FORM 2
THE PATENTSACT 1970
39 OF 1970
&
THE PATENT RULES 2003
COMPLETE SPECIFICATION
(SEE SECTIONS 10 & RULE 13)
1. TITLE OF THE INVENTION
« A MULTI-LAYER SEAT ASSEMBLY"
2. APPLICANTS (S)
(a) Name: Varroc Polymers Limited
(b) Nationality: Indian
(c) Address: L-4, Industrial Area,
MIDC-Waluj, Aurangabad-431136, Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION
The following specification describes the invention.

A MULTI-LAYER SEAT ASSEMBLY
FIELD OF THE INVENTION
[0001] The present invention relates to two-wheeler vehicles. More specifically, the
present invention relates to a multi-layer seat assembly in a two-wheeler vehicle. BACKGROUND OF THE INVENTION
[0002] Conventional vehicle seats generally include a seat cover, a hard seat base at a
lower end of the seat, and a cushion that is positioned between the seat cover and the hard seat base. The cushion is generally made of a relatively softer material compared to the seat cover and the hard seat base and serves to provide comfort to a rider of the vehicle. However, the cushion may not provide sufficient comfort to the rider for extended periods of time, which may cause a degraded riding experience for the rider.
[0003] Therefore, there is a need to introduce a seating mechanism for enhancing the
comfort of the rider. OBJECT OF THE INVENTION
[0004] To overcome the above-described challenges, the present invention proposes a
multi-layer seat assembly in a two-wheeler that provides an enhanced cushioning to a rider of the two-wheeler. This increases the rider's comfort, thereby, enhancing the rider experience.
[0005] An objective of the present invention is to provide at least a foam-based layer
in the seat assembly such that the at least one foam-based layer enhances the comfort experienced by the rider, compared to conventional seating arrangements. SUMMARY OF THE INVENTION
[0006] Embodiments of seat assembly in a two-wheeler, are disclosed that address at
least some of the above-mentioned challenges and issues.

[0007] In accordance with an embodiment, the seat assembly includes a seat cover
comprising a rexene-based material, a cushion, and at least one foam-based layer that is positioned between the cushion and the seat cover. Each layer of the at least one foam-based layer includes a foam-based material selected from memory foam, High-Resilience (HR) foam, Visco-Resilience (VR) foam, Expanded Poly-Vinyl Chloride Foam (PVC) foam, Ethylene propylene diene monomer (EPDM), or cool gel foam. The material used in one layer of the at least one foam-based layer may be same as or different from the material used in other layer(s) of the at least foam-based layer, in accordance with the embodiments presented herein.
[0008] In accordance with an alternative embodiment, the seat assembly includes a seat
cover comprising a rexene-based material, a seat base, and at least one foam-based layer that is positioned between the seat base and the seat cover. In this embodiment, the cushion may be positioned between the seat cover and the seat base such that the at least one foam-based layer is positioned between the cushion and the seat base (instead of being positioned between the cushion and the seat cover, as described in the previous embodiment). BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Further advantages of the invention will become apparent by reference to the
detailed description of preferred embodiments when considered in conjunction with the drawings:
[0010] Figures 1A and 1B illustrate a two-wheeler vehicle and its seating mechanism,
respectively, according to an embodiment.
[0011] Figure 2 illustrates an exploded view of a conventional front seat assembly of a
two-wheeler vehicle, according to an embodiment.
[0012] Figure 3 illustrates a seat assembly with one foam-based layer, according to an
embodiment.

[0013] Figure 4 illustrates a sectional view of a seat assembly with one foam-based
layer, according to an embodiment.
[0014] Figure 5 illustrates a seat assembly with two foam-based layers, according to
an embodiment.
[0015] Figure 6 illustrates a sectional view of the seat assembly with two foam-based
layers, according to an embodiment.
[0016] Figure 7 illustrates a seat assembly with three foam-based layers, according to
an embodiment.
[0017] Figure 8 illustrates a sectional view of the seat assembly with three foam-based
layers, according to an embodiment.
DETAILED DESCRIPTION
[0018] The following detailed description is presented to enable any person skilled in
the art to make and use the invention. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
[0019] The various embodiments throughout the disclosure will be explained in more
detail with reference to figures.

[0020] Figure 1A illustrates a two-wheeler vehicle 100 and its seating mechanism 102,
respectively, according to an embodiment. A two-wheeler may be, but not limited to, a motorcycle (also referred to as a bike), a scooter, or a cycle. A person skilled in the art would understand that the embodiments described herein are not limited to a two-wheeler and may be extended to a three-wheeler, a four-wheeler or any type of vehicle where a seating mechanism is used.
[0021] Figure 1B illustrate a conventional seating mechanism 102 of the two-wheeler
100 illustrated in figure 1. The conventional seating mechanism may include a front seat assembly 106 and a rear seat 108. The front seat assembly 106 may be used as a seating arrangement for a rider of the two-wheeler 100 while the rear seat assembly 108 may be used a seating arrangement for a pillion of the two-wheeler 100.
[0022] Figure 2 illustrates an exploded view of a conventional front seat assembly 106 illustrated in figure 1B, according to an embodiment. The front seat assembly 106 may include a seat cover 202, a cushion 204 and a seat base 206. The seat cover 202 may be made up of a suitable material such as, but not limited to, Rexene, leather, polyurethane leather or fabric. The cushion 204 may be made up of a relatively softer and compressible material such as foam or gel such that when the rider sits on the front seat assembly 106, the cushion can be compressed to provide additional comfort to the rider. The seat base 206 is made of a relatively harder material compared to the cushion 204 and the seat cover 202. For instance, the seat base 206 may be made up of plastic, carbon fiber, fiberglass or the like, to support the weight of the rider.
[0023] Figure 3 illustrates a seat assembly 306 with an additional foam-based layer
302, according to an embodiment. In this embodiment, a single foam-based layer such as the foam-based layer 302 may be introduced to the front seat assembly 106 to form the illustrated seat

assembly 306. A person skilled in the art would understand that this additional foam-based layer 302 may alternatively or additionally, also be incorporated into the rear seat assembly 108. The additional foam-based layer 302 may essentially include a layer of a foam-based material, which may be, but not limited to, a High-Resilience (HR) foam, a Visco-Resilience (VR) foam, an Expanded Poly-Vinyl Chloride Foam (PVC) foam, or a cool gel foam. A person skilled in the art would understand that the foam-based layer 302 may also be formulated by a combination of the aforementioned materials.
[0024] In the above embodiment, the foam-based layer 302 may be positioned between
the cushion 204 and the seat cover 202. In an alternative embodiment, however, the additional foam-based layer 302 may be positioned between the seat cover 202 and the seat base 206 in a manner that the foam-based layer 302 is sandwiched between the cushion 204 and the seat base 206.
[0025] In one embodiment, the additional foam-based layer 302 is positioned to cover
at least a portion of the seat cover that is in contact with a hip portion of a rider of the two-wheeler. In addition or alternatively, the additional foam-based layer 302 may be positioned such that it covers at least a portion of the seat cover that is in contact with a hip portion and a thigh portion (or only thigh portion) of a rider of the two-wheeler.
[0026] In one embodiment, the thickness of the additional foam-based layer 302 may
be in the range of 5 millimeter (mm) to 20 mm. However, this range of thickness is illustrated merely for an exemplary purpose. The thickness or other dimensions may vary as per design requirements.

[0027] Figure 4 illustrates a sectional view of a seat assembly 306 (e.g., a front seat
assembly) with one additional foam-based layer 302 and its position with respect to it the seat cover 202, the cushion 204, and the seat base 206.
[0028] Figure 5 illustrates the seat assembly 306 with two foam-based layers,
according to an embodiment. In an embodiment, the two foam-based layers may include a first foam-based layer such as the foam-based layer 302 and a second foam-based layer 502. In an embodiment, both these foam-based layers 302 and 502 may be positioned between the seat cover 202 and the cushion 204.
[0029] In another alternative implementation (not shown), one of these two foam-
based layers may be positioned between the seat cover 202 and the cushion 204; and the other foam-based layer may be positioned between the cushion 204 and the seat base 206. In yet another alternative implementation, both these foam-based layers may be positioned between the cushion 204 and the seat base 206, depending on design considerations.
[0030] In the above-described embodiments, one layer (e.g. a first layer) may be made
up of a first foam-based material that is different from a foam-based material used in the other layer (e.g., a second layer). For instance, the first layer may include an HR foam and the second layer may include a VR foam. Any of the above-described foam materials (or their combination) may be used in either of the two layers.
[0031] Figure 6 illustrates a sectional view of the seat assembly with two foam-based
layers the first foam-based layer 302 and the second foam-based layer 502, according to an embodiment. The two foam-based layers may be positioned between the seat cover 202 and the cushion 204 in the illustrated embodiments. However, the positioning of these layers may vary, as described above and is not limited to the illustrated embodiment.

[0032] Figure 7 illustrates a seat assembly 306 with three foam-based layers, according
to an embodiment. In an embodiment, the three foam-based layers may include a first foam-based layer such as the foam-based layer 302, a second foam-based layer such as the foam-based layer 502 and a third foam-based layer 702. In an embodiment, all these three foam-based layers 302, 502 and 702 may be positioned between the seat cover 202 and the cushion 204.
[0033] In another alternative implementation (not shown), any one of these three foam-
based layers may be positioned between the seat cover 202 and the cushion 204; and other two foam-based layers may be positioned between the cushion 204 and the seat base 206. In yet another alternative implementation, two of these foam-based layers may be positioned between the seat cover 202 and the cushion 204 and the third remaining foam-based layer may be positioned between the cushion 204 and the seat base 206. In yet another alternative implementation, all the three foam-based layers may be positioned between the cushion 204 and the seat base 206, depending on design considerations.
[0034] Figure 8 illustrates a sectional view of the seat assembly with three foam-based
layers, according to an embodiment. In an embodiment, all these three foam-based layers 302, 502 and 702 may be positioned between the seat cover 202 and the cushion 204, as illustrated. However, the positioning of either a subset of these layers or all the three layers may vary as per design considerations.
[0035] In accordance with the above-described embodiments, there may be several
advantages of using the above-specified foam-based materials such as, but not limited to, HR foam, VR foam, Expanded PVC foam, or cool gel foam. In one example, HR foam may be used in the illustrated seat assembly 306. HR form is a polyurethane foam that has a much higher responsiveness than memory foam, which has a relatively slower response. These types of foams

provide a more bounce back type of effect providing more comfort and resilience effect during longer rides in automobile seats.
[0036] In one example, these foams may be used in combination with memory foam
with HR foam placed below memory foam (e.g., as illustrated in the context of FIGs. 5 and 6). This combination provides a combined effect of bounciness/ resilience along with slow response of memory foam, thereby, providing comfort as well as resilience for longer bumpy rides. They cause an even pressure distribution and cause less sinking effect that memory foam would alone provide.
[0037] In the above illustrated exemplary scenario, the density of HR foam varies from
30 to 50 Kg/m3 and the resilience of varies between 40% to 50%. The usage of HR foam results in faster recovery time for the rider and prevention of bottoming of foam after long rides. HR foam is also soft to touch and feel and provides comfort to the rider over long rides.
[0038] In another exemplary scenario, memory foams may be used in the illustrated
embodiments. Memory foam generally has a relatively slower response time to recovery compared to HR foam. Memory foam softens when it comes in contact with the rider's body, molds to unique contours, and distributes body weight equally. The material responds differently depending on how it is subject to pressure, or "force". If pressure is applied quickly, the foam tends to change shape relatively more slowly, or "reluctantly." Memory foam also returns relatively slowly to its original shape when force is removed (on average, around 5-10 seconds). It is excellent at absorbing the force of an impact. In one example, open-cell memory foam has internal pockets (or, "open cells") that allow for ventilation and air flow throughout the topper layer, which helps disperse heat.

[0039] The density of memory foam varies from 30 Kg/m3 to 60 Kg/m3. The resilience
of Memory foam varies from 6 % to 10 %. The recovery time of memory foam varies from 10 seconds to 30 seconds.
[0040] The benefits of using memory foam are - excellent force absorption during
bumpy rides, low impact on rider during riding conditions, better air permeability and low response time creating a luxury effect while riding on a longer ride. A combination of HR foam and memory foam together may provide excellent impact absorption offered by memory foam as the top layer and resilience/ bounce back effect provided by HR foam as a middle layer between the seat cushion and memory foam layer. This provides comfort during long rides. In another implementation, this combination may also include two HR foam layers and a single memory foam layer (e.g., as illustrated in the context of FIGs. 7 and 8), which may provide comfort as well as resilience for longer rides.
[0041] In one example, cool gel form may be used in the illustrated embodiments.
These type of memory foams incorporate gel in their construction. Gels are usually formed by pumping gel-based microbeads into foam. These microbeads create pockets similar to those that exist in open-cell foams. Rather than simply letting air through the foam, these gels are generally "phase-changing" materials, implying that they actively absorb and release heat from the rider's body. The density of Cool-gel memory foam varies from 30 Kg/m3 to 50 Kg/m3. Their resilience varies from 40% to 50%.
[0042] In one example, expanded PVC foam may be used in the illustrated
embodiments. Expanded PVC foam is made up of PVC with some blowing agents. These types of foam are suitable for high-frequency welding with seat covers. Generally, they have a cotton

backing cloth on other side for preventing it from wear and tear during riding conditions. Expanded PVC foam provides 15% more comfort compared to conventional seating arrangements.
[0043] In an example implementation, the tear strength of PVC foam is greater than or
equal to 1.5 and the elongation of PVC foam is greater than or equal to 135.
[0044] In an example implementation, the foam-based layers (e.g., the layer 302, 502,
and/or 702) described in the illustrated embodiments may be referred to as a foam topper layer. In an embodiment, the foam topper layer may either cover only the sitting i.e buttock area (or hip portion) of the seat cushion or cover the sitting area as well as thigh area (of the rider) but may not cover the entire area of the seat cushion. In an exemplary scenario, the foam topper layer may be pasted to the seat cushion by using an adhesive which may recover quickly and facilitate good adhesion strength of all such layers with one another.
[0045] In an exemplary embodiment, a process to manufacture an embodiment of the
seat assembly of the present invention is illustrated herein. In the first step, polyurethane is poured in a foam topper layer mould and demoulding of the foam topper layer is conducted. Thereafter, the foam topper layer is placed in a cavity half of a seat cushion mould and then demoulding of the seat cushion with the foam topper layer is conducted. Further, it should be understood that many variations and modifications may be made in the process to cover all the embodiments described in the specification while remaining within the spirit and scope of the invention.
[0046] In accordance with the embodiments of this disclosure, the terms "comprising,"
"including," and "having," as used in the claim and specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms "a," "an," and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term "one" or "single" may be

used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as "two," may be used when a specific number of things is intended. The terms "preferably," "preferred," "prefer," "optionally," "may," and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the invention.
[0047] The present disclosure has been described with reference to various specific and
preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this invention. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This invention is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the SP network architecture described herein contain optional features that can be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that architecture.
[0048] While the invention has been described with respect to a limited number of
embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein.

We claim:
1. A seat assembly (306) in a two-wheeler (100), comprising:
a seat cover (202),
a cushion (204), and
at least one foam-based layer (302, 502, 702) positioned between the cushion (204) and the seat cover (202) wherein at least a first layer of the at least one foam-based layer (302, 502, 702) comprises a first foam-based material and at least a second layer of the at least one foam-based layer comprises a second foam-based material that is different from the first foam-based material.
2. The assembly (306) as claimed in claim 1, wherein at least one of the at least one foam-based layer (302, 502, 702) is positioned to cover at least a portion of the seat cover (202) that is in contact with a hip portion of a rider of the two-wheeler (100).
3. The assembly (306) as claimed in claim 1, wherein at least one of the at least one foam-based layer (302, 502, 702) is positioned to cover at least a portion of the seat cover (202) that is in contact with a hip portion and a thigh portion of a rider of the two-wheeler (100).
4. The assembly (306) as claimed in claim 1, wherein each layer of the at least one foam-based layer (302, 502, 702) comprises a foam-based material selected from memory foam, High-Resilience (HR) foam, Visco-Resilience (VR) foam, Expanded Poly-Vinyl Chloride Foam (PVC) foam, or cool gel foam.
5. The assembly (306) as claimed in claim 1, wherein a thickness of each layer of the at least one foam-based layer (302, 502, 702) is in the range of 5 millimeter (mm) to 20 mm.
6. The assembly (306) as claimed in claim 1, further comprising a seat base (206) positioned underneath the cushion (204).
7. The assembly (306) as claimed in claim 1, wherein the seat cover (202) comprises a rexene-based material.

8. A seat assembly (306) in a two-wheeler, comprising:
a seat cover (202),
a cushion (204),
and a seat base (206), and
at least one foam-based layer (302, 502, 702) positioned between the seat cover (202) and the seat base (206), wherein at least a first layer of the at least one foam-based layer (302, 502, 702) is positioned between the seat cover and the cushion and at least a second layer of the at least one foam-based layer (302, 502, 702) is positioned between the cushion (204) and the seat base (206).
9. The assembly (306) as claimed in claim 8, further comprising the cushion (204) is positioned between the seat cover (202) and the seat base (206).
10. The assembly (306) as claimed in claim 8, wherein the at least one foam-based layer (302, 502, 702) is installable in a front seat assembly of the two-wheeler (100).
11. The assembly (306) as claimed in claim 8, wherein each layer of the at least one foam-based layer (302, 502, 702) comprises a foam-based material selected from memory foam, High-Resilience (HR) foam, Visco-Resilience (VR) foam, Expanded Poly-Vinyl Chloride Foam (PVC) foam, or cool gel foam.