Apparatus and method for manufacturing a support frame for a seat assembly
A seat assembly includes a frame made from a first material having a first hardness, the frame including a first side and a second side opposite the first side. The seat assembly further includes a fabric component coupled to the first side of the frame, and a plurality of grooves are disposed within the second side of the frame. Each insert of a plurality of inserts are disposed within each respective groove in the plurality of grooves. Each insert of the plurality of inserts comprises a second material and the second material has a second hardness that is less than the first hardness.
1 . A seat assembly, comprising:
a frame comprising a first material that defines a first hardness, the frame including a first side, a second side opposite the first side, a top side, a right side that extends downward from the top side, and a left side that extends downward from the top side;
a fabric component coupled to the first side of the frame;
a plurality of grooves disposed within the second side of the frame, the plurality of grooves including first grooves along the right side of the frame and second grooves along the left side of the frame; and
a plurality of inserts, wherein each insert of the plurality of inserts is disposed within each respective groove in the plurality of grooves,
wherein each insert of the plurality of inserts comprises a second material, the second material defining a second hardness that is less than the first hardness,
wherein the frame defines a linear portion that extends in a substantially parallel direction with respect to a longitudinal axis and a curved portion that extends rearwardly of the linear portion, and
wherein a majority of inserts of the plurality of inserts are disposed within the curved portion of the frame.
2 . The seat assembly of claim 1 , wherein the second hardness is between about 25% and about 99% of the first hardness.
3 . The seat assembly of claim 1 , wherein each insert of the plurality of inserts is configured to deform in response to applying a load to the first side of the frame such that the curved portion of the frame is configured to flex in a rearward direction.
4 . The seat assembly of claim 1 , wherein the plurality of inserts are at least partially visible when viewed from the second side, the right side, and the left side.
5 . The seat assembly of claim 1 , wherein the first material defines a first modulus of elasticity and the second material defines a second modulus of elasticity that is between about 25% and about 99% of the first modulus of elasticity.
6 . A seat assembly, comprising: a frame defining a first length and including a first side and a second side opposite the first side;
a fabric component coupled to the first side of the frame;
a plurality of grooves disposed within the second side of the frame; and
a plurality of inserts disposed within the plurality of grooves,
wherein the plurality of inserts defines an insert area having a second length that is less than the first length,
wherein the frame defines a linear portion that extends in a substantially parallel direction with respect to a longitudinal axis and a curved portion that extends rearwardly of the linear portion, and
wherein the plurality of inserts is disposed within the curved portion of the frame.
7 . The seat assembly of claim 6 , wherein the frame comprises a first material that defines a first hardness and the plurality of inserts comprises a second material that defines a second hardness, and
wherein the second hardness is less than the first hardness.
8 . The seat assembly of claim 6 , wherein a third length of the linear portion is greater than a fourth length of the curved portion.
9 . The seat assembly of claim 6 , wherein the curved portion defines a first radius of curvature in an unloaded state and a second radius of curvature in a loaded state, and
wherein the second radius of curvature is greater than the first radius of curvature.
10 . The seat assembly of claim 6 , wherein the insert area of the plurality of inserts is located between about 40% and about 90% of the first length of the frame.
11 . The seat assembly of claim 6 , wherein the frame further includes a third side and a fourth side each coupled to the first side and the second side, and wherein the plurality of inserts are at least partially visible when viewed from the second side, the third side, and the fourth side.
12 . The seat assembly of claim 6 , wherein the plurality of grooves includes between one and 100 grooves.