Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: A vehicle seat having a bladder with more than two inflatable chambers and an integral control flap, all of one piece, integral construction. To maximize inflatable volume of each chamber, each chamber preferably has a sidewall portion that is generally perpendicular. The control flap has passages in communication with the chambers and valving for selectively controlling inflation of the chambers. Valving preferably includes pinch valves having a generally T-shaped body with legs that pinch passages in the control flap to retain gas in a chamber and selectively inflate or deflate the chamber. The bladder is connected to a gas supply having a pump in communication with a reservoir for storing a charge of pressurized gas in the reservoir so that the pump need not immediately operate when gas is needed to inflate a chamber.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: A vehicle seat having a bladder with more than two inflatable chambers and an integral control flap, all of one piece, integral construction. To maximize inflatable volume of each chamber, each chamber preferably has a sidewall portion that is generally perpendicular. The control flap has passages in communication with the chambers and valving for selectively controlling inflation of the chambers. Valving preferably includes pinch valves having a generally T-shaped body with legs that pinch passages in the control flap to retain gas in a chamber and selectively inflate or deflate the chamber. The bladder is connected to a gas supply having a pump in communication with a reservoir for storing a charge of pressurized gas in the reservoir so that the pump need not immediately operate when gas is needed to inflate a chamber.

Abstract: A flexible unitary seat shell is disclosed to include: a base section defining a base section plane, the base section including two frame sockets for engaging, along axes that are substantially parallel to the base section plane, projections on a seat frame, each of the two frame sockets protruding from a back of said base section and including an encircling aperture that defines a plane that is nonparallel to the base section plane; a back section in angular relationship to the base section; and an intermediate section connecting the base section to the back section, the intermediate section forming a hinge between the base section and the back section to permit changes in the angular relationship between the base section and the back section.

Abstract: A flexible unitary seat shell including: a base section; a back section in angular relationship to the base section; and an intermediate section connecting the base section to the back section, the intermediate section forming a hinge between the base section and the back section to permit changes in the angular relationship between the base section and the back section.

Abstract: Methods for forming a strip of thermoplastic material by punch clamping are described.

Abstract: A concealed quick attach and detach mechanism for releasably installing and automatically locking a seat against lateral movement on a vehicle of the type having spaced apart first and second cantilever supports which terminate in first and second laterally spaced free ends. The mechanism includes a seat pan having a housing that includes a concealed interior and an interior support axis and first and second spaced apart apertures in the pan housing aligned on the lateral support axis that open into the interior for slidably receiving the first and second supports therethrough, respectively, when the seat is installed on the vehicle. A deflectable first lock is provided in the seat pan interior in register with the support axis and laterally spaced from the first aperture.

Abstract: A seat suspension having a stationary support that can be mounted on a vehicle. An intermediate frame is mounted on the stationary support for vertical sliding movement relative thereto by a spring suspension. A seat support frame is mounted on the intermediate frame for upward or downward movement relative thereto. A ratchet assembly interconnects the seat support frame and the intermediate frame and includes ratchet members on one of the frames and a pawl member on the other of the frames. A pawl release, including a biasing spring and a pawl actuating member, is provided to allow the support frame to be moved from the lower to any intermediate upper position and create an impulse at each position without need to activate said activating member. The activating member is operative to selectively move the pawl to a nonengagement position.

Abstract: A seat suspension including a downstop slide element having an overall width that automatically adjusts to compensate for dimensional variations between relatively stationary and movable frame parts of the seat suspension due to manufacturing tolerances and wear. The downstop has first and second leaf members having spaced apart first and second top and bottom walls, front and rear walls, and inner and outer walls, respectively. A connecting member interconnects the leaf members to place the first and second inner walls in opposed confronting relation for movement toward and away from each other to form a longitudinally extending slide gap therebetween of variable width. A first biasing member is provided to normally urge the pair of leaf members apart. A first tapered portion is provided on the inner wall of at least one of the leaf members. A cam surface is provided on the front wall of at least one of the leaf members.