FOAM SEAT ELEMENT
A foam seat element comprising an isocyanate-based foam matrix having an A-surface for contact with an occupant and a B-surface for contact with a suspension element. An elastomeric layer is disposed on at least a portion of the B-surface for contact with the support element. This approach results in reduction in labor to produce the elastomeric layer compared with correct positioning of cloth inserts on a foam production manufacturing line. Further, since, in the preferred embodiment of the invention, the elastomeric layer is achieved by spraying a liquid elastomer-forming composition on a portion of the mold surface, the costs of achieving the elastomeric layer are significantly less than those associated with using prefabricated, pre-cut cloth inserts. Still further, the use of an elastomeric layer allows for tuning of the thickness of that layer which facilitates “tuning” the durability of the B-surface of the foam seat element based on the specific suspension system with which it will be combined.
1 . A foam seat element comprising an isocyanate-based foam matrix having an A-surface for contact with an occupant and a B-surface for contact with a suspension element, at least a portion of the B-surface for contact with the suspension element comprising an elastomeric layer.
2 . The foam seat element defined in claim 1 , wherein the A-surface and the B-surface are substantially opposed to one another.
3 . The foam seat element defined in claim 1 , wherein the foam matrix comprises an isocyanate-based foam matrix.
4 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises a thickness of less than or equal to about 3.0 mm.
5 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises a thickness of less than or equal to about 2.5 mm.
6 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises a thickness of less than or equal to about 1.5 mm.
7 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises a thickness in the range of from about 0.01 mm to about 1.5 mm.
8 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises a thickness in the range of from about 0.01 mm to about 1.0 mm.
9 . The foam seat element defined in claim 1 , wherein the elastomeric layer is substantially non-cellular.
10 . The foam seat element defined in claim 1 , wherein the elastomeric layer comprises an elastomer coating.
11 . The foam seat element defined in claim 1 , wherein the elastomeric layer is produced in situ in a mold used to produce the foam matrix.
12 . The foam seat element defined in claim 1 , wherein the elastomeric layer is derived from an emulsion composition comprising polymer particles.
13 . The foam seat element defined in claim 1 , further comprising a frame element which is at least partially embedded in the foam matrix.
14 . A vehicular seat comprising the foam seat element defined in claim 1 .
15 . A vehicular seat cushion comprising the foam seat element defined in claim 1 .
16 . A vehicular seat backrest comprising the foam element defined in claim 1 .
17 . A vehicular seat comprising the foam seat element defined in claim 1 , wherein the suspension element is in contacting relationship with the B-surface of the foam seat element.
18 . The vehicular seat defined in claim 17 , wherein the suspension element is in contacting relationship with the B-surface of the foam seat element.
19 . The vehicular seat defined in claim 18 , wherein the suspension element comprises a least one biasing element.
20 . The vehicular seat defined in claim 18 , wherein the suspension element comprises a plurality of biasing elements.
21 . The vehicular seat defined in claim 20 , wherein each of the plurality of biasing elements comprises a spring.
22 . A vehicular seat comprising a foam seat element comprising: (i) a polyurethane foam element having an A-surface for contact with an occupant and a B-surface substantially opposed to the A-surface, at least a portion of the B-surface comprising a non-cellular elastomeric layer, and (ii) a suspension element in contacting relationship with the at least a portion of the B-surface comprising a non-cellular elastomeric layer.
23 . The vehicular seat defined in claim 22 , wherein the elastomeric layer comprises a thickness of less than or equal to about 3.0 mm.
24 . The vehicular seat defined in claim 22 , wherein the elastomeric layer comprises a thickness of less than or equal to about 2.5 mm.
25 . The vehicular seat defined in claim 22 , wherein the elastomeric layer comprises a thickness of less than or equal to about 1.5 mm.
26 . The vehicular seat defined in claim 22 , wherein the elastomeric layer comprises a thickness in the range of from about 0.01 mm to about 1.5 mm.
27 . The vehicular seat defined in claim 22 , wherein the elastomeric layer comprises a thickness in the range of from about 0.01 mm to about 1.0 mm.
28 . The vehicular seat defined in claim 22 , wherein the elastomeric layer is derived from an emulsion composition comprising polymer particles.
29 . The vehicular seat defined in claim 22 , further comprising a frame element which is at least partially embedded in the foam element.
30 . The vehicular seat defined in claim 22 , wherein the seat foam seat element is disposed in a vehicular seat cushion.
31 . The vehicular seat defined in claim 22 , wherein the seat foam seat element is disposed in a vehicular seat backrest.