Abstract: In at least one embodiment, the present disclosure provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 5% to 25%, the plurality of intrusions comprising a plurality of pairs of patterns, each pair of patterns comprising a first pattern spaced apart and opposingly and inversely facing a second pattern.

Abstract: A method for forming polyurethane foams for vehicle seat components in a molding apparatus is provided. The method includes a step of directing one or more polyol compositions into a mold. Each of the one or more polyol compositions includes a polyol, water, and a catalyst. The method also includes a step of directing an isocyanate composition into the mold, the isocyanate composition including one or more isocyanates. The one or more polyol compositions and the one or more isocyanates are combined into a reaction composition that forms a foamed vehicle seat component. Characteristically, the mold has a shape that defines a foamed vehicle seat component. Characteristically, either the one or more polyol compositions and/or the isocyanate composition includes a liquid antimicrobial agent that is a liquid at temperatures above 10° C.

Abstract: The present disclosure relates to a method of making polyurethane foam, the method comprising providing a polyol mixture comprising polyether polyol and unmodified vegetable oil having a hydroxyl number of less than 10; and reacting isocyanate with the polyol mixture to form a polyurethane foam, wherein the unmodified vegetable oil does not react and does not form part of the polyurethane foam. The present disclosure also relates to polyurethane formed by the method and polyurethane compositions.

Abstract: A vehicle seating system may include a seat part having a trim material positioned over a base material. A method for producing the seating system may include configuring an attachment arrangement to have an adhesive material and a non-adhesive material bonded to the adhesive material. The method may also include molding the base material onto the non-adhesive material such that a surface of the adhesive material faces outward away from the base material. The trim material may be disposed over the base material such that a back side of the trim material is adhered to the adhesive material.

Abstract: In at least one embodiment, the present disclosure provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 5% to 25%, the plurality of intrusions comprising a plurality of pairs of patterns, each pair of patterns comprising a first pattern spaced apart and opposingly and inversely facing a second pattern.

Abstract: A composition for forming polyurethane foams is provided using epoxidized triglycerides with unopened rings. The composition further includes a polyol, a blowing agent, and a catalyst that catalyzes the reaction of polyols with isocyanates to form polyurethanes. The polyol is a polyoxyalklylene and the epoxidized triglyceride is an epoxidized soybean oil. A method for forming polyurethane foam using the aforementioned composition is also provided.

Abstract: A seat assembly having improved trim appearance is provided as well as a method and mold tool for making the seat assembly. In certain embodiments, the seat assembly has at least one narrow trench having a substantially constant width of up to 5 mm, which provides for better tolerances when installing a trim cover on the cushion and provides improved appearance and comfort. In certain embodiments, the mold tool has at least one tool insert that is configured to create the at least one narrow trench with a substantially constant width in the cushion.

Abstract: A vehicle seating system may include a seat part having a trim material positioned over a base material. A method for producing the seating system may include configuring an attachment arrangement to have an adhesive material and a non-adhesive material bonded to the adhesive material. The method may also include molding the base material onto the non-adhesive material such that a surface of the adhesive material faces outward away from the base material. The trim material may be disposed over the base material such that a back side of the trim material is adhered to the adhesive material.

Abstract: The present disclosure relates to a method of making polyurethane foam, the method comprising providing a polyol mixture comprising polyether polyol and unmodified vegetable oil having a hydroxyl number of less than 10; and reacting isocyanate with the polyol mixture to form a polyurethane foam, wherein the unmodified vegetable oil does not react and does not form part of the polyurethane foam. The present disclosure also relates to polyurethane formed by the method and polyurethane compositions.

Abstract: A vehicle seat assembly is provided with a structural member adapted to be mounted within a vehicle to provide support to an occupant. The structural member has at least one channel formed therein. A cushion member is provided adjacent to the structural layer. The cushion member has at least one channel formed therethrough. A trim member is secured over the cushion member to form a seating surface. At least one attachment member is mounted to the trim member extending through the at least one channel of the cushion member. The at least one attachment member extends into the at least one channel of the structural member such that at least one of the trim material and the cushion layer is retained on the structural member.

Abstract: The present disclosure relates to a method of making polyurethane foam, the method comprising providing a polyol mixture comprising polyether polyol and unmodified vegetable oil having a hydroxyl number of less than 10; and reacting isocyanate with the polyol mixture to form a polyurethane foam, wherein the unmodified vegetable oil does not react and does not form part of the polyurethane foam. The present disclosure also relates to polyurethane formed by the method and polyurethane compositions.

Abstract: A composition for forming polyurethane foams is provided using epoxidized triglycerides with unopened rings. The composition further includes a polyol, a blowing agent, and a catalyst that catalyzes the reaction of polyols with isocyanates to form polyurethanes. The polyol is a polyoxyalklylene and the epoxidized triglyceride is an epoxidized soybean oil. A method for forming polyurethane foam using the aforementioned composition is also provided.

Abstract: A seatback assembly is provided having a thoracic support structure. The thoracic support structure includes a center portion extending in an upright direction and is adapted to be positioned adjacent the seatback to align adjacent a thoracic region a user's spine. The center portion is formed of a first foam material having a first hardness. A pair of side portions are disposed adjacent to and connected with the center portion. The side portions are formed of a second foam material having a second hardness. The first hardness is greater than the second hardness for providing support to the user's spine. An adjustment mechanism is connected to the thoracic support structure for positioning the support structure along the seatback so that the center portion provides support to at least a portion of the thoracic region of the user's spine.

Abstract: A thoracic support for a seat back of a seat is provided. The thoracic support structure is pivotally attached to the seat back and pivots between a first position and a second position. In the second position the support structure supports at least a portion of the thoracic region of the user's spine. An actuator disposed between a support surface and the support structure pivots the support structure from the first position to the second position upon actuation.

Abstract: A vehicle seat is provided, in at least one embodiment, comprising a seatback comprising a cushion having a first hardness, and a pneumatic thoracic support structure positioned adjacent the cushion. In at least one embodiment, the pneumatic thoracic support structure comprises a first bladder selectively inflatable to provide a first area having a second hardness higher than the first hardness, with the first area being disposed along a thoracic region of a user's spine when a user is seated in the seat to provide support to at least a portion of the thoracic region of the user's spine.

Abstract: A vehicle seat is provided, in at least one embodiment, comprising a seatback comprising a cushion having a first hardness, and a pneumatic thoracic support structure positioned adjacent the cushion. In at least one embodiment, the pneumatic thoracic support structure comprises a first bladder selectively inflatable to provide a first area having a second hardness higher than the first hardness, with the first area being disposed along a thoracic region of a user's spine when a user is seated in the seat to provide support to at least a portion of the thoracic region of the user's spine.

Abstract: A seat assembly having improved trim appearance is provided as well as a method and mold tool for making the seat assembly. In certain embodiments, the seat assembly has at least one narrow trench having a substantially constant width of up to 5 mm, which provides for better tolerances when installing a trim cover on the cushion and provides improved appearance and comfort. In certain embodiments, the mold tool has at least one tool insert that is configured to create the at least one narrow trench with a substantially constant width in the cushion.

Abstract: A thoracic support for a seatback of a seat is provided. The thoracic support has a center portion extending in an upright direction and adapted to be positioned adjacent the seatback to align adjacent a thoracic region a user's spine and having a first hardness. A pair of side portions are each disposed on opposing lateral sides of the center portion. The side portions have a second hardness less than the first hardness of the center portion. The pair of side portions and the center portion to define a smooth forward support surface.

Abstract: A seat assembly having improved trim appearance is provided as well as a method and mold tool for making the seat assembly. In certain embodiments, the seat assembly has at least one narrow trench having a substantially constant width of up to 5 mm, which provides for better tolerances when installing a trim cover on the cushion and provides improved appearance and comfort. In certain embodiments, the mold tool has at least one tool insert that is configured to create the at least one narrow trench with a substantially constant width in the cushion.

Abstract: A vehicle seat assembly a seat bottom and a seatback pivotally attached to the seat bottom. The seatback comprises a seatback support shell comprising a shaped resinous sheet comprising a main seat portion, a left side bolster, and a right side bolster. The seatback support shell further comprising a left side hinge extending between and connecting the left side bolster and the main seat portion to allow relative movement between the left side bolster and the main seat portion and a right side hinge extending between and connecting the right side bolster and the main seat portion to allow relative movement between the right side bolster and the main seat portion. The vehicle seat assembly further comprising trim cover disposed over the seatback and the seat bottom.