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;;:!;; kn of 3eneit: 01F Filing Date
The- present application claims the benefit of the filing date of United States ":r:. visional Amplication Serial No. 60/312,874, filed August 15, 200', and .0/ $35,430, filiMJ October 31, 2001 the contents of which are hereby incorporated by ■■3l: rence.
f*e: hnicai Field
The pro.c;::'ft!: invention relates to an improved siting system, and more :an;;u!eM/ to -in improved system for automotive vehicle seating. The present aviation .also rulatas to improved automotive vehicle interior systems.
•3cii:kgrotincl
Th*re is IT. ever-growing nee- for' improved sea:hcj systems in automotive i3" des. The -HUCI-S in popu larlty cf hatchbacks, sport utility v'ehicieo and nhivans, )■?,'.■ posed unique design challenges, in view of the need for seating to be adjustable
.;. Y: ;n many }r,:a'.£:Mce-s to retrain cargo carried toward the rear of the vehicle. In ■;jh of the: incrtSf-.Eod consumer usage of these vehicles- for stowage and transport cf
'.;3 '\o along wiui passengers (particularly passengers in rear seals), manufacturers
■..a-3 turred their attention lo improving the ability cf the seating systems to
ivii stand large o«.ds.
Ofi-3 approach nas been to devebp improved system?; for transmitting loads .:; \B seat track;;, of vehicle seating assemblies. A growing number of applications, ;o.' ever, ernplcy .'attachment of seating components direct'y to the vehicle t>ody in :h e for load distribution to the oody m white. For the improved seat track :.:c: nolocjy to 'JO viable in the latter applications, it wvould require substantial ■c :ification, Yvhioh is believed wouid unduly complicate the manufacturing TC'-fcdures, requiTr the development of expensive new processing techniques, or rf:; substantias v-'Gight to the vehicles. Accordingly, there is a need for an improved, i.-ui.iily msnufac^ired seating system that is capable of meeting vehicle manufacturer .■.3:-;cjn crneria ciic. government standards fcr vehicles, and which can be efficiently
aiki convenient; y adapted for use in a variety of applications including those involving sent track load distribution, body in white load distribution or both.
In addition to having load bearing characteristics, ft may he desirable for ■suiting system-;; to include one or mora additional functional features, ordinarily p£i.-:kagec: elsey.tie-re (e.g., in other locations ol a vehicle). Examples of such futures include ducts, vents, motors, electronic devices, entertainment devices, .■-.cnnmunioatiorMs devices, other comfort, convenience or utilitarian features and the iik-. Accommodation of these features in conventional seats often poses difficulties ai,'\5n the limits:! packaging space available, Thus, there is also a need for a seating :iy:.tem that cen Integrate one or more comfort, convenience or other utilitarian features.
Examples- cf advanfagsous improved systems fcr seating are disclosed in conmonly-owned and co-pending U.S. Application Sena! No. 09/766,792 (filed January 22, 200'!), and 60/312,874 Jfi-ed August 15, 2001), and 60/335,430 (tiled 0,;:ober 31, 2001), the teachings of which are hereby expressly incorporated by ■e :renc3 herein for all purposes.
Sunmary of \h& Invention
The neec's ;.n the art are met by the automotive vehicle seating system of the present invention, which includes a plastic seat back having a first panel portion and an opposing so::;ond pane! portion, optionally made separately from the first pane! pc ticn, snci secured (e.g, with attachments such as weds, adhesives, mechanical ,o ds, fasteners*, tack-offs or the like) to the the first panel portion. In a preferred Lirr ocdim^m, cn*> or both of the first and second panels portions include one or more migrated reinforcement structures for providing strength to the seat back when as:: embied. Optionally, the invention also includes an assembly for receiving the . ::■ e=;";t back and s-scuring it to the vehicle body in white. Advantageously, the seating ■••y:tem displays no fragmentation upon rapid acceleration up to about 20 to shout 30 ;i, vith at leacr, >a 36 Kg mass placed behind the s^eat back. The system is easy to mifnufactjre and '.viii not add substantial weight to the vehicle as compared with oti =T commercial seating systems.
FI'3.1 us t perspective* view of a seatback assembly;
FIG. 2 ill jstrates a sectional view of the seaiback in FIG. 1;
FIG. 2A iJustratres a perspective view of an alternative seat back assembly w:in an irtegratsd -.'entilation system;
F!(3. 2(5 is a front elevation of one seating configuration of the present ■iv.~ntion.
FIG. 20 is a sectional view of another seating configuration of the present iiT'=,ntion.
FIGS. 2£-'2-:r are side sectional views to Illustrate different pan&i portion :-£:ombUiS.
FIGS. 3,'V illustrates examples of alternative seatback integrated e nforcenent shucr:uro components and patterns;
FIGS. 4A and 4B are perspective views of illustrative seatback assemblies;
FIG. 5 is a perspectives view of one preferred hinge structure;
FIG. 6 is a perspective view of another preferred hinge structure;
FIGiS. 7A-/D illustrate examples of alternative hinge configurations;
FIGS. 3AO 'lustrates examples of alternative hinge bracket configurations;
FIGiS. 9A-UF illustrate examples cf seat back reinforcements;
FIG. 10 ::iiist;ates a sectional view of a preferred latah assembly;
FIGS 11A-11F illustrate examples of alternative striker assembly ■on'igurat oris;
FIG. 12 illustrates a perspective view of another exemplary seat back
F1G-. 13 is an elevation view of a seat back assembly;
FIG. 14 frustrates an example of s.n alternate pivota! mounting configuration;
FIG. 15 i« a perspective view of an exemplary seatback assembly;
FIG. 16 is 5. perspective view of another exempiary seatback assembly;
FIG. 17 i-; a perspective view cf a seatback assembly illustrating associated Disponents;
FiG. 18 Is a pespective view of an instrument panel in accordance with the
nvention.
FIG. 19s a sides sectional view of another instrument panel assembly.
FIG". 20 is c plan view illustration of one illustrative sirucaire for a seat back.
FIG. 21A is a sectional v:ew through line A-A of FIG. 20.
FIG». 21B ii; a sectional view through line B-B of FIG. 20.
FiG. 22 is a side view showing an alternative approach to forming a joint.
FIG. 23 ii;: •- view of another embodiment to illustrate a reinforcement pane!.
FIG:. 24 is a view of anothsr embodiment to illustrate an alternative :t;i:hrnent assiisrr-bly.
FIG:. 25 is a seciion of an illustrative blow molded seat back.
^Bi: ailed Description of the Preferred E-Imbotiiment
Rel'errincj to Figs. 1 and 2, the present invention is premised upon the :'3\'?lopm'3nl of a;* improved seating assembly 10 having a plastic seat back 12
tcltiding a first ;:iar.ei portion 14 secured tc and opposing a second pane! portion 16.
i one particularly preferred embodiment (although net necessarily in all
;r:odiments) erf the present invention, the first pane! portion 14 is manufactured .:;*!.■ "irately frori ihe second panel portion 16 and the two are joined together. In
nolier embod-mtnt, the seat back is melded (e.g., bicw-moided) to integrally
incorporate the first panel portion and t.e second panel portion 16. Additional panel :p:\bns nay also be included, and may be fabricated differently from or integrally !vi::h sithe; or boih of the first or second panel portions. The panel portions may be ru-Js of any si likable material, including but not limited to metal, plastic (including ^i. forced or untsinforced plastic), other composite material or otherwise. :,r;;,ferab!y, at lecst one of the panel portions is plastic. More preferably, the first and he second panel portions are plastic. In a particularly preferred embodiment, all ;2i tsl portions ar-3 plastic.
Tho employment of microceilular foam plastics is also contemplated within the ■C'.:;J6 of :he pxs&r.t invention. In accordance therewith, a gas/polymer solution is or iec, and tha :>o:ution is rendered thermodynamically unstable in order to nucleate ,ii;:'ovoids. The* growth of nuclei is then controlled as desired.
It is pc:;-£.ible to make one or more of the portions using arf-cisclosed .at:iiniqu©3 for :he Fabrication of the material selected. Thus, for example, one or nee of the.poit'ons may be formed, molded, machined or othen/vise configured to ic desired sha;:»e.. Where the portions 3re plastic, it is possible to use any suitable lici: .tic fabrication technique including, without limitation, injection molding (including ;Li! not lirriterj ic externa! or internal gas injection molding), blow molding, ,0- ipresson molding, rotational molding, thermoforming, extruding, vacuum forming, •on riing-in-piace or otherwise. Accordingly, as can be appreciated, in one J.T )odim€»nt, hybrid seat assemblies can be fabricated, thereby taking advantage of lie; benefits of different respective materials and different respective fabrication eciiniquo:*, an-:;! also advantageously permitting for the ability to design additional 3b ures or otherwise package components into any space between the panel ■or ions. In or us iumbodimont, the first panel portion is a first material, and the ;c:::nd peine! potion is a second matenal that is different from the first maleial. In ,ri:.tner embodiment, the material is the same in both portions, in both of the above, ;K: fabrication technique for each of the panel portions may be the same or different. ■y A'ay of iHustie t;on, in one particularly preferred embodiment, the entire saat back i ;i,rmec. by blow molding. In another embodiment, an injection molded pcrtion will ;2 cined with aiclher portion made with the same or a different technique. For ■ :•;
1) A blow molded portion of a first material joined with an Injection Molded portion of a second material;
2) A. blow molded portion of a first material joined with an injection molded portion of the first material;
3) h thermoforrned portion cf a first materia! joined with an injection molded portion of a second material;
4) h. tiiermoforrned portion cf a first materia! joined with an injection molded portion of the first material;
5) Ar: injection molded portion of a first material joined with a portion that employs the first material but is made from a technique selected from the group consisting of compression molding, thermoforming, e-xt-uding, vacuum forming, and foaming-in-place; or
6) An injection molded portion of a first material joined with a portion that employs a second material and is made from a technique se'ftcted from the croup consisting of compression molding, triermcformir.g, extruding, vacuum forming, and foaming-in-place.
In yet another preferred embodiment, a first material is injection molded to ■;•■ i the ftst per:fo;i, and a second material (which may be the same as o\' different y\ the first (Material) is injection molded to form the second portion. The first D ion and "he s^c::>nd portion are then secured to each other.
This first panel portion 14 optionally may be secured to the second panel r ton 1*3 employing one or more joints 18 of any suitable structure; In some Tihodimenis there may be nc joint at all. in the embodiment shown, the joints 18 rerably are afesive joints, however, other suitable attachments (e.g.. as a result ■' ;■ tack-off) may be employed in lieu of or in combination with the adhesive. One Terred adhesive joint will employ an adhesive in contact w'th the entire opposing in ng su/facei of die respective pane! portions (e.g., about substantially the entire 3 ohery). Kvv/^/er. anctier joint contemplates intermittent placement cf the d" = sive for contacting selected portions of the opposing joining surfaces (e.g., trmittentiy s;xiCod about the periphery). In another embodiment, it may be
' j.o
An examoie of one preferred costing is a carbon-silica based plasma ci::=pv>3ited coatinc? z$ described In U.S. Patent 5,293,587; U.S. Patent 5,52-3,875; I.,Si. Patert 5,4:i&//B6 and U.S. Patent 5,494,712 incorporated herein by reference. (if.hr surface; tr«s«:*tnents rnigfrt also be employed such as plasma surface treatment p.;r:?;ant to art ubcosed teachings as found in U.S. Patent 5,837,958, incorporated h;;:niin by reference.
The? seat :>£.ck 12 may farther include one or mere integrated reinforcement s a; lutes 20 dknosec between the first panel portion 14 and the second panel p:.:r;!on 16. A hrvye assembly 22 might; fce employed for pwotally anchoring the seat t-.-ic* 12 to an autcmctive veftiae. The hinge assembly 22 includes a receiving p .ir.i.3n 24 for st;r.,jrr»g the seat back to the hinge assembly, and a mounting portion i :i ;:->r securing 'trie hinge assembly to the vehicle, A retention mechanism 28 is c- np'oyed for WB\oiaining the saat back in a generally upright position. The hinge c surnbiy 2.2, retention mechanism 28 or a combination of the two effectively define c i i!i3semb!y for reaching the seat back 12 to the vehicle and anchoring it to one or r on: body in white portions of the vehicle.
As iserf herein, and illuslrated in FIG, 2, by reference to an exemplar molded Sweden 30, the p.irase \vs!f stock thickness" or "wall thickness" shall refer to the c iTHinsion (T,v) bc-hveen a first surface 32 and a second surface 34 of a wail, such 5; i first wall -36. Moreover, the phrase "part section thickness" or "section 'it ;■:■; tess" (1\) shall refer *o the dimension between tha first surface of the first wall Gi i.nd an outvrarrily disposed surface 33 of a second wail 40, if cut by an
ntirrsectng plans. According to preferred embodiments of the present invention, •7S.li thicknesses- may vary between about 1 mm and 4 mm, and mere preferably behveen about :2.0 mm and 3.0 mm and section thicknesses may vary between i:b::-!Jt 10 mm an;i 1 DO mm, and more preferably between 20 mm and 35 mm.
Tht3 phrase "integrated reinfo'cement structure" shall refer to a location ,.,'h: re, as sho.vn i'\ Fig. 2 (and FIG, 25), the first wall 36 and second wall 40 of a iclied compci:sn:: are joined, enlarged or reduced in wall thickness, section nic-cness, or cihsr.vis© configured to effectively create a beamed structural section : >r creating a bcsliy modified bending moment or otherwise imparting additional i gfuly, toughness or impact resistance to a seat back assembly.
8y way ol further references to FIG. 2, various different structural o::>r -igurat-oris ars shown, one or more of which can be employed in the design of iw- bac^s for 'rz\ present invention,, it will be appreciated that the ability to s;.:i'p.-rate!y mold and assemble different panel portions allows for a wide design ho.:'scape. Fc ristance, the JISO of molding processes such as injection molding <.ilcws the ability to design in various section profiles including for instance variable t: section-: continuously incrementally or both>
Furi her, the present invention contemplates thai reinforcing structures, hshiners, hook:;, handles, or other utilitarian or ornamental features are insert rol:'&d in the oiiaslic portion jsing art-disclosed insert molding techniques. For insti nee, a bright (s.g.. chromed) bezel, a soft touch surface (e.gf| textile or leather* j: "ic::od or not) or ether trim might be insert molded to be exposed en a surface of tl'3 oorticn. An dentif cation badge (e.g., a logo or namepiate) might be insert n ;:)!;ed as well. Tie downs, baggage hooks or the like might be molded to be s.;pi:sed tc view. Also, it is possible to include a reinforcement member (e.g., made o s:3el, macnesiurr^ composite, foam, carbon fibre or otherwise) insert maided or c'!u wise fabricat-sri or placed within the portion and not exposed to view.
Aspects ol the disclosure herein have focused on seat backs that are c:-n::i"meted from plural portions that are joined together. Such aspects of the present lr /e:.tion
'p '!o* 1:0 meld ng, by defining tooling for achieving a certain blow molded structure or tl e .ke).
Oris prewired embodiment contemplates that at Isasl one of the portions it oJu-ies a suite!; Ie> reinforcing structure thai is molded integrally into the portion. Flefi-rring again to FIG* 2, one such configuration includes a rib configuration 42, r -vhig a plurality of wails 44 (shown optionally in contact with the wall 40 that are si;31: &d apjart to e fa;;tively define a beam structure. Another illustrative configuration ;roi\i:es a rib 3l::*jc:.ire 46 having continuously sloping curved walls 48. Yet another ii!.,is:*ative confi::| action includes a single wall rib 50. Still anot.ner configuration may if oluie an enlarged rib 52 (Le. having an enlarged portion en one or more of its s\.:e::) or seme otiiur like configuration. Another configuration includes a wall portion 3■;. i at has a different wall thickness relative to an adjoining wail portion.
The present invention contemplates the use of,the present integrated r>; ia:)rcem-3nt siyurtures for imparting additional rigidity: toughness or impact r«: :•;(:; :ance to a :>e:;ii back assembly, or otherwise locally modifying the bending iror: onx of a structure.
As indicated previously, preferably, the first pane! portion 14 is secured to the ■3.:o:nd pane,' pcrlion 16, to define one or more open internal spaces 56 between the :..im;i portions 14; 115, Prior to, or during the time that the pane! portions 14. 16 are 5.;c.red icgeth&r. one cr more components may be packaged within the open :3j-a::=s 56. Alternatively, the structure of a desired component might be actually noI::=:d into on
By way c: i iteration, in one exemplary embodiment, a cress section of which iSi sr^wn in F:iG. 2A, a seat back 12' has a first pane! portion 14", a second panel p"1');i 16' and & jc.'rt 18'. Ribs 42'define a channel CO for functioning as a duct arid •: jT.iT.uniCctting n\: hrough a grille, louver,.or other suitable vent opening 62 (which n*::iy be openablo'i r.tegrally defined in or otherwise attached to one or both of the p:rt'Os 14' or ■Ji;.'. A hose frting cr other suitable attachment (e.g., a male-female ;a!a:::ment, a quick connect attachment or the like), may connect the channel 60
/,v;l; a source o; air, such as a. duct routed along the floor, along a vehicle console, hr-ugh door panels, or a combination.
Though \*he above discusses integral formation of components, it s also •c;*.;b!e the! s-p-rately fabricated components may be made and assembled into hr spaces between paneis prior to securing the panels to each other. For example, « :otor nay be installed. A heating or cooling unit (e.g., a resistive unit, a !K. moelectric device or the liKe) may be installed. A speaker for a sound system rit: / be Installed. Entertainment devices may be installed. A communications device vie. f be inste led. A global positioning sensor may be installed. Other like ■.opponents may l-e installed as well {e.g., transducers, solenoids, sensors, air bag opponents, liyrdng, wi'ring harnesses, pumps, seat belt tensicners, seat belt et* actors, seal belt webs, tethers, compass, thermometer, or the like), li is also :o:-:.3ible 1o fill the space with sounc deadening materials or other materials for oc jclng noise or vibration.
Addition.:!*/., in one embodiment, one or more of the seat back portions is i o-i:igurecl to support, receive or define other components such as a picnic tray, !;;»Ci!3 (e.g., jire chisnge kits), a tonnesu cover, a ski rack, an arm rest, a foot rest, i.a:;:' rest a n-jcliner, flooring, cosmetic features, cargo nets/restraints, supportive !o::
Separately fabricated components nay be supported within the seat back 12
isi.g any severs-1 different techniques. In one example, one or mere of tho panels
4 16 of the sea:; back 12 may be adapted to receive one or more fasteners or other
: !t;:hmerts, vri:;h can support the modules. In this regard, it may be desirable to
iciJ a bess or insert mold a nut, a stud, a bolt or the like into the panel portion.
' Alternatively, the first and second panels 14, 16 may be designed tc frictionally c::ic;nge tho corn pen ent, or otherwise nestably receive the component to contain it vithn one or mere cif the open spaces 56. in another embodiment the first panel 14, t ,e second pant?! 18 or both are molded with the component within it. For instance, tiS ;ompcnent ibsef (e.g., an encapsulated component, such as an encapsulated e -3*:: ronic device;) is an insert for insert molding.
Optonallv, ore or both of the panel portions 14, 15 nay respectively include a f.-.in*e that extends about at least a portion of its periphery, or some other structure f:;r Increasing s..rfa::;e area to which a'i adhesive may be applied, in Figure 2, for €<: si fiance is formed on panel portion as will be appreciated from the ci.si.jssion further herein i also possible to form joints using integrated kin structures or sone other intermediate structure a rigid member. c gj- sket orothe>
As an aocieci advantage, the different forming techniques and parlicuiary iiijei-tion nrioWir.c. cen allow the panel portions to be designed more easily to include on" cured surfeicK&s. such that the seat back can be better fit within the vehicle and iic iase passencer and cargo space within a vehicle. Additionally, the techniques |.emit for the eibility to add shoulder wings for accommodating wheel wells, or cer: ral disposed v/hgs to meet above an arm rest or a center pass through door. I.elijrring io Fie. ;2B, there is a pair of molded sealbacks 56 formed with opposing I arils ac:ordii"io to the present invention. As can be seen, each seatback 66 i isliides a contoured or curved ponon 68 that is designed to accommodate wheel '••ells 70 of the ve-hicie. Fig. 2B also illustrates central disposed wings 72 such as for .: c;t. .mrnuda;incj ?;.n optional arm rest or center pass through door 74.
Attractive contours (symmetrical, assymetrica! or a combination thereof) can •Ms;, be rroldeo onto the rearwardly disposed panel portion. Alternatively, the rear ■ an h\ port on car t-o molded :o include features intended to function when the seat is
i -.]. folded position. For instance in FIG. 2C there is sho*n one such contoured :on iguraton 7<:> including a forward portion 78: a rearward portion 80, ribs 32 and at
■s: t one or a p! jnai'ty of joints 34 (e.g., an adhesive bonded joint).
It will be appreciated that in either the forward or rearward portion there can :■&■:) be molded ar.y of a varie?/ of functional features as well, such as guide tracks or receiving acLlilicnal components, cup holders, work or rest surfaces, or the like.
if employ 3d, the adhesive used to join panel portions 14, 16 may be any -;IT able adhesive. Preferably it is a urethan© based adhesive, and more preferably a ..n;:.hane adheres. Alternatively, the adhesive may include a functional component ■e isted Irotn aayoni'irile butadiene slyrere (ABS), polycarbonate (PC), era mixture hooof (e.g. Pw-ABS), In a further alternative embodiment the adhesive is a silane ;.d esive, a siiiorvu adhesive or a mixture thereof. In yet another embodiment, the id'-osive is an acrylic adhesive. The achesive may be epoxy based. It may include :c /olefin cs, styrfcnics, acryiics or mixtures thereof, in yet another embodiment, a inferred adhesive includes; alkyl borane. Examples of suitable adhesive© are disposed in e:.n.pnonly owned U.S. Patent No. 09/466,32" (fifed December 17, ;9i0). Ar.y su;n adhesive may include suitable performance modifiers including art • lUii:losecl tackifiens, elastomers, impact modifiers, or the like.
in addition "o or as an alternative to the use of adhesive to join portions, other
.ji'r-.ble joining techniques may be used, such as welding. Examples of suitable
■vcijing techniques include art-disclosed techniques of ultrasonic welding, linear
•■■■ib alien weld:-!,;, orbital vibration welding, spin welding, hot plate welding, laser
R:\A or ccmbir-silions thereof. If welding is performed, preferably the plastics of
•■a;h respective pcrtion to be joined are related, sharing a: least one common repeat
in". For instance, it may be possible to welc po!ycarbona:e acrylonStrile bu;adiene
:/:ytene t;> acr/lonitrile butadiene siyrenev polycarbonate aorylonitrile butadiene
::iy;ene or poi-sbiy pofycarbonate. Suitable systems for this type of joinder are
;;V!:iiable comrnercially from Branson Ultrasonics Corporation. Examples of such
://:;,ems are a too described, without limitation, in U.S. Patent Nos- 5,355,706;
■Z,l 16,377; and 5,658,408, hereby incorporated by reference.
By way ai'-summary, such techniques generally apply relatively high stresses
o he parts (coiionally supported or an anvil) being joined to induce hysteresis
1:3^. ting at the bond line. One or more resonators, for inducing high frequency
' ibialiens at predetermined frequency are brought into engagement with the
vc.:kpiec€! during the weld cycle. Responsive to resonance, energy is transmitted :e losing softening ^nd flow of the thermoplastic materia!.
Av> disabled previously, integrated reinforcement structures nay s;iso be 01;red
FlO. 3 illustrates examples of various alternative predetermined geometric or figurations fcr individual integrated reinforcement structures 2C. FIG. 3 also lutrates example:;; of various integrated reinforcement structure patterns 36. The u: vidua! intennfed reinforcement structure 20, the integrated reinforcement it dure pattern 56 may include one or a combination of any suitable letter, h;:r3cter, shap:*, or symbol. Examples of components of such structures or a;erns Include, without limitation, the "C" shape, "D" shape, ".H" shape,V shape, I shape "L" shape, "M" shape, "N" shape, lO" shape, "S" shape, "T" shape, "U" [y-^e, V shi-ipe, yW" shape, 'X shape,. UYJ' shape, UZ' shape, curves (e.g. iriisoidai curvss), zig zags, "+" shape, or the like. Integrated reinforcement fracture patterns} 86 include a plurality of individual integrated reinforcement Ti.ctures 20. .H.; seen in Fig. 3F and 3G, without limitation, the individual integrated ■sii forcem&nt savtfure 20 may be a composite of multiple component shapes. The al erns S6 ITKJV be random, as seen in FIG. 3B and 3G; o; repetitious, as seen in ■K! S. 3A or 3E. One or mora different type of integrated reinforcement structures 20 ■f! i3 typo iliusihrxd in FIG. 2 may be employed to define each pattern 86 used in a e,i-: back 12.
The reinforcement structures of the seat back 12 may be formed in a variety ;rf manners. Referring to FIG. 2, the reinforcement structures may be formed of too ■racing cr corresponding ponions, thai are respectively attached to each of the pane! ;e joined to the other panel portion 14, 15 with a '■■so Jiting acheswo joint 13, either about some or all of the periphery of the panel >c ;ions, wiihir "hi: space defined between the opposing panel portions, between a enforcement structure and an opposing pane! portion, or otherwise.
In je"si£-n cf the integrated reinforcement structure pattern, the location of the ;p: nings is praferabiy staggered to help reduce or eliminate-hinge points. Further, ■vL-re a plurality of vertically oriented integrated reinforcement structures is used in a ;a;em, the he rental spacing (V in FIG, 3A) between each individual integrated ■si-.forcerlent t;:ru:;;ture will V;ary from about 5 mm to afcojt 100 mm and more :ni!,:erably about 20 mm to about 50 mm.
0"ie cr mora horizontally oriened integrated reinforcement structures might re ncorporatecl -*■ addition to-or \n lieu of vertical integrated reinforcement structures o hslp improve: cross-car direction stiffness in a seat back. When employed with ver.icaHy orieried integrated reinforcement structures, the horizontally oriented . ib: cjratec reinrcrcement structures 83 preferably are staggered between vertically orknted htegnst-u:! reinforcement structures 90 or otherwise located to help reduce ' ■«;« iikelnood lh-;?y will servo as a hinge point- (See, e.g., FIG. 3G). Horizontally 5:'>:rrted htegrotijd reinforcement components 38 structures may be added directly
4
o existing venicaiK' oriented integrated reinforcement structures 90 (see, e.cj., FlG. .-JG and FiG. 3K). individual vertically oriented structures 92 may also be employed.
h: horizontally oriented integrated reinforcement structures alternatively may bo
heoporatod into an overall pattern so that the integrated reinforcement structure is '
The design and location of each Integrated reinforcement structure 20 and };:,:;om 85 fabricated in the seat back 12 may be optimized for each individual application, iak:ng into account some or all of the following criteria. For e3ch replication, the skilled enisan will appreciate that the specific integrated nirrorcsmerrt sirucairo employed is configured to heip minimize the bending or }-iri':;.3. effect caused by loads, resulting from rapid deceleration or acceleration of a vehicle in the presence of a passenger or cargo behind a seat (e.g., that which *;.
The use of integrated reinforcement structures is further illustrated in the ioibjvir.g discusE;i:n, by reference fc
For a number of applications, it is particularly ©tractive to incorporate an iivx-^rated reinforcement structure around at least a portion of the perimeter 94 of the .■ittc;:: back 12 to h&Ip increase horizontal stiffness, vertical stiffness, or boih in the I ai.r.etor regies; cf the seat back. With illustrative reference to FIG. 3A, for most .•■ pp» isations it i;> contemplated that an outboard edge 96 of the integrated i wvoroerr.ent ssiruaure 20 is at or within about 50 mm (and more preferably about '3 rim) cr lesfi cf an edge defining the perimeter 94 of the seat back 12. With ■"-rJier reference* tc FIG. 2, the width fw") of any integrated reinforcement structure \M--i in the perifi-kr.er regions of a seat back preferably ranges up to about 30mm, ,:-nrl more prefersb!;,' it is about 4 to about 20 mm. Such dimension helps to minimize i-.onjing in the racossed vailey portion 1C0.
It is a'so p'cerable to form an integrated reinforcement structure in th-3 vicinity o: ;;in.y latch stn'vor: or latch members. In some applications, such as where the seat
is ntended to cany the lead for a center belt, or a child seat tether, it may be durable to r;i:HJr/, further. reinforces or eliminate the top perimeter horizontally oriented integrrteci reinforcement structure to reduce the potential for hinge effect .sit.-tjss concentrator in that vicinity. By reference to FIGS. 4A and 4B (which show ilii strativc-! hinga structures), in these applications and others, the bottom end 102 of a vertically oriented perimeter integrated reinforcement structure 104 wiii be petitioned beiow the highest point 106 of a hinge assembly bracket 108 or other »enforcement I'll) (e.g., internally positioned) securing the seat back to the vehicle. .VI:: re preferably, the overlap ("O") will range from about 25% to as high as about 1 (:*:)% of the vertical length ("LH") of any hinge or reinforcement. Further, the nop end •|i:i of sush vertic&! perimeter integrated reinforcement structure will be spaced from ;e j,, within about 10 to about 200 mm of) the top of the seat Alternatively, a thicker Oci,t section thiol ;r ess as available by the use of structures 52 or 54 of FIGS. 1 and 2, nay te Incorporated at the top or bottom of the seat back to help increase st'frhess.
It sftoulrl be recognized that the present invention advantageously also ■::€nrnits for ins;=:ir; molding of brackets or other hardware for securing the seat jic-inpon&it to ihs vehicle.
In nstarcas* where a center passenger shoulder belt system is employed, or a w.. chile seat .ether is employed, optionally, design criteria is employed to help eouce the forward, downward and torsional or diagonal bending of the seat back '■hi-t are caused by perimeter loads at or adjacent the shoulder belt or tether jtl.ichmeits. Preferably the integrated reinforcement structures will provide good ■/eiiical sliflheas (.=is this is the plane that is anticipated to endure the more severe sending forces), as well as cood torsional stiffness (responsive to the diagonal offset ■3.:i;j5 a passenyer Imparts to a shoulder belt system). In such instances, it is .;.-;; ferablo to alternate geometries of the integrated reinforcement structures: either in a jandom or pnscetermined pattern, or to maintain the integrated reinforcement -structure width ip to about 40 mm, and more preferably up to about 30 mm (e.g., ifcic Mjt 5 to about 30 mm).
Ths ernptoy.'neni of vertically oriented integrated reinforcement structures is •'.aiLcularly preffirrsd in the load path for center belt loads and upper chid so3t
tethers to help avoid vertical bending Preferably, for these applications, the iiiteujrated reinforcement structure width (W) will vary up to about 50 mra and more f: re drably will be abouc 4 to about 40 mm, and still more preferably will be about 15 tu snout 25 mm. The? vertically oriented integrated reinforcement structure length {„ft: will vary bawesn about 70 to abou'; 95% of the vertical seat back height, and ( ior■? preferably ?;bout 80 to about 90%.
it will be -appreciated tiat the above design criteria are preferred but are not in.e,!ided as limitinc. Depending upon the particular applications, variations to the i:3(.■'$ rneiv be mnda. Moreover, it should be appreciated that forming an Integrated i ,;r arcerrent ij;njc;ure need not occur In every application, and the need for and i isc nitude of sun jieneraily will be directly proportional relationship to the size of the J;.-*!; back. Thu^ tor exampie, a smaller folding seat may not require a perimeter ii..te:.|:ra;e«f reinfaroornent structure or it may only require it in limited areas.
Refarrinc by way of illustration to FIGS. 1 and 4A-7D (and 24)(without limilotion as.to "ha other configurations, such as ones excluding a vertically oriented {.■>{ x.eter integrated reinforcement structure), for folding seat backs, ths hinge ;: ,:.;;
The ugh l 'Vi possible :hat locally reinforced structures integral with ihe seat I: ;:u::; may be employed, in ere preferred embodiment, \x is contemplated that one or no'3 hinge as.;;:=rrl.;iies 22 are secured to :he seat back 12 after fabrication of the ::.:;*.■ back XI:- hinge assemblies 22 preferably include relatively tough &nd high i!».rtv-igth to weight materials (such as plain carbon or aiioy steels, or a comparable ny.al, cornposte c;r ether material)., and are configured for facilitating controlled <: ak-rmation for iransmitting loads.>
The- hin;ie. assembly 22 thus includes a bracket portion 114 adapted for ;■ :;C: iving or othrwise engaging the seat back 12, and a suitable pivot portion 116, \ :a- can b3 securec to a vehicle body or other mounting surface, hingedly anchoring i ie overall sein back assembly 10. !n ens preferred embodiment, the hinge ;;;;*»rnbly 22 (a"id any other anchorage system) is connected to an anchoring . .,i. ..■-,....** r%».^«,-,M,/ +v,o v*»h!r:te bodv-in-white or an associated structure that; has a
:■)% iking :streng:r
As generciiy shown in FIG. 4A and S-7D, the bracket portion 114 is adapted :> !=coiv£ the r^ai; back in a nesting or mating type relationship, with the bracket oi .ion acting m- either or boil of a male portion (e.g.. if it i« structured as; a plate liiii foreement frwairber 110, or another such insert member as in FIG. 4B) or female ;DI' ion. As Illustrated in FIGS.. 4A, 5, 8, for the female poaion bracket type includes :i ;;!urality cf adjoir.ing wails for defining a well or a generally "U-shaped" channel wl./i or withou': al least one closed end) for receiving anc holding tine seat back 12. Th: average wa!: thickness of the bracket, assuming a high strength metal such as ■toil, will rang*-! from about 1 to about 3 mm.
In or.a enbodirnent, the bracket portion is an elongate member, having a ;;:n r:h of tfbou*; 30 -o about £00 mm, and a width of about 10 to about 75 mm, (See, k;. 5) The v.o I or wells can be disposed anywhere alcng 'ihe length of the hinge i3!:smbiy (e.g.. ;.it rjne or both of its ends, cr at an intermediate location), The walls uv ' be CDnfigjr -KJ in any suitable manner, with FIGS. 5 and 6 illustrating two such :Q\ f.guralions. In ,:::iG. 5, the walls include a first side wall portion 126 and a second ■:p;:osing side wail portion 128, both of which are about the same length, and have ■n ntermeclatfc will portion 130 bridging them. In FIG. 5t a first side wall portion
1.52 and a seconc. side wall portion 134 are joined with an intermediate portion 136. Tie first «nd sec.and side portions are arranged so that a distal end 138 of the s icond side wail portion 134 extends beyond a distal end 140 of the first side portion 132;. The internaciate side portion 13(3 is such that il optionally includes a section raninatinci at an ec;ge 142 that extends beyond the distai end 140 of the first side p:iri5:n IS;! toward the distal end 133 of the second side portion 134. The edge 142 r iiay be any suitaUfc configuration, e.g., linear, curved, steppec or the !ike; as shown \ t"c: illustration oi' FIGS. 8A-8D. Fuiher, though FIGS. 9A-9D illustrate a front to mar upward slope- x the edge 142, the slope of the edge cou;d be dov/nward
The hings. assembly is ssoured to the seat back 12 using any suitable joining tiicnique. It ray be mechanically fastened (e.g., by screws or shoulder bolts), vi:\\' ssively fastened insert molded, a combination thereof, or otherwise. !n a f:ar:c;ularly prer'igir&d embodiment, as illustrated in FIG. 7A, a fastener 144 is jirr/ciiired th:rougJv Itn* first wali portion and second wall portion of the seat back and tie linge brack'::I; 114. In FIG. 7C a fastener 144 is fastened to a stud that is formed \\\ ' ie hinge bracket 114 cr otherwise placed between the opposing side wali I" or; ;ons.
As shown n FIG;. 73, in another embodiment, one possible bracket ir.ci-jdes a
i;:d:i' wall portion configured with a projection 146 for cooperating with an integrated
; .Mr,,'orcinc .Mrucrure 20 sj,d establishing an interference connection, thereby
I'.'jii-rbrcinCi trie ,a-:tn;;hnent in response to forward directed longitudinal forces (as
!u-i::rated in FIc. 70). For irstance, the bracket may be crimped into, preformed to
■■ci'ide a project' on that penetrates the volume of, or otherwise grips an Integrated
.iiiiiorceinent stricture.
Reletting to FiGS. 9A-SF, the hinge assembly optionally may be further ■■si'forced by rhi3 placement of a supplemental reinfcrc'ng insert 148 of suitable ::e.;rnetry (such a1-; triangular, square, polygonal, rounded or otherwise) between or ;-u:: .ide of the wE;!is of the seat b^ck, preferably in the vicirity of the bracket. Though i r ay be a steal (as with a hinge bracket), the reinforcing insert 148 preferably is irciii-3 of
t-pirn of the bracket or only a portion of it, or even beyond the bracket. By way of
■ .•xsrriple, for spl't seats, the typical vortical length ct one sixh reinforcement may
iar, je up ";o about 300 mm, with a cross car width of about 10 to about 75 mm and a
;or: /aft depth ol aDout 12 to about 37 mm,
it should i)e appreciated that the use of supplemental reinforcements- is not l.nr.i-ed tc the regions adjacent the hinge assembly, but may be anywhere within the ;r5:;3mbly in II fe regard, a relatively rigid member, such es a meta! (e.g., steel, v.Vf jnesium. a*u:.iinum or tne like), composite, unfoarned plastic, or foamed plastic
■ ai'.iar profoansc or foamed in situ) may be incorporated between walls of a seat
\.a\\K wh-sreve; Realized reinforcement is sought. Without limitation, examples of
:.uii£.ble foams incudes polyue thanes, spoxies, styrenics, or the like. Softer foams
i Vt f also De empla/ed for ncise and vibration absorption.
Genera: y, rie hinge assembly 22 will result in a portion of the seat back 12
\\vc. is Sijsceptibte to function as a deformation site or stress concentrator in the
ovarii of
IC. 1, such iiitieipsted deformation sit-3 is placed towa:c the wall thai will be
on/ard feeing wvzn assembled in the vehicle. For instance, it may be located along
■ if; leading edge:: o,rtha sea- back for inducing a compress ve load in that regicn.
Aa will l.:e appreciated, the brackets described above are particularly iid'.antagtfously used in folcJable seat applications such as found \n rear seats of iia-..:hback vender sedans or coupes. However, they may also be suitably ■■ :.T )Ioyed \r trot standing seating assemblies, in which case "hey will be mounted to
■ :i j:- jdests! or oihsr structure associated with a sea: track. -They nay also be used as
*Cf 1 seat backs.
As disci.;:: stid elsewhere herein, and referring now also io FiGS. 1 and 10 the .'Hi.'sent s/sterns n ay incorporate one cr more retention mechanisms 28 (e.g., latch .:s:;arr!bli€:s) at any of a number of different locations on ths seat assembly (e.g., ;ic: i;j ths sea*: nicies, on the seat back, or along the top of the seat task), for ..fl: rding release bb self locking of the seat back io the vehicle relative to its hinge. It :• .referred ihu! my such retention mechanism provide a sufficient combination of iic i strength and good load distribution over the structure? Io which it is attached. 't;;ferabiy, the so/ifiguration is such tnat the seat is ma*n:ained in place by the
■■.ijli'f.tion mechanism in the event of a sudden or rapid acceleration, deceleration or ;th*r fores, so :ha; load or. the seat back can be transferred as desired within the
:;e ;it back.
It shcuk: h% recognized that, though illustrated with reference to a twc part ■;e;;t back the hiiKjes, retention mechanism and other features disclosed herein may .to! Aise be employed in a blow molded structure, as is taught (for example) in cc-::e: ding U.S. Application Serial No. 09/766,792 (filed January 22, 2001}; not upon:-lee by reference.
Ro'.enliori .r.echanism configurations may vary application to application, •icwever, once er.gaged, for s forward-facing seat preferably such mechanism .:ro:erably will net release or fail when a forward longitudinal force (Newtons), equal ■::> lie product of 8.8 and 2C times the mass of the hinged or folding portion of the ■sei; t (kilocratnsj, is applied approximately through the cen.er of gravity cf the latched :.B\A poriDn. !vlc:ieover, once engaged, the mechanism preferably also will not ek&se or fail v/!ien subjected to an acceleration of about .20 g., in the longitudinal .iir<: ction opposi: t: the seat folding direction.>
On 3 pref-s-rrerd retention mechanism is a latch assembly 150, as shown in FIG. !0 whicf* inckde; a conventional latch 152 having a retractable pawk and a oi esponding striker 154. Though illustrated with reference to a striker secured to !:<: seat back o ther the striker or latch may be secured to with :p: ropnaie ccirrgtrations avoid having it pull through>
Illustrative alternative configurations are disclosed in FIGS. 11A-F. h each :i;i=.nce the sri'ier 154 includes at least one mounting portion 156 for attaching to hti: seat back 12 (either adhesively, with suitable fasteners, insert molded or .:-ti\ srwisei anc r. projecting striker bar 158 (which projects through an apereture or ,!tr in the seal back 12). The mounting portion 156 includes one or more? Ganges '6! for overiapphg with zrd engaging the seat back 12 or an integrated -si'.forcernent i.ructure 20 associated with it (e.g. FIG; 1 1 F). The overlap preferably an .33s from aLoui" 3 mm (and more preferably about 10 mm to about 150 mm). As ;h;:wn in ~IG. V'G and 11D. in some embodiments a supplemental reinforcing plate :6; or like struct.no may also be employed.
As iiIustni.O(J in FIGS. 113 and 11E, without limitation, shoulder bolts 164 or i;tf ir like struuiur&s may optionally be employed as desired for securing the i ot: ntion mechanism 28 to the seat back 12,
it may br= desirable to further reduce the potential fcr the retention mechanism :■::> - reate a ninrje point, by locally reinforcing the seat bac-'c in or adjacent the region ■.a ,/nich the ialdi member is secured. This can be done in any suitable manner, for ■ns: arics, by th^ in'corporation of one or more integrated reinforcement structures in :Ui; regicn or by Incorporation of an additional or supplemental metal, plastic or ;0; :posit«! reinxreemsnt member within the seat back, about the entirety o: at least ] i::rticn of the ptsrimater of the seat back. For instance, FIG. 12 illustrates an L-;.i;;p0d sjpplerri'S.'ital CGrnQt reinforcement 165, which is a relatively rigid member oci;ed between i the opposing wafis of the seat back. The supplemental ei fcrcenen.t '.?o can also te reoriented orthogonally about the z-axis relative to the 0:i;icn shown in FIG. 12. Of course, in such regions, integrated reinforcement ;:r .:(;tures may be smployed as desired to achieve such reinforcement. Typically, if ru; striker oar -113 is iocatac below about 20% of the height of the seat back, ru-asurec from the top of the seat back, then the supplemental reinforcement rui:nber is incorporated and positioned generally in the anticipated load path ;-e; *een n seat bet: mounting point (if any) and the striker bar 118.
It wiii bo appreciated that the use of a supplements reinforcement member is :c: limited to he vicinity of tie iatch. One or more supplemental reinforcement nc: iibers may ho i.-sod elsewhere in tiie seat back. For instance, a hybrid seat back -.sv-iiig a rigid ■■■L'pplementei reinforcement member may be placed between or .AJI side of the seat back wails generally about the perimeter of the seat back.
Wi:h relorance to FIG. 13 there is shown a typical spilt folding seat back ■5-: tirnbly. This location of the retention mechanisms may te anywhere proximate IK.; -:op or sid&i; of the seat backs. Illustrated are alternative first, second and third £:;; oaotivo loc^io'w 2BA illustrating atong a seat back side; 23B illustrating ir one of ;ii: seat back co Tiers; and 23C illustrating along the top ol' the seat back.
Refe*rin;.j to FIG. 14, a seatback configuration is illustrated with a pivotai sKjjnting member, This configuration illustrates a saatback 12 with an extending >k ■>! member toS. The extending pivot member 168 Is configured such that the
nattiDacK -\& muy oe pivoiaiiy mourned ro a uracKet portion i^u tr.us negating me •im-id for a cross ba-" 118.
As will I:-? appreciated, proper material selection will permit efficient design
uvi mold.ng c» optimal wall thicknesses, part section thicknesses or both, for :di eving the duurad performance without substantially increasing vehicle v/eighf or
itiuding into inferior space availability. By way of example, it is desired for many i.iip'.icaticris ther: the maximum wall stock thlckhesa will r.nge up to about 0 mm or
:ig. er, more pi -lierab!;/ it will range from about 1 mm to about 4.0 mm, and still more ^efarably. it wil ranga from aoout 2 ram to about 3 mm. Likewise, the maximum :«!.. ion thickness, will range up to about 100 mm, more preferably it will range from ;::x:-Jl 10 mm to about 60 mm, and stiii more preferably it will range from about 20 to
:x: Jt36 mm.
The* rnatens's selected \o
The preferred fiexurai modulus will be at least about SCO MPa, more eiarably it will cinge from about 20C to about 500 ksi (1300 to about 3500 MPa), ■:.-v:l still more preferably about 250 to soout 350 ksl (1700 to about 2500 MP-.a).
Thti prate-crod yield strength of the malarial ranges from about 20 to about 200 1pn. Mo-e piofsrably il will range from about 25 to about 70 MPs and still more :a:^rably about 35 to about 55 Mpa. Moreover, the ductility (as measured by .-ar.tfjnt elongalicn) of "he material preferably ranges from about 20% to about 150%, :."H; more prefe.'uhly it is at least aboit 30% and still more preferably, it is at ieest ;.:y:-:t 100%.
The ma^crlai also will preferably exhibit attractive processing characteristics,
;.!!.; i as a melt iw rate (230°C/3.8 kc-l; according to ASTM D';238) of abcut 0.300
■;j Mbout 5.0 g'10 min to about 0.900 ro about 3 g/10 min; a softening point
...sordine to ASTIvi D1525) of less than about 130°C, and more preferably about
9CrC to s.bout 150;SC; linear-flow mold shrink (according lo ASTM D 955) of about I).::76 mm/mm (0.003 in/in) about 0.203 mm/mm (0.008 in/in) and more preferably •ibojt 0/I52 mm/mm (0.006 in/in) to about 0.178 mm/mm (0.007 in/in); or a combination of "ihase properties.
Acxrdincly. in one preferred embodiment, the seat back of the present Invantiori prefers;:-'/ is made from a plastic material, and more preferably a lihurmoplcistic material, in a particularly preferred embodiment, the seal back is ;-?;::.£ from a hk-h strength Iherrnoolastc resin selected f.-en styrenics, pclyarnides, :;c-i/otefin3, pely'csdonates, polyesters or mixtures thereof. Still more preferably h:!y are se!ec;:;:d from the group consisting of acryioritrlle butadiene siyrene, i.:ol/cs.rbonate/:K.r>,.onilriIe/butadiene styrene, polycarbonate, poiyphenyiene ;\ je/pa-ystyrono, polybutyiene terephthalate, pciyphenylene oxide, polyphenylene Uiar, syndio-3:;:ic polystyrene, ethylene alpha olefin, polybutyiene ■:i3n;jphtha"ste/po:yc3rbonate, polyarnide (e.g.. nyion), polyesters, polypropylene, x I/ethylene, an J mixtures thereof.
Examples of preferred commercially available materials include PULSE® :>2;0 BG cr 20-30 EZ and MAGNUM© 1150 EM, both available from The Dow "tf'-jmical Company.
As indicstec previously, another advantage of the present invention i«; that the
rr. portion ar ::i tins second portion may be either the same material or a cifrerent
:Ki.erial. In thit. regard, either cr both of the materials /nay be a thermoset cr a
riornopl-istic nv-iterial. Preferably, both materials are thermoplastics selected from
■ic above-ic!en:ticrl materials.
By way of particular example, without limitation, in one embodiment a seat ja:k is fabricate:! having a first portion, that is to be forward facing upon installation a .-in automotive vehicle, "he seat back also has a second portion that is to be ■iSii! H'ard racing up jn installation into the- vehicle. The first portion is injection molded a nciuct! ribs, gussets or another type of integrated reinforcement structure. ::r::fereb!y the l:.rst portion inciud&s polycarbonate/acTylenitrile/butadiene styrene ■:?.:., PULSED £000 EZ from The Do*v Chemical Company). The second portion is :it!" er Injection rc;lded; bio// melded or thermoformed from an olefinic material, .n/erabiy a hig!' density olefin, such as high density polyethylene (HOPE).
standards for motor vehicles (e.g., as addressed in FMVS8 207, FMVSS 210, IWVSS 225 (4i3 CFR 571.207..210, .225) or ECE 17; al! such standards being
i
i!x;:::essly incorporated by reference herein) as wel! as the requirements of i:ij!omobil3 oricina! equipment manufacturers and their suppliers.
In oris embediment, the seating system (1) is capable of withstanding without ;upure st leas*; about 11000 Newtons in the direction in which the seat faces in a ::ictie, parallel to tie longitudinal centerline of the vehicle; (2) exhibits, upon rapid !<: up to sat least about g substantially no fragmentation of the seat back at a kc mass placed behind or both and>
More preferably, the seating system (1) is capable of withstanding without
,r:>jre at leas': about 13000 Newtons in the direction in which the seat faces in a
■te'e, parallel tc the longitudinal cenlerline of the vehicle; (2) exhibits, upon rapid
,w-iteration of cbout 20 to stout 30 g, substantially no fragmentation of the seat
aol
Though /of Intended to oe limited thereby, In one embodiment, the goats, the MK; wages, ai'Xid.ment hardware, and attachment bolts for the systems of the -rei ont invention are capable of withstanding without complete rupture al. least a : 0U3 pound force ^r\6 more preferably a 5,000 pound force. In one particularly , re I erred ernbolr.ent, the system is capable of withstanding a force of at least .bo jt 13/J00 N !o about 22,000 N generally in the direction in v/nlch the seat faces > o i.\ pelvic body bbck)ln a pane parallel to the longitudinal eenterline of the vehicle, v!i.,! an initial term application angle of not less than about & degrees or more than i:!xijt 15 (iecjroo;;. above the horizontal. Still more preferably, the system withstands '-..u: i fores even wren applied at an onset rate of not more than about 133,000 N per :;I!K.-J!U3 to about 222,000 N per second, whereby the force is attained in not more 11a: ■ abou*: 30 seconds and is maintained for about 10 seconds.
Irs yet anoiher embodiment, each seat assembly is capable of withstanding i i) ft any positin 1o which the seat can be adjusted, a force (Newtons) cf 20 times I le mass of the ;;;e:.:il in kilograms multiplied by 9.8 applied in a forward or rearward Ii.n;:i;udinal direction; or
In another embodiment it is contemplated that a laminate or blend of at least :A'O different pta's-iis materials is provided for forming at feast one of the portions. This ■i£r be accomplished in any of a number of different ways. For example, in one :!Tibcdifnen1, a oosxtrusion of two cr more different materials is provided and then it ■: subject to a furihar processing step, such as thermoforming.
In another smbodimom, suitable for forming any of the components or ■.:.s:i:3mblies of :r.e present invention, a parison is provided for blow molding. The orison includes a first material at least partially encapsulated in a second material. .jp;n blew moldino. adjoining layers of each of the materials are formed. Such a i arison may ba formed using any suitebte art disciosed technique. One possible ;iD!.: roach tc stir..- technique is illustrated in U.S. Patent No. 5,963,431 (Issued 0/-9/99; Ang^: al.i.
f\ parison is preferab'y extruded of one cr more inner and outer layers of i. iff-rent plasties, e.g., recyclable plastics* from the same family. During blow molding, vie layers Q: the; plastics will join at their respective interfaces. A support substrate i: ar. be formed fret): the inner layer(s), with a suitable show surface on the outermost i ;yi-r. For example: the oute;most layer may be a relatively soft or flexible material vii:'. a relatively rigid underlying layer. The characteristics of the ouier and inner i.jyurs msy be l\v?. same or different with respect to a wide range of properties i (Ci'.i'Jir.g but not limited to strength, rigidity, tactile feel, porosity (e.g.. one or both i !3j- foam tc different densities), melting point, resistivity, conductivity, or otherwise.
While llva technology of the present invention has been illustrated in connection wit" certain fabrioa'icn processes, it is not intended to be limited to such processes. I.iki: resu'ts may be attainable using the teachings of the present invention in \.or bination wi'h other fabrication techniques, including but not limited to injection i :c.-ling, lost core processing, rotofcrrning, compression molding {with or without
As will ;;■£ appreciated 'from the above, preferred seating systems that are
*
(■,>{ liizec in accedence with the criteria outlined herein, and using the referenced i :a\-3:ials, consistently should pass United States and European government test
io; in its rearmost pcsi:ion, a fcrce that produces a 373 Newton meters
mctr.ent about Ite -seating reference point for each designated seating position that ina treat provides {as applied to an upper cross-member of the seat back or the iip;:-sr seat tacit, in a rearward longitudinal direction for forward-facing seats).
In yet another highly preferred embodiment, the seatback of the present i"v:ntion s incorporated into a seat assembly, and two 18 kg masses (e.g., cubes ".'it' an ecge leutfSi of about 330mm) are placed about 2C0 mm from the seat back. Upon rapid acce:i-eraHcn to at least about 20 to about 20 g, the seatback maintains !;*.€! cargo disposed behind the seat back, with no visible fragmenting of the seat la:;
Advanteceously, in one additional preferred embodiment, the seat backs i-ciiie in accordance with the present invention ar» capable of exhibiting a sat less laaii 6 mm ufor peaking for about A hours ai about 82° C with an applied load of •ibout 244 kg/nr and a momentary load of about 615 kg/m:.
The* "stifffie&£., impact strength, and crack resistance cf "his seat back also will ::s jreato" than conventionally fabricated current blow molded polyethylene, fined :iOl)ethylene, polypropylene, or filled polypropylene seat backs.
The pre:5.unl invention contemplates techniques and methods for the .jp-:: nidation of one or more of material selection, wall tnicknesfe, section thickness, ■jin: e design, and iatch design, for realizing the desired stiffness and strengrh to i*-i:i tradiiionaily cernanding load requirements in automotive vehicles occasioned of ; ■:?:;.or mojntec {-.huulcier belt loads, chid seat anchor loads, or cargo intrusion. The ; -;iii2d artisan will recognize, however, that from application to application, design ^quirermnte v/ill vary, and therefore a reasonable amount of experimentation may .-3 .'iseded to edapl; the various teachings to the unique intended environment. By ,.-a\ of example, p«.irt size, seat belt location, hinge points, jaxh locations, and split ■:n; ma> affect final design, it is believed that the use of conventional computer .i.6:-ii engineering ;CAE) techniques in combination with: the present teachings will fei-i satte'factoiy Jesuits, which can be improved as desired with conventional :;c nique-ii for 'y.aYizeti steel reinforcement (e.g., in high stress areas, such as hinge : ;>i' ts, latch areas, seat belt mounting areas, and armrest support areas).
Thuti, the present invention finds useful application in connection with any of a r jnoer of different types of seating systems, including but not limited to, adjustable s-i-a:*, fixed position seats, foldabie seats, seats pivotal about an axis, including but r ,:it I mired to hinted seats. The seats may be vehicle rear seals, vehicle front seats, 1 .ird row seats, jump seats or tne iike. As already indicated, in another particularly P Blurred embodiment, vehicle front sea:; backs are assembled in accordance with he uocve teachings;. Moveable seats IT ay be held In place by latches disposed in he i.-entrs.l portion of the seating configuration (e.g., at the top), along the seat sides (i-„n>//hero from the top to the bottom), or elsewhere. Fixed seats may include no i re * assemb-y ncr r.ny assembly. The seating system ma> include one or more rear S^EJS that fold downward to a larger sto-'age area, and which may require the seat t: ;.c:i to act es k;&£ rlocr. The? seat may be a split design (e.g., about 50/50, 30/40, 7I)/::J or the iil ;.:••;, or the seats may constitute a one piece design, h one tirnl'odiment, th>;* -saat back is latched to either a structural package shelf (top Lstci es) or to the :):>dy in white (side outboard latches), and seat belt anchors or seat l:*i! guidance system [as may be needed for a center mounted belt) for the two t uhoard seats m rat attached on the soat. (See FIG. 1).
A sliding bck pin might be incorporated between two folding seats. The sliding \:\r\ -;an be- unloc:l-.e».i to fold down one portion of the seat and seif locking v/hen the i::;;c: back;; are .:o;;h upright. Localized reinforcement (e.g., steel reinforcement or I'iai-tic fo;am) for spreading loads may be incorporated into potential stress t'-or..;-3ntralIon locations, such as hinge points, latch areas, seat belt anchorage ' .c;; lions, child suai. tether anchor locations, head rest attachments, armrest support ;: e;:s, or tne iik:In another embodiment, seat belt anchors or a sea" belt guidance system for . )€• center seat oeit and/or child tether anchors are attached :o the seat. Preferably, ;-"!e. Lop center Mat belt mounting iocatcn is towards the middle of the seat back to *ie: minimise I he extent of cantilever, thereby helping to minimizing bending in lesjtonso :o a fop.;#.
Though i fnds application in a variety of other environments (e.g., rail i:3i spoliation having, air transportation seating, amusement park rides, auditorium or Milium applicators, or elsewhere), the present invention is particularly sjite.ble for
amplication in automotive vehicles of a number of different types, inciudhg but not Jfnvled to passenger cars (including sedans, coupes, station wagons, convertibles, or ;h<: like mull passenger vehicles sport utility activity rrinivans or the trucks and buses.>
Systems of the present invention are not limited to seat backs, but may aiso in::iude one or mre additional components for a vehicle interior system, particularly ::;i .seating! system, such as seat bells, and seat bell anchorage components for ■T inferring sea! :>elt loads to the vehicle structure, including, but not limited to, the -thcfrment hardware, seat frames, seat pedestals, the vehicle structure i-.self, and .::*!'■ &r par:s of th-3 vehcle that help to prevent separation of the belt from the vehicle •tscture. The* systems may optionally include supplemental inflatable restraint -.;>•: terns, such # $ j-Jr bags. Other seating system components that are contemplated :is. v/ithh the systems of the present invention include, v;ithout limitation, seat ■idjjsters (poW'Sr actuated and manual), lumbar supports, child seats, chJd seat .e-ii^r anchors, wheels, integrated handles, telescoping, retractable or adjustable eri.jlh handles, synthetic upholstery, natural upholstery (such as leather), seat .*/;,:'mers, seat ';o<:>iers, headrests, integrated stereo components, arm-rests, leg "£■■&, cup ho^<::r or the like. while in a preferred embodiment seat belt norporated irv.o system shoulder and more preferably three point leiress ot beit types may also be used such us lap belts only .vii i separate detachable torso>
As will l>& appreciated, the present invention also affords considerable Je- ign and rnaivjfHcture flexibility, including but not limited to the ability to vary the ::c figurations and contours of the respective opposing walls of a seat back. F-ot rii: cince,. a first wail could be moidably configured to provide a suitable lumbar iu: port. An opposing wall (i.e., the rearward facing'wall when the seat back is in its .ip*;ght position) could be configured to provide a relatively flat surface for carrying ::>* is. Option;:ii;y, the opposing wall could be configured with suitable component •.cvsings or cargo carrying implement':, such as troughs, lie down members, tonneau :o/jr brackets, seat belt retractor housings, or the like.
it v/ill be appreciated that one preferred embodiment of the present invention ia; focused oy/s) panels that oppose each other over substantially their entire faces.
rfcwever, the :'svention is not -irnited thereto. A seen in FIG. 2D, it is possible that a !..u;nei portion "70 onty spans over a portion of an opposing pane! portion 172. A kirole panel portion. 170 may oppose plural pane! portions 172, 174, as shown in :~T;.S. 2E. Plural panel portions 170, 17(3 rosy oppose plural pane! portions 172, 174, :JE; showr in FIG. 2F. Other variations are also possible.
t will islso be: appreciated that the present invention need not be limited to ■;:e--J bac\s. The teachings may be extended also to the seat base porions of ••e; liny nssurn:' a::\ In th's retjard, it may also be possible for the seat base and the ;e; 1 bacl
I "i another embodiment, shown in FIG. 18, the concepts of the present iv: ntion are applied for manufacturing an instrument pane! 178. The instrument ■•iWSii includes al east one and preferably two opposing molded (e.g.. blow molded, i :](• ;tion moldec. or the like) cross vehicle panels 180, 182, which may be the same t~ ■:: iffere it ma-i^a1, and preferably is plastic. Preferably the panels are joined (e.g., i.airci a fasten&r, at: adhesive or a welding technique as discussed in the foregoing). /1: vast one hollDw passageway 184 is defined between the panels, which preferably ')■• wjitabl'S for arncliomng as; an air duct for a vehicle cabin heating and cooling t; .'sism. The pix'tli preferably are configured with suitable* openings 135 or molded £!!*?£: :hment struct ires 188 adapted for receiving one or more instruments, gauges, or c'.:h:*r com pone: ils, cr communicating air to a vent opening into the passenger c :ir,r:artnvsn-;, A joht (e.g., an adhesive joint, weld joint, mechanical joint or the like) jt.iai the panels, :>u:'h as along flanges ISO. Flanges 190 may extend along one or i: "ith of the panels i: 30,182, on one or both sides of the same.
In one ^'odiment, the opposing panels are generally symmetrical relative r.<: e: c:h other s shown in fig. however th ntsed not be the case all inrt for example one embodiment sho-.vn fig pane jo at joint to a dashboard dashboa d lurn adjoins w r.ountsc vehicle body structure>
For this embodiment, as well as the other embodiments disclosed herein, ?Ki'/ant3ceou£!y a shew surface (e.g., a surface exposed to view in or on the vehicle) rn-'y be fabricated from a molded-h-color thermoplastic poiyolefin (e.g., a molded in ocor thermophore poiyolefin outer surface) joined to an underlying component for .in'parting strength and rigidity to the resulting assembly. For example, a molded-in-rx: or thermoptes-iic poiyolefin outer pane! might be joined to a polycabonate ■ici ylonitriie butsctene styrene support structure. The above teachings of coextruded pci iisons may aho be suitably smployed for blow melding instrument panels.
The tachnolcgy of the present invention may also be applied in providing .;a!tial or entitv: vehicle interior systems, including but not limited to headiiners, -•e'l-lcle doo:s, ::bve compartments, knee bolsters; and the like. In this regard, it may ■;i6- possible to ;:itech two or more components to eacn oiher (whether the same 'VKOria! or not) using one of the presently described adhesives.
in anofc'vsr embodiment, the seating system of the present Invention, the ,3.; ting system of commonly-owned and co-pending U.S. Application Serial No. :>d:7Qo.792 (filed January 22, 2001; incorporated by reference herein), or both are ip'-olstemd will l
I) a suitable fabric cover, leather or suede cover, simulated leather or suede cover, oru combination thereof;
I) a carpel *r other floor covering; or
J) a c^mbiii-ilio-i thereof.
In one embodiment, a hock and loop fastening system is applied to the seat .■-a-::;
Another advantage of the present Invention is that i~ lends itself well to die c:i;»ii-y \o preview seat assemblies that can be recycled. Accordingly, in another
ss-oect o-: the present invention, after the product life has concluded the products of th;; presorr: insertion are recycled using art-disclosed recycling techniques. In this regard, in one preferred embodiment, the plastics that are employed to fabricate a a:.npcnsnt an-! from the same plastic family for recycling purposes. Of course, in ar.jthsr embodiment, they may be from different families.
Fl«3. 20 i:;; a plan view illustration of one illustrative structure for a seat back. P'Ki. 21 A is a <: view through line a-a of fig. to illustrate the section file.> i* a sectional view through line 21 B-B of FIG. 20, also Illustrating a ■:e:.tion p 'Oiile. Preferably a forward pane! portion is mace separate from s rearward ;ic:iiel portion sne the two panels are joined at a joint ir. accordance with the ■■3ii! rhings herein. As seen, an example of a preferred Integrated reinforcement ■.'g|.:ern preferabiy includes one era combination of a plurality of elongated integrated •enforcement structures, a plurality if integrated reinforcsment structures* having a or jih that is approximately the same as the width of each structure, or at least one rlc; igatec1 integrated reinforcement structure having a plura'ity of longitudinally >p;- ced transverse ribs.
FiG. 22 i=, ;:i side view showing an alternative approach to forming a joint for a ; e.-t back 200 raving a first panel 202 and a second pane! 204. The second pane! is ■.h :-*r. wi h ribs ;236 or another suitable integrated reinforcement structure (although il'i€i first psnel may also have a suitable integrated reinforcement structure). A joint i.:; -termed by bnrcihg together, with art intermediate adne-sive 203, opposing flanges i,;;.!;.( firsl and second arcuaie flanges 210 and 212), and placing an adhesive ! :e:: ©between, VA'th or without a suitable surface treatment, such as a primer coating, IE: ma truatrmru or the like. The flanges are shown as arcuate, but may be other : h;i :es as well o; possibly flat.
Referring ::o FIG. 23, there is shown another type of seat back essembly :i l': In the astf-mbly 214, a seat beck 218 optionally includes one or more grab • -shj-es 218 (separately attached or Integrally formed therewith}. They can be i :3:;ted a« ehou'n aiong an edge of "he seat back, or elsewhere, such as on a i >r.* ard or rear wall portion 220 of the seat back 216.
/Mso ;•:;{ own in FIG. 23 It one Illustrative* location for an external i ir orcerr ent pane! 222 that is laminated or otherwise attached over seme ci' all of a
wall portion 220 of the seat back 216. The reinforcement panel 222 may be a metal
or plastic, layer (e.g., a film, such as an adhesive backed film); it may bo a natural
rmrteriai [e.g. leather or suede); it may be a woven or unwoven fabric (e.g., from a
fibrous plastic or glass material); it may be a carpet; or it may be some other suitable
i:t5.ioture for al hast partially covering or encapsulating the seat back 216. The pane!
le.txi not be c-ipaofe of supporting its; own weight, though in one embodiment it is.
:>r iferabl/ the reinforcement panel is suitable for containing or restraining any
:ra<:turecl seat back components in the event of failure or for otherwise>
'ix ally impartir.g strength or toughness *:o the assembly. The reinforcement panel is
■jhvv/n in FIG. 23 as extending across the width of a seat back, over oniy a portion of
he- vertical heiyir: of the seat back. It can extend the full height or width of the seat
;a:k or both, i: may also extend oniy a portion of the height, or a portion of the
iei:nt an J a portion of the width! of the seat back. It may foici over from a front wall
!■■■or ion to a rear wall portion. The reinforcement panel may be secured to the seat
!:>3::
I he reinforcement panel is plastic, the panel may be thermoset or thermoplastic or a
:.on bination theracf, Examples of materials include, without limitation, high molecular
:.'(• T;B Iik3. TI'i-s pane! may include an alastomeric component The panel may
or--;prlse one 0'
e painteble. h: niay have a surface topography that is contin-jous or variable. The
;: :.ir: ace may hav« a texture tha: is formed or intrinsic in ihe material itself.
As sh:>v>n in FIG. 24, there is shown another approach to attaching a seat l::;ic;: to the vehde. In this approach, a seat back 224 has one or more posts 22G 1 al project fro/v a bottom portion 223 of the seat back. Trie posts are removably or p-manerv:!y received in a mounting bracket 230, which optionally has a pivotaily c;::>paceatle pation 232 for allowing the bracket to also function as a hinge. The nesting bracket, in tu-n, is secured to the vehicle body in white 234, such as with a i-jit;ble fastener, weld, or otherwise. In another embodiment, the posts penetrate v-3 x>dy-h-wh
DO ils to thair respective-brackets. For example, the actuator might be attached to th-
The above should be understandable to the person skilled in the art, as will ■hi: application d :he novel concepts herein for use in a blow molded seai back. As ind'oated, examples of various blow rnoided structures are depicted in co-pending ■J.::. App'icaticn Saria! No. 09/766,792 (filed January 22, 2001), hereby incorporated :;y reference. By way of illustration, a section of a b.'ow molded seat back 238 ill. .;tratinj3 dif-rarrt reinforcing structures is shown in FiG. 25. One such ^figuration induces a tack-off 240, having a plurality of walls 242 (shown optionally ;i ;dntact with tfi^ wall 244) that are spaced apart to effectively define a beam ;tr. oture. Anotf ei illustrative configuration includes a tack-off 246 having a plurality :f adjoining wails 248 in contact with each other; yet another illustrative ,orf.gura\ion includes a single wail rib 250, which can be formed, for instance, by :n ;3loyincj one or a plurality of movable inserts in the tooling during forming. Still ;n:;tier ccnficjLuation may include an enlarged rib 252 (i.e. having an enlarged i-or.ion on or\i) or more of its sides) or some other like configuration. Another !:o-;-1guraiion incudes a wall portion that has a different wall thickness relative to an i:d;:'ining /vail potion.
11 another embodiment, it is possible to vary the materials used for the seat iiacss across fis width or" the seating assembly in a vehicle. For example, for a split :£i;; arrangemt-rt (e.g. 60/40) one seat back may be one material, and the other-a
:fl'i rent nia^rl;::! For example, one seat back is made of PC/ABS and the other one
i HOPE.
The; skilled artisan will recognize that although the seating system of the ji/e-ent invention has been described in relation to automotive seating, the system ! :a, also 3e ustxl 1br other seats such as airplane and bus seats or auditorium and
jnai'ium stsats.
The fop::;i(;ii!g discussion discloses and describes merely exemplary (.ni::tdim.snts of ho: present invention. One skilled in the art will readily recognize
hon such discission and from the accompanying drawings and claims, that various changes, modifiestions anci variations can be made therein without departing from ;5r- spirn and scope of the invention as defined in the foliov/ing claims, in particular rscard to the various functions performed by the above described components, ass ombiios, da^cos, compesitiens, etc., the terms used to describe such items are iir.i.'nded to ccrr-sspond, unless otherwise indicated, to any item that performs the •specified function of the described item, even though not necessarily structurally ■\o\ Ivalert to llvs disclosed structure. In addition, while a particular feature of the nv*:iticri may ra-ve been described above with respect to only one of the r'.r.iboclimsnts, such feature may be combined with one or more other features of :;t!i2r illustrate;! orr.hodirneriis.
CLAIMS
What s claims:! is;
An automotive vehicle interior assembly, comprising;
a seat back (ncucing a first portion; ia second portion formed separately from th= first portion but which is joined with the first portion via at least one joint to Form a seat back.
wherein at least one of the first portion or the second portion is fabricated from a molded plastic and further is defined to include a plurality of individual integrated reinforcement, structures for defining an inregratecj reinforcement structure pattern;
and
wherein the combination of components results in tft& seat back b«:ng capab;e of (1) withstanding without rupture at least about 13000 Nsiwtons in ths direction in which the seatfa:es in a plane, parallel to the .ongitudina! centertlne of the vehicle; and (2/ upon rapid acceleration up .a about 20 to about 30 g, exhibiting substantially no fragmentation of the
:$tf£t back with at leasta 35 kg mass placed behind the seat bade.
'."h:;.' assembly of claim *, further comprising an adhesive for bonding the firs! pcrtion with the second portion to define* the joint.
Tho assembly of claim 1 or 2. wherein the nrat portion and thst second portion are formed of dissimilar materials.
Thu assembly of cteim 1, 2 or 3, wherein ':he dissimilar materials are
politic.
In* assemb'y of any of claims 1 to 4. wherein one of the first or second portions is blow molded and the other of the first or second portions is
:t JB:.1(Dn molded.
The assembly of claims 1 to 4, wherein each of the first and second portions are injection melded plastic.
T-is assembly of any of cairns 1 to 0, wherein the material of the first portion and the material of th6 second port'on are from the same plastic family.
The assembly of cisim -any of claims 1 tc 7, further comprising upholstery sheeted from a suitable fabric cover, leather or suede cover, simLiiated iciiather or st-atie cevsr, or a comoir.afior, thsraof; a carpet or other floor covering; or a combination thereof.
Ths assembly of any of claims 1 to 8, wherein the first and second portions are shaped for defining a grab handle.
Ths assembly of any of risJnis 1 to 9, therein the molded plastic is a
rnicroccllular lanm plastic.
This assembly of any of claims 1 to 10, wherein the first portion; and the .-=i:.onci pcrticn are spared apart to define a plurality of open interna!
therebetween.
I r=! assembly of any of claims 1 to 11, wherein at least one of iha open S3a::es defines a channel that runs to a vent opening in one or both of ihe first or s&cond portions for functioning s$ a cuct and communicating air
T-rcuyh the vent opening.
v"H:j assembly of any cf c;a[ms 1 to '12, further comprising a soft-touch
surface over at least one of the first or second portions.
I'?*? assembly cf any of claims 11 to 13, father comprising a separately -Ti*>ri,:at«d component that is Moused \r\ at least one of the open internal
The assembly of any of claims 1 to 14, wherein the first portion includes pciycarbDnate/acryionilriie/butadiene styrene
The assembly of any of claims 1 to 15, wherein the second portion inrJUdes an olefinic materia!.
Ths assembly of any zf claims 1 to 16, wherein the high density olefin is high density polyethylene.
T)vi assembly of any cf claims 1 to 17 further comprising an instrument
;;v;ine[ assembly, comprising at least on? cross-vehicle molded plastic psnei support structure having a hollow passageway and adapted for receiving a vehicle instrument panel component
An automotive vehicle interior assembly, comprising:
a seai back including a first portion; a second portion formed Separately frcm the first portion but which is joined with the first portion vici
wherein at least on© of the first portion or the second portion is Fabricated from a moloed pfastic and furfner in defined to include a oluralrty of individual integrated reinforcement structures for defining an integrated reinforcement structure pattern;
and an attachment; assembly adapted :o anchor the "seat back dlwdiy to at least one body in white portion of She automotive vehicle with n h.ir.ge assembly;
wherein the combination of components results in tha soai back b-siny capable cf (1) withstanding without rupture at least about 13000 in the dir&ction =n which the seat faces in a plane, parallel to the cenieriine of The vehicle; and (2) upon rapid acceleration up TO about 20 to about 30 g, exhibiting substantially no fragmentation of the jack with at least a 36 kg mass placed be-iind the seat back.
20. An automotive vehicle interior assembly substantially as hereinabove described with reference to the accompanying drawings.
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