Vehicle seat component and method for making same

Abstract

A vehicle seat component ( 14, 14 a , 14 ′) and its method for making same with a seating portion ( 20 ) molded from either expanded polyethylene or expanded polypropylene to have a density in the range of 0.3 to 2.8 pounds per cubic foot with a softness to provide seating comfort. A seat support ( 22 ) of the seat component is molded from expanded polypropylene and has a density in the range of 5 to 10 pounds per cubic foot so as to provide structural support. The seating portion ( 14, 14 a ) can be molded from either expanded pellets ( 28 ) or extruded and expanded tubes ( 34 ) of either polyethylene or polypropylene, while the seat support ( 22 ) is molded from expanded polypropylene pellets ( 30 ). The seat component ( 14 ′) may have a cover ( 36 ′) molded to the seating portion ( 20 ), and both the moldings may be sequentially in the same mold ( 44 ).

What is claimed is:  
     
         1 . A vehicle seat component comprising: 
 a seating portion molded from an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene with the seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; and    a seat support for mounting the seating portion on a vehicle body, and the seat support being molded from expanded polypropylene and having a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support.    
     
     
         2 . A vehicle seat component as in  claim 1  wherein the seating portion and the seat support have a molded interface with each other.  
     
     
         3 . A vehicle seat component as in  claim 1  wherein the seating portion is made from expanded polymeric pellets that are fused to each other during the molding, and wherein the seat support is made from expanded polypropylene pellets also fused to each other during molding.  
     
     
         4 . A vehicle seat component as in  claim 1  wherein the seating portion is made from extruded polymeric tubes that are expanded and then fused to each other during the molding, and wherein the seat support is made from expanded polypropylene pellets fused to each other during molding.  
     
     
         5 . A vehicle seat component as in  claim 1  further including a cover to which the softer seating portion is molded.  
     
     
         6 . A vehicle seat component as in  claim 1  wherein the seating portion has vent passages through which air passes to provide cooling to the seat.  
     
     
         7 . A vehicle seat component as in  claim 6  further including a fan mounted by the seat support to supply air to the vent passages of the seating portion.  
     
     
         8 . A vehicle seat component as in  claim 7  wherein the seat support includes a vent opening in which the fan is mounted to supply the air to the vent passages of the seating portion.  
     
     
         9 . A vehicle seat component comprising: 
 a seating portion molded from an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene with the seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort;    a seat support for mounting the seating portion on a vehicle body, and the seat support being molded from expanded polypropylene and having a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support;    the seat support and the seating portion having a molded interface with each other; and    a cover to which the softer seating portion is molded.    
     
     
         10 . A method for making a vehicle seat component comprising: 
 injecting an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene into a mold and heating thereof to provide molding that provides a seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort;    injecting expanded polypropylene into a mold and heating thereof to provide molding that provides a seat support having density in the range of 5 to 10 pounds per cubic foot so at to have sufficient rigidity to provide structural support; and    securing the seating portion to the seat support.    
     
     
         11 . A method for making a vehicle seat component as in  claim 10  wherein the seating portion and the seat support are molded in the same mold so as to have a molded interface that provides the securement thereof to each other.  
     
     
         12 . A method for making a vehicle seat component as in  claim 10  wherein the seating portion is made from expanded polymeric pellets that are fused to each other during the molding and wherein the seat support is also made from expanded polypropylene pellets fused to each other during the molding.  
     
     
         13 . A method for making a vehicle seat component as in  claim 10  wherein the seating portion is made extruded polymeric tubes that are expanded and fused to each other during the molding and wherein the seat support is made from expanded polypropylene pellets fused to each other during the molding.  
     
     
         14 . A method for making a vehicle seat component as in  claim 10  wherein a cover is initially inserted into the mold in which the expanded polymer is subsequently injected into the mold and heated to provide the seating portion which is molded to the cover, and wherein the expanded polypropylene is subsequently injected into the same mold and heated to provide the seat support which has an interface with the seating portion.  
     
     
         15 . A method for making a vehicle seat component as in  claim 10  wherein the seating portion is molded with vent passages for air flow that provides cooling.  
     
     
         16 . A method for making a vehicle seat component as in  claim 15  wherein a fan is mounted by the seat support to provide cooling air to the vent passages of the seating portion.  
     
     
         17 . A method for making a vehicle seat component as in  claim 16  wherein the seat support is molded with an opening through which the air flows to the fan for flow to the vent passages of the seating portion.  
     
     
         18 . A method for making a vehicle seat component comprising: 
 inserting a cover into a mold;    injecting an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene into the mold and heating thereof to provide molding that provides a seating portion secured to the cover and having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; and    injecting expanded polypropylene into the mold and heating thereof to provide molding that provides a seat support having a molded interface with the seating portion and a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support.