WO2010033965A1

WO2010033965A1 - Automotive seat back structure

Info

Publication number: WO2010033965A1
Application number: PCT/US2009/057782
Authority: WO
Inventors: Bill Dieter
Original assignee: Porteon Electric Vehicles, Inc.
Priority date: 2008-09-22
Filing date: 2009-09-22
Publication date: 2010-03-25

Abstract

A lightweight seat back and headrest structure for an automotive seat comprises a tubular perimeter frame with a removable fabric envelope stretched over the frame. The envelope is preferably of mesh type. Stretching and fastening the fabric cover on the tubular frame forms the shape of the seat back and serves to provide cushioning and support to the occupant. Both frame and cover have unique features to facilitate stretching, fastening and controlling the shape of the cover when installed.

Description

Automotive Seat Back Structure

Field of the invention

[0001] The present invention relates to structure for the seat back and headrest portion of a seat and in particular a seat installed in a vehicle.

Background

[0002] There exists a wide variety of automotive seat designs. They range from simple plastic or metal shells, with or without foam or other type of padding, to complex articulated structures with motor-driven adjustments, heating, ventilation and a number of covering options. In addition to varying comfort, adjustability, weight, esthetic and cost requirements, automotive seats and in particular the seat backs have to withstand forces that could be transmitted from the occupant's body in the event of a crash. In contrast to home and office seating, a high degree of lateral support for the occupant's upper body is desirable to provide comfort and control while cornering. Further, in the case of seats which may have additional occupants seated behind them, it is desirable to provide some cushioning for aft-seated passenger's knees and also to isolate them from the back of the occupant of the seat.

[0003] A mesh-covered seat back has many advantages in that it is light, low in cost, provides ventilation and can deliver a high degree of comfort in some configurations. Many examples of mesh-covered seat backs are known in office and home chair applications, such as those disclosed by Edwards, et al. (7,144,084), Koepke, et al. (6,729,691), Chou, et al. (6,957,861), Cvek (6,439,665) and others. However mesh- covered automotive seats are not common, due at least in part to the additional requirements as discussed above. A seat back design that could meet the requirements of the automotive application and deliver the benefits provided by mesh covering would prove advantageous in many vehicular applications. The present invention discloses such a design.

Summary

[0004] The objective of the present invention is to provide a seat back structure for an automotive seat which can be covered with mesh fabric and meet the structural and other requirements of the automotive application. To achieve this objective, a lightweight tubular framework is disclosed over which a mesh fabric envelope is stretched and fastened.

[0005] The shape of the tubular framework along with the tension in the mesh fabric envelope provide shape to the back rest surface and provide support for the occupant's back as well as cushioning and separation to keep the knees of aft-seated passengers from contacting the seat occupant's body. The tubular framework provides the necessary strength to meet structural load requirements of the automotive application. A headrest support is included in the framework.

[0006] A fastening apparatus consisting of a tensioning flap, a tensioning bar and buckle-fastened straps is provided as a means of removably attaching the fabric envelope to the tubular framework.

Brief description of the drawings

[0007] Embodiments of the present invention is described herein with reference to the following drawings:

[0008] Fig. 1 shows an automotive seat with the seat back structure according to an embodiment of the present invention;

[0009] Fig. 2 is an illustration of the tubular framework of the seat back structure according to an embodiment of the present invention;

[00010] Fig. 3 illustrates the mesh fabric envelope of the seat back structure according to an embodiment of the present invention; and

[00011] Fig. 4 shows details of fastening the fabric envelope to the tubular framework according to an embodiment of the present invention.

Detailed description

[00012] An automotive seat featuring the seat back structure according to an embodiment of the present invention is shown in Fig. 1. Generally, it consists of a tubular framework 100 over which an mesh fabric envelope 200 is stretched and fastened. In one embodiment of the invention, pockets may be added to the envelope for insertion of foam to create a more fitted or customized seat. The ease with which the fabric envelope may be removed makes such insertion possible. A seat cushion 50 is also attached to the tubular framework 100. An embodiment having a continuous framework 100 with direct attachment of the seat cushion 50 is illustrated, however the framework 100 may further incorporate lockable hinges at the base of the seat back to facilitate reclining of the entire seat back relative to the seat cushion. Many examples of such hinges are known and it will be apparent to those skilled in the art, based on the disclosures made herein, how such hinges may be incorporated within the scope of the present invention. A detailed description of hinges is therefore not included.

[00013] Fig. 2 illustrates the tubular framework 100 according to an embodiment of the present invention and Fig. 3 shows the details of the mesh fabric envelope 200 according to an embodiment of the present invention. There are several features which allow the framework to achieve the objectives of the present invention. The main structural part consists of a robust perimeter frame 105 which provides the primary support for the mesh fabric envelope 200. The perimeter frame 105 is preferably formed from a continuous steel tube of sufficient diameter and thickness to accommodate the required loads. The exact calculation of the loads and corresponding tube dimensions may be performed according to methods well known in the art and is not included herein. The embodiment illustrated in Fig. 2 shows the perimeter frame 105 continuing underneath the seat cushion as a single unit. As previously disclosed, hinges may be incorporated at the base of the seat back to facilitate reclining of the seat back relative to the seat cushion, without departing from the scope of the present invention.

[00014] The perimeter frame 105 preferably features forward- angled lateral support elements 110, which may be formed as bends in the continuous tube. The support elements extend forward and laterally outward from the primary plane of the seatback to provide lateral support for the occupant's body during cornering and also to facilitate shaping of the mesh fabric envelope. [00015] A second main element of the tubular framework according to an embodiment of the present invention is a horizontal bar 130 which serves to provide retaining means for the mesh fabric envelope. The tensioning flap 220 of the fabric envelope is wrapped around the horizontal bar, as further discussed below, to both tension the primary seat back panel 205 and retain the envelope on the tubular framework. The horizontal bar 130 further serves to strengthen the assembly. While the embodiment depicted illustrates bar 130 as being straight, in one embodiment, horizontal bar 130 may be curved to create a more "cupped" seat back.

[00016] A fabric support structure 120 is provided to stretch the rear- facing portion of the fabric envelope in the rearward direction. Preferably it is located centrally in the tubular framework structure and is connected between the horizontal bar 130 and the upper portion of the perimeter frame 105. In the illustrated embodiment the fabric support structure 120 is formed as a continuous inverted U shape with the uppermost portion also forming the headrest support 125. Other embodiments are possible without departing from the scope of the present invention. The purpose of the fabric support structure 120 is to stretch the rear- facing portion of the mesh fabric envelope 200 and tension the separation panels 207 to provide cushioning for the knees of aft- seated passengers and to separate them from the body of the seat occupant. The support structure 120 is dimensioned and located so as to avoid interference between the knees of aft-seated passengers and the structure itself.

[00017] Fig. 4 shows the details of the fastening and tensioning means for the attachment of the fabric envelope 200 to the tubular framework 100. The tensioning flap 200 is coupled to the forward-facing portion of the fabric envelope and is preferably the continuation of the primary panel 205. At its edge the tensioning flap preferably incorporates a sewn loop through which tensioning bar 210 is inserted. Embodiments omitting the tensioning bar are possible but not preferred. During installation, the fabric envelope 200 is slid and stretched elastically over the perimeter frame 105. The tensioning flap 220 is then wrapped around horizontal bar 130 and the tensioning bar 210 is inserted through the sewn loop at its edge. To tension and secure the assembly, straps 230 are looped around tensioning bar 210 and fastened with buckles 235. In embodiments omitting a tensioning bar, one or more tensioning straps may engage the tensioning flap 200 by means of grommets or any other known means. Alternatively, one or more tensioning straps may be sewn to the tensioning flap 220 and engage the main portion of the fabric envelope by means of grommets, metal or fabric loops, or other similar means. Many examples of tensioning straps and buckles exist in the art and a detailed description is therefore not necessary herein. After installation, the fabric envelope can subsequently be readily removed for cleaning or replacement.

[00018] The combined unique features of the seat back structure according to the embodiments of the present invention, as set forth herein, facilitate the manufacture of an automotive seat that provides the benefits of mesh fabric covering while meeting the structural and other requirements particular to the automotive application. The embodiments disclosed herein are illustrative and not limiting; other embodiments shall be readily apparent to those skilled in the art, without departing from the scope of the present invention.

Claims

ClaimsWhat is claimed is:

1. An automotive seat back structure comprising: a tubular framework including: a tubular perimeter frame; a horizontal bar coupled to the tubular perimeter frame and located substantially at the base of the seat back structure; and a fabric support structure coupled to the tubular perimeter frame and the horizontal bar; and an elastic fabric envelope including: a rear-facing portion, wherein said fabric support structure is to stretch the rear-facing portion in a rearward direction; a forward-facing portion; a tensioning flap coupled to the forward-facing portion to wrap around said horizontal bar; and a tensioning strap to couple in tension the rear-facing portion of said fabric envelope and said tensioning flap.

2. The automotive seat back structure of Claim 1 further comprising a tensioning bar and wherein said tensioning flap further comprises a sewn loop to receive said tensioning bar; and wherein said tensioning strap is to engage said tensioning bar.

3. The automotive seat back structure of Claim 1 wherein said elastic fabric envelope is constructed of mesh fabric.

4. The automotive seat back structure of Claim 1 wherein said rear-facing fabric support structure further incorporates a headrest support.