Vehicle seat assembly having a hardness gradient via hollowed sections and/or protrusions

Abstract

In at least one embodiment, the present invention provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface to the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 8% to 25%.

1 . A vehicle seat assembly comprising:
 a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, the cushion having a plurality of intrusions extending from the “A” surface to the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 8% to 25%.   
     
     
         2 . The vehicle seat assembly of  claim 1  wherein the at least one bolster areas has a hardness that is at least 8% to 25% greater than the hardness of the central portion. 
     
     
         3 . The vehicle seat assembly of  claim 1  wherein the central portion has holes formed in the “A” surface of the central portion to provide a reduced hardness relative to the at least one of the bolster areas. 
     
     
         4 . The vehicle seat assembly of  claim 3  wherein the holes have a diameter of 0.2 to 5.0 cm. and a length of 5 to 15.25 cm. 
     
     
         5 . The vehicle seat assembly of  claim 4  wherein the cushion comprises a molded foam cushion and the holes are formed during the molding of the cushion. 
     
     
         6 . The vehicle seat assembly of  claim 4  wherein the holes are formed on a sub cushion assembly that is attached to a main cushion assembly having holes substantially aligned with the holes of the sub cushion assembly. 
     
     
         7 . The vehicle seat assembly of  claim 3  wherein the “A” surface has protrusions formed therein. 
     
     
         8 . The vehicle seat assembly of  claim 7  wherein the protrusions extend from the “A” surface, away from the “B” surface, a distance of 0.1 to 5.0 cm. 
     
     
         9 . The vehicle seat assembly of  claim 1  wherein the cushion comprises a seat bottom cushion, with the central portion having a front half having a lower hardness than a rear half of the central portion. 
     
     
         10 . A vehicle seat assembly comprising:
 a cushion having an “A” surface and a “B” surface, a central portion, two side bolster areas adjacent the central portion, and a front bolster area extending between and connecting the side bolster areas, wherein the central portion of the cushion has a first plurality of intrusions extending from the “A” surface to the “B” surface to form a hardness gradient between at least one of the side bolster areas and the central portion of between 8% to 25%, and the front bolster area has a second plurality of intrusions, less than the first plurality, extending from the “A” surface to the “B” surface to form a hardness gradient between the front bolster area and the central portion of 5% to 20%.   
     
     
         11 . The vehicle seat assembly of  claim 10  wherein the central portion comprises a front half adjacent the front bolster area and a rear half spaced from the front bolster area and adjacent the front half, the front half having a hardness gradient relative to at least one of the side bolster areas of between 8% to 15% and the rear half having a hardness gradient relative to at least one of the side bolster areas of between 12% to 25%. 
     
     
         12 . A method of making a vehicle seat assembly, the method comprising:
 providing a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, the cushion having a plurality of intrusions extending from the “A” surface to the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 8% to 25%;   securing the cushion to a frame; and   covering the cushion with a trim member.   
     
     
         13 . The method of  claim 12  wherein the at least one bolster areas has a hardness that is at least 8% to 25% greater than the hardness of the central portion. 
     
     
         14 . The method of  claim 12  wherein the providing step comprises molding a polymeric material to form a foam cushion. 
     
     
         15 . The method of  claim 14  wherein the central portion has holes formed between the “A” surface and the “B” surface of the center area to provide a reduced hardness relative to the at least one bolster area. 
     
     
         16 . The method of  claim 15  wherein the holes have a diameter of 0.2 to 5.0 cm. and a length of 5 to 15.25 cm. 
     
     
         17 . The method of  claim 15  wherein the holes are formed during the molding of the cushion. 
     
     
         18 . The method of  claim 15  wherein the location, shape and/or size of the holes are based upon occupant pressure modeling. 
     
     
         19 . The method of  claim 18  wherein an area of the central portion determined to be subjected to a relatively high occupant pressure has less and/or smaller holes than an area of the central portion determined to be subjected to a relatively low occupant pressure. 
     
     
         20 . The method of  claim 16  wherein the holes are formed on a sub cushion assembly that is attached to a main cushion assembly having holes substantially aligned with the holes of the sub cushion assembly.