Cushion and trim cover for contoured cushion presenting seat

Abstract

A seat cushion and method of manufacturing a seat cushion suitable for use with a seat having a contour presenting device configured to move the seat cushion between a non-presented position and a presented position is disclosed. The seat cushion generally includes a substrate having a first portion and a second portion that are separated by a trench. A connector is provided for registering the substrate to a contour presenting device. The trench is designed to provide the seat cushion with a consistent, high quality craftsmanship, finish and appearance. According to one exemplary embodiment, the trench comprises a first side wall having a substantially vertical surface and a second side wall having an angled surface.

1 . A cushion for use with a seat having a contour presenting device, the cushion comprising: 
 a substrate having a first portion and a second portion;    a trench separating the first portion from the second portion and defined by a first side wall and a second side wall; and    at least one connector coupled to the substrate for registering the substrate with the contour presenting device,    wherein the second portion of the substrate is adapted for rotating a first angular distance when moving between a non-presented position and a presented position,    wherein the trench is configured to provide a substantially vertical trench when in the presented position.    
   
   
       2 . The cushion of  claim 1 , wherein the first portion of the substrate is integrally formed with the second portion of the substrate.  
   
   
       3 . The cushion of  claim 1 , wherein the first side wall defining the trench has a substantially vertical surface and the second side wall defining the trench has a relatively angled surface compared to the first side wall.  
   
   
       4 . The cushion of  claim 3 , wherein the first portion of the substrate is configured as a main portion of a seat back and the second portion of the substrate is configured as a side bolster portion of the seat back.  
   
   
       5 . The cushion of  claim 4 , wherein the first side wall is provided on the main portion of the seat back and the second side wall is provided on the side bolster portion of the seat back.  
   
   
       6 . The cushion of  claim 1 , wherein the angle formed between the first side wall of the substrate and the second side wall of the substrate when the cushion is in the non-presented position is approximately equal to the first angular distance that the second portion of the substrate is rotated to achieve the presented position.  
   
   
       7 . The cushion of  claim 1 , wherein the second side wall of the substrate is substantially parallel with the first side wall of substrate after the second portion of the substrate is moved into the presented position.  
   
   
       8 . The cushion of  claim 1 , further comprising a wire coupled to the substrate, wherein the wire is configured to be engaged by the connector for registering the substrate to the contour presenting device.  
   
   
       9 . The cushion of  claim 1 , further comprising a first connector member and a second connector member, wherein the first connector member is provided for registering the substrate in a first direction and the second connector member is provided for registering the substrate in a second direction that is different than the first direction.  
   
   
       10 . The cushion of  claim 9 , wherein the first direction is substantially horizontal to the substrate and the contour presenting device, and wherein the second direction is substantially vertical to the substrate and the contour presenting device.  
   
   
       11 . The cushion of  claim 1 , further comprising a trim cover disposed about the first portion of the substrate and the second portion of the substrate.  
   
   
       12 . The cushion of  claim 11 , further comprising a trim cover retaining flap coupled to an edge of the trim cover at a first end of the trim cover retaining flap.  
   
   
       13 . The cushion of  claim 12 , further comprising a connector coupled to a second end of the trim cover retaining flap, wherein the connector is configured to engage the contour presenting device for securing the trim cover.  
   
   
       14 . The cushion of  claim 12 , wherein the trim cover retaining flap is formed of a relatively non-stretchable material.  
   
   
       15 . The cushion of  claim 11 , wherein the trim cover includes a first portion formed of a first material having a first coefficient of expansion and a second portion formed of a second material having a second coefficient of expansion that is less than the first coefficient.  
   
   
       16 . The cushion of  claim 15 , wherein the second material is aligned with the second portion of the substrate and the first material is aligned with the first portion of the substrate.  
   
   
       17 . A vehicle seat comprising: 
 a seat back movably supported relative to a seat bottom;    a substrate supported at one of the seat back and the seat bottom and having a trench separating a main portion of the substrate from a side bolster portion of the substrate;    a contour presenting device adapted for moving the side bolster portion of the substrate between a non-presented position and a presented position;    at least one connector registering the substrate with the contour presenting device; and    a closeout device adapted for concealing a gap created when contour presenting device is moved from the non-presented position to the presented position, wherein the trench provides a visually square trench when the side bolster portion is in the presented position.    
   
   
       18 . The vehicle seat of  claim 17 , wherein the closeout device comprises a plurality of telescoping panels configured to outwardly telescope as the side bolster portion of the substrate is moved into the presented position.  
   
   
       19 . The vehicle seat of  claim 17 , wherein the closeout device comprises a slide member having a first end coupled to move with the side bolster and a second end slidably coupled to move until being retained by a stop formed in the second end.  
   
   
       20 . The vehicle seat of  claim 17 , wherein the closeout device comprises a side facing stretchable material configured to stretch as the side bolster is moved into the presented position.  
   
   
       21 . The vehicle seat of  claim 20 , further comprising a biasing element having a first end coupled between a first end and a second end of the side facing stretchable material, wherein the biasing element urges the side facing stretchable material inward as the side bolster portion moves from the presented position to the non-presented position to reduce bunching in the side facing stretchable material.  
   
   
       22 . A method of manufacturing a cushion having a main portion and a bolster portion for use with a seat having a contour presenting device configured to angularly rotate the bolster portion between a non-presented position and a presented position, the method comprising: 
 predetermining the angular rotation of the bolster portion between the non-presented position and the presented position;    providing the cushion with a trench separating the first portion from the second portion;    forming the trench with a first side wall provided on the main portion of the cushion and a second side wall provided on the bolster portion of the cushion; and    designing the angle formed between the first side wall and the second side wall when the cushion is in the non-presented position so that the first side wall and the second side wall are substantially parallel when the side bolster portion is moved to the presented position.    
   
   
       23 . The method of  claim 22 , further comprising the step of designing the first side wall as a substantially vertical surface and the second side wall as a relatively angle surface compared to the first side wall.