S to provide a consistent appearance/finish of the bottom edge of the trim assembly 201’. However, the reception slots 238S in the cover clip enable a tool to be more easily inserted behind the base trim component 208’ to release the hook tab 256 from the latch tab 254, if and when the trim assembly 201’ is to be disassembled. This enables removal of the outer trim component 204’ from the base trim component 208’ in a direction substantially parallel its clean surface 277’ between its top edge 205’ and bottom edge 235. The position of the slots 238, which is visible (albeit not intrusively), enables the location of the tabs 256 to be identified along the trim assembly. It is to be noted that the stiffening ribs 232’ are relieved (see Figure 10C) where the tabs 256 are provided to enable insertion of the release tool behind the base trim component 208’.

The order of assembly of the trim assembly 201,201’ is therefore to assemble the seat support structure 104 as discussed above on the floor area 200 of the vehicle 700. Fixing brackets 116 are attached to the heel board 306 at mounting points 204, and the fixing brackets 118 are attached to the vehicle body floor via mounting points 208. The PJB 302 is exposed through the opening 126 in the support structure and covered by a suitable detachable cover 202C (Figure 8A). The carpet 234 is then laid on the floor 108 with a rough edge thereof along a line under the storage cavities 106L, 106F and 106R. The base trim component 208, 208’ is then connected to the seat structure 104 using the screws 230 in the bosses 211,214. In the case of base trim component 208, the rear edge 209 is carefully engaged with the shoulder on the support structure to ensure a close joint therebetween. Finally, in both cases, the outer trim component 204,204’ is fitted to the base trim component 208, 208’, in the case of outer trim component 204’, taking care to ensure that its rear edge 209’ engages the support structure shoulder in a close joint. Finally, the seat cushion 102 is fitted, attaching inter alia to the cushion clips 202.

Part of the reason why the arrangement is as described is because access may be required from time to time to serviceable components of the vehicle under the vehicle seat 102. Access to the PJB 302 is straightforward by removing the cover 202C. Access to the switch under cap 122 only requires removal of the cushion 102 and the cap 122 in the support structure 104. However, other serviceable components, such as the vehicle battery 301 (see Figure 6), may be accessed only by removing the support structure 104 entirely, and this involves release from the carpet 234. Therefore, it is not acceptable to adhere or otherwise bond the carpet to the support structure 104. Nevertheless, a neat and clean transition between the carpet and seating of the vehicle is necessary and this is achieved by a trim assembly in accordance with the present invention.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims.

The following list of numbered clauses comprise statements of invention.

1. A support structure for a vehicle seat, the support structure comprising a moulding;

wherein the support structure comprises a reinforcement structure;

the reinforcement structure being located at least partially within the moulding; and wherein a storage cavity is provided in the support structure.

2. A support structure as described in clause 1, wherein the reinforcement structure comprises a metal wireframe.

3. A support structure as described in any preceding clause, wherein the reinforcement structure comprises at least one bracket located outside the moulding.

4. A support structure as described in clause 3, wherein the at least one bracket comprises at least one fixing bracket configured to be connected to a body of the vehicle.

5. A support structure as described in clause 3 or clause 4, wherein the at least one bracket comprises at least one mounting bracket configured to be connected to a portion of the vehicle seat.

6. A support structure as described in any of clauses 3 to 5, wherein the at least one bracket is connected to the reinforcement structure.

7. A support structure as described in any preceding clause, wherein the reinforcement structure comprises at least one thin-walled portion.

8. A support structure as described in clause 7, wherein one or more apertures are formed in the at least one thin-walled portion.

9. A support structure as described in clause 7 or clause 8, wherein the at least one thin-walled portion comprises a first planar section located within the moulding near an upper surface of the moulding and a second planar section located within the moulding near a lower surface of the moulding, and a connecting portion between the first and second planar sections.

10. A support structure as described in clause 9, wherein the at least one thinwalled portion comprises a C-shaped bracket.

11. A support structure as described in any one of clauses 7-10, comprising a plurality of thin-walled portions.

12. A support structure as described in any preceding clause, wherein the reinforcement structure comprises at least one compression portion, the compression portion being contained within the moulding;

wherein the compression portion is arranged to be compressed between the body of the vehicle and the seat cushion if the seat cushion is compressed towards the body of the vehicle by more than a predetermined amount.

13. A support structure as described in clause 12, wherein the cavity has first and second transverse ends and one of said compression portions is located in the moulding proximate each of the first and second transverse ends.

14. A support structure as described in clause 13 as dependent on any one of clauses 7-11, wherein the compression portion comprises a thin-walled portion.

15. A support structure as described in any preceding clause, wherein the storage cavity has a maximum uninterrupted length of at least 90cm, preferably at least 95cm.

16. A support structure as described in any preceding clause, wherein the storage cavity has a depth of at least 15cm.

17. A support structure as described in any preceding clause, wherein the moulding comprises expanded polypropylene (EPP).

18. A support structure as described in clause 17, wherein the moulding comprises EPP with a density of 55-60kg/m³

19. A support structure as described in any preceding clause, wherein the storage cavity comprises a front portion and at least one rearward portion, the front portion being located between an opening of the storage cavity and the at least one rearward portion.

20. A support structure as described in clause 19, wherein the front portion has a maximum length of at least 90cm, preferably at least 95cm, and wherein the maximum length of the rearward portion is less than the maximum length of the front portion.

21. A support structure as described in clause 19 or clause 20, wherein the storage cavity comprises at least two of said rearward portions.

22. A support structure as described in clause 21 where dependent on clause 12, wherein one of said compression portions is located in the moulding between said rearward portions.

23. A system comprising a support structure as described in any preceding clause and a vehicle seat cushion.

24. A system as described in clause 23, wherein the vehicle seat cushion comprises a sheet metal base portion.

25. A vehicle comprising a system as described in any one of clauses 23-24.

26. A vehicle as described in clause 25, wherein the system forms a bench portion of a second or third row seating arrangement.

Claims

1. A trim assembly for a vehicle, wherein the vehicle comprises a carpet and a support structure defining a storage cavity, the trim assembly comprising:

2. A trim assembly as claimed in claim 1, wherein the base trim component comprises:

a carpet holding means;

a fastening mechanism for releasably securing the base trim component to a wall of the support structure adjacent an opening of the storage cavity.

3. A trim assembly as claimed in claim 2, wherein the fastening mechanism comprises a series of bosses formed along the length of the base trim component to receive screws or bolts for engagement with the support structure which, when tightened causes the base trim component to press the carpet holding means into holding engagement with the carpet.

4. A trim assembly as claimed in claim 2, or claim 3, wherein the carpet holding means serves also to stiffen the base trim component along its length.

5. A trim assembly as claimed in any preceding claim, wherein the trim assembly comprises an outer trim component configured to be mounted on the base component.

6. A trim assembly as claimed in claim 5, wherein the outer trim component comprises second retention mechanism for engagement with a first retention mechanism of the base trim component.

7. A trim assembly as claimed in claim 6, wherein the outer trim component comprises a first edge, for engaging the support structure or base trim component to provide a close joint against the support structure or base trim component.

8. A trim assembly as claimed in claim 6 or claim 7, wherein the outer trim component comprises a second edge, for engaging the carpet or base trim component to provide a close joint against the carpet or base trim component.

9. A trim assembly as claimed in claim 8, wherein the outer trim component comprises a clean surface between said first and second edges.

10. A trim assembly as claimed in any of claims 6 to 9, wherein the first retention mechanism comprises a slot in the base trim component and the second retention mechanism comprises a tab on the outer trim component, which tab is adapted to snap into engagement with the slot in the base trim component.

11. A trim assembly as claimed in claim 10, wherein the direction of insertion of the tab in the slot is transverse the direction of said clean surface.

12. A trim assembly as claimed in claim 11, wherein a tool inserted behind said surface enables the outer trim component to be levered away from said base trim component in said transverse direction to spring said tab out of engagement with said slot.

13. A trim assembly as claimed in claim 12, wherein the direction of insertion of the tab in the slot is substantially parallel the direction of said clean surface, the tab comprising a hook to engage with a latch on the base trim component.

14. A trim assembly as claimed in claim 13, wherein a tool inserted behind said base trim component enables the tab to be released from the latch and the outer trim component to be lifted away from said base trim component in said direction.

15. A trim assembly as claimed in any preceding claim, wherein the item retention feature is disposed on the outer trim component.

16. A trim assembly as claimed in any of claims 1 to 14, wherein the item retention feature is disposed on the base trim component.

17. A support structure for a vehicle seat, the support structure comprising a moulding;

wherein the support structure comprises a reinforcement structure;

the reinforcement structure being located at least partially within the moulding;

wherein a storage cavity is provided in the support structure; and wherein a trim assembly as claimed in any of claims 1 to 16 is employed to

5 secure carpet against the moulding of the support structure adjacent the opening of the storage cavity.

18. A system comprising a support structure as claimed in any preceding claim and a vehicle seat cushion.

19. A system as claimed in claim 18, wherein the vehicle seat cushion comprises a sheet metal base portion.

20. A vehicle comprising a system as claimed in any one of claims 18-19.

21. A vehicle as claimed in claim 20, wherein the system forms a bench portion of a second or third row seating arrangement.