Seating durability layer electrical, mechanical and connecting system integration

1. A vehicle seat assembly comprising:

a seat bottom adapted for attachment to a vehicle, the seat bottom having a foam layer;

a first expanded polymer layer disposed adjacent the foam layer, the first expanded polymer layer defining a first cavity configured to receive an electrical component; and

a wire assembly including a wire and an insulating material, the wire assembly being partially enveloped by the first expanded polymer layer such that a portion of the wire assembly is completely enveloped within the first expanded polymer layer and a portion of the wire assembly extends externally from the first expanded polymer layer.

2. The seat assembly of claim 1 wherein the electrical component is a motor assembly.

3. The seat assembly of claim 1 wherein the first cavity has a negative draft angle to retain the electrical component within the first cavity.

4. The seat assembly of claim 1 wherein the first expanded polymer layer comprises expanded polypropylene.

5. The seat assembly of claim 1 wherein a substantial portion of the electrical component is enveloped by the first expanded polymer layer and is bonded to an interior surface of the first cavity.

6. The seat assembly of claim 1 further comprising a second expanded polymer layer disposed adjacent the first expanded polymer layer, the second expanded polymer layer defining a second cavity that aligns with the first cavity to enclose the electrical component.

7. The seat assembly of claim 1 wherein the first expanded polymer layer is configured to receive the electrical component in a snap fit relationship.

8. The seat assembly of claim 1 wherein the first cavity comprises an elongate channel having opposing walls, the elongate channel being configured to receive and retain a first wire assembly between the opposing walls.

9. The seat assembly of claim 8 wherein a pair of spaced apart steps are defined by the opposing walls, the steps being spaced apart from one another by a distance that is less than a distance separating the opposing walls, the steps being configured to receive and retain a second wire assembly between the steps, the second wire assembly having a diameter that is narrower than a diameter of the first wire assembly.

10. The seat assembly of claim 8 wherein the first expanded polymer layer includes a first pair of tabs spaced apart from one another by a first distance, the first pair of tabs being disposed within the elongate channel, the first pair of tabs being configured to retain a second wire assembly having a second diameter within the elongate channel.

11. The seat assembly of claim 10 further comprising a second pair of tabs spaced apart from one another by a second distance, the second distance being less than the first distance, the second pair of tabs being disposed within the elongate channel, the second pair of tabs being configured to retain a third wire assembly within the elongate channel, the third wire assembly having a third diameter that is less than the second diameter.

12. The seat assembly of claim 1 further comprising a clip partially molded into the first expanded polymer layer.

13. The seat assembly of claim 1 wherein the portion of the wire assembly that is completely enveloped within the first expanded polymer layer has less insulating material than the portion of the wire assembly extending externally from the first expanded polymer layer.

14. The seat assembly of claim 1 wherein the first expanded polymer layer comprises a first portion of polyolefin having a first density and a second portion of polyolefin having a second density.

15. A vehicle seat component for use with a vehicle seat assembly, the vehicle seat component comprising:

a seat bottom adapted for attachment to a vehicle; and

an expanded polymer member connected to the seat bottom, the expanded polymer member defining a cavity for receiving an electrical component; and

a second expanded polymer layer disposed adjacent the expanded polymer layer, the second expanded polymer layer defining a second cavity that aligns with the first cavity to enclose the electrical component.

16. The seat assembly of claim 15 wherein the cavity has a negative draft angle.

17. The seat assembly of claim 15 further comprising a wire assembly that is at least partially enveloped by the expanded polymer member.

18. The vehicle seat component of claim 15 wherein the cavity is configured to retain the electrical component within the cavity through at least a partial interference fit.

19. The vehicle seat component of claim 15 wherein the expanded polymer member comprises expanded polypropylene.

20. A method of manufacturing a vehicle seat assembly comprising:

providing a seat body having a seat bottom that includes an expanded polymer layer defining a cavity for receiving an electrical component;

providing an electrical component; and

positioning the electrical component within the cavity.