Seat assembly, clip and method of manufacture

Abstract

A clip, a seat assembly and a method of manufacture. A clip is disposed in the pad. The cushion may include a filament mesh structure. The clip has at least one barb that secures the clip to the pad and at least one retention feature that secures the trim cover to the clip.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 508,301 filed on June 15, 2023, Danish Patent Application No. PA202370583 filed on November 21, 2023, and U.S. Non-Provisional Application Serial No. 18 / 629,363 filed on April 8, 2024, the disclosures of which are hereby incorporated by reference in their entirety. Technical Field

[0003] Various embodiments are directed to seat assemblies, clips for securing trim covers to seat assemblies, and methods of manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 is a perspective view of an example of a seat assembly.

[0005] Figure 2 is a perspective view of an example of a cushion for a seat assembly.

[0006] Figure 3 is a schematic diagram of an example of a manufacturing system for manufacturing a filament mesh structure for a cushion.

[0007] Figure 4 is a perspective view of an example of a clip.

[0008] Figure 5 yes Figure 4 End view of the clip shown.

[0009] Figure 6 yes Figure 4 A plan view of a portion of the clip shown.

[0010] Figure 7 yes Figure 4 A side view of a portion of the clip is shown.

[0011] Figure 8 is a flow chart of a method of manufacturing a clip and installing it into a pad.

[0012] Fig. 9 is a simplified side view of a filament network structure.

[0013] Fig.10 is a simplified side view of a filament mesh structure with slits.

[0014] Fig.11 is a side view of a filament mesh structure with a clip shown in end view.

[0015] Fig.12is a simplified side view of a filament mesh structure with a trim cover secured to a clip.

[0016] Fig.13 is a side view of a filament mesh structure with a clip, the clip being shown in side view.

[0017] Fig.14 is a plan view of an example of a portion of a filament mesh structure with a clip.

[0018] Fig.15 is a simplified side view of a filament mesh structure showing clips positioned at different heights in the filament mesh structure. Detailed Description

[0020] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it is apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0021] It should be understood that the disclosed embodiments are merely exemplary, and that different and alternative forms are possible. The drawings are not necessarily to scale; some features may be exaggerated or reduced in order to show the details of particular components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to implement the embodiments according to the present disclosure in various ways.

[0022] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed fashion), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0023] It should also be understood that, although in some cases, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0024] The terms used in the description of the various embodiments described herein are only used for the purpose of describing specific embodiments and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to also include plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the relevant listed items. It should be further understood that when used in this specification, the terms "includes", "including", "comprises" and / or "comprising" specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0025] As used herein, the term "if" is optionally interpreted to mean "when..." or "upon..." or "in response to determining..." or "in response to detecting...", as the context requires. Similarly, the phrases "if it is determined" or "if [the condition or event] is detected" are optionally interpreted to mean "upon determining..." or "in response to determining..." or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]", as the context requires.

[0026] refer to Figure 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly (e.g., for land vehicles, such as cars, trucks, buses, etc.), or for non-land vehicles (such as aircraft or ships). For example, the seat assembly 10 for land vehicles can be shaped and sized to be used as a front driver or passenger seat, a second, third or other rear seat, and can include a bench seat, a bucket seat or other seat styles. In addition, the seat assembly 10 can be a non-stowable seat or a stowable seat, and the stowable seat can be folded or can be folded and can be stowed in a cavity in the vehicle floor. In addition, the seat assembly 10 can be configured to be used in non-vehicle applications, such as furniture.

[0027] exist Figure 1 In the illustrated configuration, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool.

[0028] The seat bottom 20 is configured to receive a seated occupant and support the pelvis and thighs of the seat occupant. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0029] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In one or more configurations, the seat bottom frame 30 includes a panel, a seat pan, a suspension pad, or a suspension wire on which the cushion 32 is disposed.

[0030] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat bottom frame 30. The cushion 32 and associated manufacturing methods will be discussed in more detail below.

[0031] The decorative cover 34 covers at least a portion of the cushion 32. In addition, the decorative cover 34 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 34. The decorative cover 34 is made of any suitable material or materials (such as fabric, leather, artificial leather, vinyl or a combination thereof). The decorative cover 34 may include a plurality of decorative panels assembled in any suitable manner, such as by fusing or stitching. The decorative cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the decorative cover 34 may include decorative attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to inhibit the removal of the decorative cover 34 and help the decorative cover 34 conform to the contours of the seat bottom frame 30, the cushion 32, or both. It is contemplated that different types of decorative attachment features may be used to attach the decorative cover 34 to the seat bottom frame 30 instead of attaching it to the cushion 32.

[0032] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and adjacent to the rear side of the seat bottom 20. The seat back 22 extends in a generally upward direction away from the seat bottom 20. In some configurations, the seat back 22 is mounted to the seat bottom 20 and may pivot relative to the seat bottom 20. In other configurations, the seat back 22 is not mounted to the seat bottom 20. For example, a vehicle seat back may be mounted to a vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a decorative cover 44, and an optional headrest 46.

[0033] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made of any suitable material, such as a metal alloy, a polymer material, a fiber reinforced polymer material, or a combination thereof. In one or more configurations, the seat back frame 40 includes a panel, a base, a suspension pad, or a suspension wire on which the cushion 42 is disposed. It is also contemplated that the seat back frame 40 can be integrally formed with the seat bottom frame 30.

[0034] A cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a compliant material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or separate from the cushion 32 of the seat bottom 20. The cushion 42 and associated manufacturing methods will be discussed in greater detail below.

[0035] The decorative cover 44 covers at least a portion of the cushion 42. In addition, the decorative cover 44 provides one or more visible outer surfaces of the seat back 22. When sitting on the seat assembly 10, the seat occupant can be placed on the decorative cover 44. The decorative cover 44 is made of any suitable material or materials (such as fabric, leather, artificial leather, vinyl or a combination thereof). The decorative cover 44 may include a plurality of decorative panels assembled in any suitable manner, such as by fusing or stitching. The decorative cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the decorative cover 44 may include decorative attachment features that are attached to the seat back frame 40, the cushion 42, or both to inhibit the removal of the decorative cover 44 and help the decorative cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both. It is contemplated that different types of decorative attachment features may be used to attach the decorative cover 44 to the seat back frame 40 instead of attaching it to the cushion 42.

[0036] A headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed on a top portion of the seat back 22, or at an end of the seat back 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be integrally formed with the seat back 22.

[0037] refer to Figure 2 , an example of a cushion 50 is shown. For ease of reference, the cushion is generally indicated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0038] In some embodiments, the cushion 50 is a non-foam component or includes at least one non-foam component. The non-foam component is primarily referred to as a filament mesh structure, but may also be referred to as a mesh cushion, a mesh structure, or a twisted mesh. Figure 2 , the cushion 50 is described as a non-foam component that does not include a foam component or foam material (e.g., urethane or polyurethane foam); however, it is contemplated that the cushion 50 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or localized cushioning to the seat occupant. For example, the foam material may be disposed between the cushion 50 and a trim cover (e.g., trim cover 34, 44) disposed on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided by the cushion 50 or removing foam material from the cushion 50 may reduce weight and may improve support and comfort for the seat occupant.

[0039] The cushion 50 is described below primarily in the context of a cushion 50 that does not include a foam material. In this case, the cushion 50 is made of filaments 52 of a polymer material that are randomly looped, bent, curled or entangled and bonded together, as will be discussed in more detail below. Fig.11 and Fig.13 An enlarged view of an example cushion is shown with filaments 52. The filaments 52 are directly bonded to one another filaments 52, rather than being indirectly bonded with a resin or other intermediate material.

[0040] Long filament 52 can also be referred to as strand or line, is made of any suitable one material or multiple materials.In some configurations, long filament 52 is made of polymer material or thermoplastic material, and polymer material or thermoplastic material are for example based on polyamide, based on polyester, based on polyimide, based on polyolefin (for example, based on polypropylene, based on polyethylene etc.), based on thermoplastic resin of polystyrene or its combination.As an example, long filament based on polyethylene can be made of linear low density polyethylene (LLPDE).Different from foam material, long filament material can be recyclable, or is easier to recycle than foam material.Also contemplate that long filament 52 can comprise reinforcing fiber, and reinforcing fiber may not be made of thermoplastic material.

[0041] In some configurations, the filament 52 can be a monofilament made of a single material. In some configurations, the filament 52 is made of multiple materials. For example, the filament 52 made of multiple materials can include a core made of a first thermoplastic material and a sheath around the core and made of a second thermoplastic material that is different from the first thermoplastic material. It is contemplated that the pad 50 can include a combination of monofilaments and filaments that are made of multiple materials and are not monofilaments.

[0042] The randomly looped, bent, looped, curled or entangled filaments 52 are bonded together where one filament 52 contacts another filament 52, thereby creating a lightweight, breathable pad (e.g., pad 32 and / or pad 42) or a mesh structure (having openings or gaps between the filaments 52). Figure 3 Also shown is an example of a manufacturing system 60 for making a cushion or filament web structure. In this example, the manufacturing system 60 includes a material supply 70, an extruder 72, and a hopper 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0043] refer to Figure 3 The material supplier 70 holds the material raw material to be extruded, such as solid beads, flakes, granules, pellets or powder made of the material. In some configurations, the material supplier 70 is configured as a container or a hopper. The material supplier 70 provides the material raw material to the extruder 72.

[0044] The extruder 72 melts the material raw material and extrude the material raw material into a group of filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw forces the material to pass through the barrel and helps heat the material due to the friction generated when the screw rotates. The material leaves the barrel under pressure and in a molten state and is transported to the die 80 of the extruder 72.

[0045] The die 80 (also referred to as a die plate or extrusion die) has a plurality of through holes or openings forming filaments, through which the molten material passes. A single filament 52 is extruded from each through hole. The filament 52 falls downward from the die 80 into the funnel 74 under gravity.

[0046] The funnel 74 merges or groups the filaments 52 into a more compact arrangement, wherein the filaments are bent, curled or looped, and the filaments 52 contact and are bonded to at least one other filament 52. The funnel 74 has a funnel inlet and a funnel outlet smaller than the funnel inlet. The filaments 52 separated individually enter the funnel inlet. When the filaments 52 accumulate, the filaments 122 are bent, curled or looped and move to contact. The filaments 52 slide toward the funnel outlet along the funnel 74. Each member in a group of filaments 52 can be bonded to at least one other member in the group of filaments 52. The bonding between the filaments 52 is formed at the contact point, and the opening or gap between the filaments 52 exists in other positions where one filament 52 does not contact or is bonded to another filament 52. The filaments 52 wound and bonded pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For ease of reference, the bonded filaments 52 are referred to as filament mesh structure 90.

[0047] Cooling tank 76 holds liquid, for example water or water and the mixture of another fluid.Liquid in cooling tank 76 helps to support the long filament 52 of winding and combining, further compacts or consolidates into the arrangement of less opening or less holes to limit long filament 52, and keeps the desired porosity and the density of long filament network structure 90.Therefore, liquid provides some buoyancy or resistance, and these buoyancy or resistance can cause the extra bending, curling or looping of the long filament 52 in adjacent liquid surface or funnel 74, to further build long filament network structure 90.When long filament 52 is in liquid, liquid also cools down long filament 52.For example, liquid cools down long filament 52 from outside to solidify long filament 52 and prevents long filament 52 from combining in additional position.At this moment, long filament 52 is relatively hard and no longer in plastic state, therefore keeps shape usually, and cannot be plasticized or reshaped when not being reheated.

[0048] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyor belts that help move the filament mesh structure 90 through the liquid and out of the liquid. In some configurations, a traction conveyor 92 is provided in the cooling tank 76 to help pull the filament mesh structure 90 out of the funnel 74 and to counteract the buoyancy of the filaments 52.

[0049] One or more other rollers (e.g., roller 94) keep the filament mesh structure 90 immersed in the liquid and guide the filament mesh structure 90 through the cooling tank 76. For example, the roller 94 can guide the filament mesh structure 90 to a conveyor belt 96 and a shaker table 98 disposed outside the cooling tank 76. The shaker table 98 vibrates the filament mesh structure 90 while the filament mesh structure 90 is on the conveyor belt 96 to remove the liquid. Alternatively or additionally, the filament mesh structure 90 can be squeezed to remove the liquid, air can be blown to the filament mesh structure 90 to remove the liquid from the filament mesh structure 90, or both.

[0050] Above-mentioned manufacturing system 60 is a continuous flow process, wherein when long filament is extruded without interruption, long filament net-like structure 90 is formed into a continuous structure.After leaving cooling tank 76, further processing to long filament net-like structure 90 is provided, so that long filament net-like structure 90 is cut into single sheet or blank for single liner.This processing is carried out by the cutting subsystem of manufacturing system 60.The cutting subsystem can be any suitable type.For example, the cutting subsystem can use blade, knife, hot knife, saw, fluid jet etc. to cut the long filament 52 of long filament net-like structure 90 into blank.The cutting subsystem can also cut the slit of receiving clip in long filament net-like structure 90, as will be discussed in more detail below.In some configurations, long filament net-like structure 90 is molded or shaped before cutting, after cutting or in both situations.

[0051] refer to Figure 4 , an example of a clip 100 is shown. The clip 100 is configured to secure a trim cover to a cushion, such as a cushion 50 including a filament mesh structure 90; however, it is also contemplated that the clip 100 may also be provided with a cushion including or made of foam. For ease of reference, the trim cover is generally indicated by reference numeral 102. The trim cover 102 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22. Fig.12 An example of a portion of the trim cover 102 is shown.

[0052] Continue to refer Figure 4 , the clip 100 is made of any one or more suitable materials. In some configurations, the clip 100 is made of a polymer material. The clip 100 can be made of the same material as the filament 52, or of a material different from the filament 52. The polymer material can be recyclable. The clip 100 is manufactured using any suitable process. For example, the clip 100 can be molded or manufactured using an additive manufacturing process (e.g., 3D printing). It is envisioned that the clip 100 is manufactured as an integral one-piece component that can be cut to a length suitable for installation in the filament mesh structure 90.

[0053] The clip 100 includes one or more clip segments 110. In a configuration having a plurality of clip segments 110, a ridge 112 is provided with the clip 100. In this configuration, the ridge 112 is interconnected with the clip segments 110. The clip segments 110 are spaced apart from one another such that a gap 114 is provided between one clip segment 110 and an adjacent clip segment 110. The clip 100 will be primarily described in the context of a clip 100 having a plurality of clip segments 110.

[0054] refer to Figure 4 and Figure 5 , an example of a spine 112 is shown. The spine 112 is flexible and allows the clip segments 110 to be positioned in different orientations relative to each other, as will be discussed in more detail below. Figure 4 As shown, when the ridge 112 is in a free state, the ridge 112 may be linear or extend along a linear ridge axis 120. The ridge 112 includes a bottom side 130 and a top side 132.

[0055] The bottom side 130 faces away from the clip segment 110. In some configurations, the bottom side 130 extends the length of the clip 100.

[0056] The top side 132 is disposed opposite the bottom side 130. As such, the top side 132 can face the clip segment 110. In some configurations, the top side 132 is segmented and extends from one clip segment 110 to an adjacent clip segment 110, or is visible between adjacent clip segments 110, 110.

[0057] exist Figure 4 and Figure 5 In the illustrated configuration, the ridge 112 is positioned below the clip segments 110. It is also contemplated that the ridge 112 may be positioned at a higher elevation than shown in these figures. For example, rather than being positioned below one or more clip segments 110, the ridge 112 may extend from a side of a first clip segment 110 that faces an adjacent second clip segment 110 to a corresponding side of an adjacent clip segment 110 that faces the first clip segment 110. As an example, the ridge 112 may extend from a side of a first clip segment 110 that faces an adjacent second clip segment 110 to a corresponding side of an adjacent clip segment 110 that faces the first clip segment 110. Figure 5 The position shown is moved upward so that Figure 5 The top surface 132 in the embodiment becomes the bottom surface 130 , and from the perspective shown, the top surface 132 may be hidden behind the clip segment 110 .

[0058] Main references Figure 5 , the clip segment 110 includes at least one retaining feature 140 and at least one barb 142 .

[0059] The retention feature 140 extends from the spine 112. In some configurations, the retention feature 140 extends from the top side 132 of the spine 112. Figure 5 In the illustrated configuration, the clip segment 110 includes a first retention feature 140 and a second retention feature 140. For ease of reference, in Figure 5 , the first retaining feature 140 may be disposed on the left side and the second retaining feature 140 may be disposed on the right side.

[0060] The first retention feature 140 and the second retention feature 140 each have an arm 150 that extends away from the spine 112. For example, the arm 150 can extend away from the spine 112 in a first direction 152 along or relative to a center plane 154 of the clip segment 110. The center plane 154 can bisect the clip segment 110. In the illustrated configuration, the center plane 154 is disposed between the first retention feature 140 and the second retention feature 140, or at a location where the first retention feature 140 meets the second retention feature 140. The first direction 152 extends away from the spine 112, or from Figure 5 The perspective shown extends in an upward direction. The center plane 154 can extend through the spine 112. For example, the center plane 154 can bisect the spine 112. The spine axis 120 can be disposed in the center plane 154 of the clip segment 110, such as when the clip 100 is in a free state.

[0061] The arms 150 of the first retention feature 140 are spaced apart from the arms 150 of the second retention feature 140. As such, the arms 150, 150 cooperate to at least partially define a cavity 156 therebetween.

[0062] In some configurations, the arm 150 includes a hook 160 disposed at a distal end of the arm 150. The hook 160 of the arm 150 of the first retention feature 140 can extend toward the hook 160 of the arm 150 of the second retention feature 140, thereby providing a gap 162 between the hooks 160, 160 that is narrower than adjacent portions of the cavity 156. The hooks 160, 160 help retain and secure the trim attachment feature of the trim cover 102 in the cavity 156, as will be discussed in more detail below.

[0063] One or more barbs 142 are provided with the clip segment 110. The barbs 142 extend from the retention feature 140, the ridge 112, or both. Figure 5 , two barbs 142, 142 are shown, with the first barb 142 extending from the first retention feature 140 and the second barb 142 extending from the second retention feature 140. In some configurations, the barbs 142 are spaced apart from the ridge 112 and do not extend from the ridge 112. In such configurations, the barbs 142 extend from the corresponding retention feature 140 in a direction extending away from the center plane 154 and the cavity 156. Similarly, the barbs extending from the ridge 112 may also extend in a direction extending away from the center plane 154, the cavity 156, or both.

[0064] The barbs 142 are disposed in a non-parallel and non-perpendicular relationship to the center plane 154. In addition, the barbs 142 are oriented to extend away from the bottom side 130 of the ridge 112, or from the bottom side 130 of the ridge 112. Figure 5 The perspective shown extends upward. Thus, as the distance from the ridge 112 increases, the barbs 142 extend in the first direction 152. Thus, as the barbs 142 extend away from the ridge 112 and the center plane 154, the barbs 142 can extend further away from the bottom side 130. In the configuration shown, the first barb 142 extends away from the second barb 142. Thus, the first barb 142 and the second barb 142 can extend in opposite directions relative to each other or relative to the center plane 154.

[0065] The barbs 142 may extend away from the bottom side 130 in a linear or non-linear manner. Figure 5 , each barb 142 is shown extending along a corresponding barb axis 170. The barb axis 170 intersects the center plane 154 at an acute angle 172, as shown in FIG. Figure 5 As shown, and when viewed from above or in plan view, the barb axis 170 can be arranged substantially perpendicular to the center plane 154, such as Figure 6As shown. The term "substantially vertical" is used herein to refer to features or axes that are the same as vertical or very close to vertical, and includes features within ±3° of being perpendicular to each other. In some configurations, the barb axis 170 intersects the center plane 154 at a position that does not intersect the ridge 112 (e.g., at a position where the first retention feature 140 and the second retention feature 140 meet). It is also contemplated that the barb 142 can be curved or extend in a non-linear manner. For example, the barb 142 or a portion thereof can extend along an arc or curve that can bend upward from the perspective shown or convex relative to the ridge 112.

[0066] In some configurations, the barb 142 includes an upper side 180 , a lower side 182 , a first lateral side 184 , and a second lateral side 186 .

[0067] The upper side 180 faces away from the ridge 112. In some configurations, the upper side 180 extends from the corresponding retention feature 140. For example, the upper side 180 can intersect with or extend from the arm 150 of the corresponding retention feature 140. As the upper side 180 extends away from the corresponding retention feature 140 from which the upper side 180 extends, the upper side 180 extends further away from the ridge 112. The upper side 180 can have a planar or non-planar configuration.

[0068] The lower side 182 is disposed opposite to the upper side 180. Thus, the lower side 182 faces the ridge 112. In some configurations, the lower side 182 extends from the corresponding retention feature 140. In some configurations, the lower side 182 intersects with the ridge 112 or extends from the ridge 112. The lower side 182 can have a planar or non-planar configuration. When the lower side 182 extends away from the corresponding retention feature 140 (from which the lower side 182 extends), the lower side 182 extends further away from the ridge 112. In some configurations, the lower side 182 has a length greater than the upper side 180.

[0069] In some configurations, the lower side 182 is disposed substantially parallel to the upper side 180. The term "substantially parallel" as used herein means the same as parallel or very close to parallel, and includes features or axes within a range of ±3° that are parallel to each other. When the lower side 182 is disposed substantially parallel to the upper side 180, the lower side 182 does not intersect with the upper side 180. In some configurations, the lower side 182 and the upper side 180 are disposed in a non-parallel relationship. For example, as the distance from the center plane 154 increases, the lower side 182 and the upper side 180 may become closer. In some configurations, it is contemplated that the lower side 182 may intersect with the upper side 180, for example, at the distal end of the barb 142.

[0070] refer to Figure 5-Figure 7 , the first lateral side 184 extends from the corresponding retention feature 140. For example, as Figure 5As best shown, the first lateral side 184 can extend from the protrusion 190 of the corresponding retention feature 140 and can be spaced apart from the arm 150 of the retention feature 140. It is also contemplated that the first lateral side 184 or a portion thereof can extend from the arm 150. The first lateral side 184 extends from the upper side 180 to the lower side 182. Figure 6 As best shown, the first lateral side 184 extends toward the second lateral side 186 as the distance from the center plane 154 increases. For example, the first lateral side 184 may extend toward or become closer to the corresponding barb axis 170 as the distance from the center plane 154 increases. It is contemplated that the first lateral side 184 may be planar or non-planar.

[0071] The second lateral side 186 extends from the corresponding retention feature 140 and is disposed opposite the first lateral side 184. For example, the second lateral side 186 can extend from the protrusion 190 of the corresponding retention feature 140 and can be spaced apart from the arm 150 of the retention feature 140. It is also contemplated that the second lateral side 186 or a portion thereof can extend from the arm 150. The second lateral side 186 extends from the upper side 180 to the lower side 182. As the distance from the center plane 154 increases, the second lateral side 186 extends toward the first lateral side 184. For example, as the distance from the center plane 154 increases, the second lateral side 186 can extend toward the corresponding barb axis 170 or become closer to the corresponding barb axis 170. This configuration can facilitate installation of the clip 100 into the liner 50, as will be discussed in more detail below. It is contemplated that the second lateral side 186 can be planar or non-planar.

[0072] In some configurations, the first lateral side 184 intersects the second lateral side 186 at the distal end 192 of the barb 142. When the first lateral side 184 and the second lateral side 186 have a vertically oriented planar configuration, this may result in the barb 142 having a triangular configuration when viewed from above, such as Figure 6 It is also contemplated that the distal end 192 may be rounded or have a radius rather than meeting along a linear edge.

[0073] refer to Figure 8 , a flow chart of a method of making and installing a clip 100 into a liner 50 is shown. The liner is described in the context of being a filament mesh structure 90. Figure 9-12 Examples associated with method steps are provided.

[0074] At block 200, a filament mesh structure 90 is manufactured. The filament mesh structure 90 may be manufactured using the manufacturing system 60 as previously described. Fig. 9 An example of a portion of a filament mesh structure 90 is shown. Fig. 9is a simplified representation of a filament mesh structure 90, which, for simplicity, does not show the individual filaments 52.

[0075] At block 202, slits 210 are provided in the filament mesh structure 90. In some configurations, the slits 210 are provided by a cutting subsystem of the manufacturing system 60 as previously described. Thus, the slits 210 can be provided by cutting off some of the filaments 52 of the filament mesh structure 90. Examples of slits 210 are shown in FIG. Fig.10 As shown. The slits 210 extend from a first side 212 of the filament mesh structure 90 toward a second side 214 of the filament mesh structure 90 disposed opposite the first side 212. In some configurations, the slits 210 are partial cuts through the thickness of the filament mesh structure 90 and do not extend to the second side 214. In some configurations, the slits 210 are provided by forming indentations in the filament mesh structure 90 without cutting the filaments 52. For example, the slits 210 can be provided by molding the filament mesh structure 90 or reshaping the filament mesh structure 90 to provide slits 210 similar to channels or grooves extending from the first side 212. For example, the filament mesh 90 or the area of ​​the filament mesh 90 where the slits 210 are to be provided can be heated with a fluid (e.g., gas, liquid, or both) to soften the filament mesh, thereby allowing the softened filaments 52 to conform to the shape of a forming surface of a mold or other tool (e.g., a rod or bar against which the first side 212 is engaged). Alternatively, the fluid can be provided under pressure, such as via one or more nozzles, and can both heat the filaments 52 and exert a force sufficient to form the slits 210 on the filaments 52. The filament mesh 90 can then be cooled to harden the filaments 52 and set the shape of the filament mesh 90 and the slits 210.

[0076] At block 204, the clip 100 is inserted into the slot 210 and attached to the filament mesh structure 90. The insertion of the clip 100 is shown in FIG. Fig.11 A tool 220 having an enlarged tip 222 is inserted toward the bottom of the cavity 156 through the gap 162 between the first retention feature 140 and the second retention feature 140 of the clip 100. The gap 162 is Figure 5 The force applied by the tool 220 causes the arms 150 of the first retention feature 140 and the arms 150 of the second retention feature 140 to flex away from each other, thereby allowing the enlarged tip 222 to move past the hooks 160 , 160 and into the cavity 156 and temporarily secure the clip 100 to the tool 220 .

[0077] The tool 220 and the clip 100 are aligned with the slit 210. The relative movement between the tool 220 and the filament mesh structure 90 causes the clip 100 to move into the slit 210, for example, by actuating the tool 220 and the clip 100 toward the slit 210, which is indicated by the downwardly directed arrow line. The force applied by the tool 220 is sufficient to cause the clip 100 to enter the slit 210, and the ridge 112 enters the slit 210 before the arms 150, 150 enter the slit 210. The clip 100 pushes the filaments 52 to separate, and the barbs 142, 142 act like wedges. The filaments 52 can be flexible enough so that the insertion of the clip 100 does not cut or sever the filaments 52.

[0078] The clip 100 is inserted to a sufficient depth such that the clip 100 is inserted to pass through the first side 212 of the filament mesh structure 90, or such that the clip 100 is spaced apart from and does not extend from the first side 212. Depending on the configuration of the slits 210, such positioning may allow some of the filaments 52 to extend above the clip 100. For example, the filaments 52 may be disposed between the first side 212 and the uppermost region of the arm 150 that is disposed farthest from the spine 112. These filaments 52 may help provide cushioning to an occupant of the cushion so that the occupant does not perceive the presence of the clip 100.

[0079] In some configurations, when the clip 100 is installed in the filament mesh structure 90, the clip 100 is spaced apart from and does not extend to the second side 214 of the filament mesh structure 90. As a result, the clip 100 does not contact the second side 214.

[0080] Insertion of the clip 100 causes the barbs 142 to intersect the filaments 52 such that at least some of the filaments 52 contact the barbs 142 and the barbs 142 are captured in the filaments 52, thereby retaining the clip 100 in the filament mesh structure 90. At least a portion of the barbs 142 are received in the gaps or interstices 230 between members of a group of filaments 52. For clarity, in Fig.11 Only a few gaps 230 are marked in FIG. 1. At other locations, the barbs 142 contact one or more members in the group of filaments 52.

[0081] As the filaments 52 are looped or curled, the filaments 52 may contact the clip 100 at various locations. In some configurations, at least one member of the set of filaments 52 contacts the first barb 142 and the second barb 142 of the clip segment 110. An example of this is Fig.11In some configurations, at least one member of the set of filaments 52 contacts at least one retention feature 140 and a barb 142 extending from the retention feature 140. Filament 52' also provides an example of such a configuration; however, it should be understood that a filament may contact a retention feature and a corresponding barb while contacting or not contacting another retention feature and / or its corresponding barb.

[0082] In some configurations, at least one member of the set of filaments 52 contacts more than one clip segment 110. An example of this is Fig.13 shown. Fig.13 A side view of the first and second clamp segments 110 and 110 inserted into the slits 210 of the filament mesh structure 90 is shown, and the slits 210 cannot be clearly seen from the perspective shown. At least one member of the group of filaments 52, such as filament 52", contacts the first and second clamp segments 110. Fig.13 , the first clamp segment 110 can be the leftmost clamp segment and the second clamp segment 110 can be the rightmost. The filament 52" is shown as being looped or curled to surround and contact the barbs 142 of the first clamp segment 110 and the barbs 142 of the second clamp segment 110; however, it should be understood that the filament 52" need not surround or encircle one or both of the barbs 142 to form a closed loop. For example, the filament 52 can extend above the barbs 142 and engage the upper side 180, can contact the other side of the barbs 142, or a combination of the two. In some examples, the filament contacting the lower side 182 of the barbs 142 can help limit downward movement or tilting of the clip 100, and the filament 52 contacting the lateral side (e.g., the first lateral side 184 or the second lateral side 186) of the barbs 142 can prevent or limit the clip 100 from moving along the slit 210 or in at least one direction within the slit 210.

[0083] Once the clip 100 is inserted into the filament mesh structure 90, the tool 220 is disengaged from the clip 100. For example, relative movement between the tool 220 and the filament mesh structure 90 in a direction opposite to the direction associated with the insertion of the clip 100 into the slit 210 causes the arms 150 of the first retention feature 140 and the arms 150 of the second retention feature 140 to flex away from each other, thereby allowing the enlarged tip 222 to move past the hooks 160, 160 and out of the cavity 156, thereby disengaging the clip 100. The clip 100 remains secured in the filament mesh structure 90 due to the resistance or retention force provided by the filaments 52 intersecting the clip 100.

[0084] refer to Fig.12, for simplicity, a simplified representation of the filament mesh structure 90 without showing the individual filaments 52 and the decorative cover 102 are shown. In some configurations, the decorative cover 102 is installed after the clip 100 is inserted into the slit 210 and secured to the filament mesh structure 90. For example, the decorative cover 102 can include a decorative attachment feature 240 that is inserted through the slit 210 into the cavity 156. The decorative cover 102 can be disposed on or extend across at least a portion of the first side 212 of the filament mesh structure 90. The decorative attachment feature 240 extends from one or more exterior panels of the decorative cover 102 through the slit 210 and into the cavity 156.

[0085] Inserting the trim attachment feature 240 through the slot 210 with sufficient force causes the arms 150 of the first retention feature 140 and the arms 150 of the second retention feature 140 to flex away from each other, thereby allowing the trim attachment feature 240 to enter the cavity 156 .

[0086] The decorative attachment feature 240 can be shaped in a manner that prevents the decorative attachment feature 240 from being removed from the cavity 156. For example, the decorative attachment feature 240 can have a tapered or arrow-shaped configuration that is narrower at its tip. The decorative attachment feature 240 can be wider as it approaches the decorative cover panel, or can be otherwise configured so that the hooks 160, 160 engage or grab the decorative attachment feature 240 to help retain the decorative attachment feature 240 in the cavity 156. It is also contemplated that the decorative attachment feature 240 can be inserted into the cavity 156 before the clip 100 is inserted into the filament mesh structure 90.

[0087] refer to Fig.14 , a portion of the pad 50 is shown with the clip 100 received in the slit 210. The slit 210 has an example of a linear portion 250 and a non-linear portion 252. The non-linear portion 252 extends along an arc or curve. Due to the flexibility of the spine 112, when the clip 100 is installed, the clip 100 follows the path of the slit 210. Therefore, when the clip 100 and its spine 112 are disposed in the filament mesh structure 90, at least a portion of the spine 112, such as the portion received in the non-linear portion 252 of the slit 210, is non-linear.

[0088] refer to Fig.15 , for simplicity, a simplified representation of the filament mesh structure 90 without showing the individual filaments 52 and a portion of the clip 100 are shown. The spine 112 is flexible not only along a curved path within a plane, but also outside of the plane to follow a straight or curved path. For example, the spine 112 can extend along an arc so that one or more clip segments 110 are positioned at different heights in the filament mesh structure 90 relative to each other. For ease of reference, Fig.15The clamp segments 110 in FIG. 1 are referred to as a first clamp segment, a second clamp segment, and a third clamp segment from left to right.

[0089] In this example, the first clip segment is disposed at a higher elevation than the second clip segment, which may position the first clip segment further from the second side 214 than the second clip segment, or further from a horizontal reference plane 260 extending through the pad than the second clip segment. The horizontal reference plane 260 is a reference plane or reference plane that may be disposed at or near the center of the pad, such as at a midpoint between the first side 212 and the second side 214. The second clip segment is shown to be at a higher elevation than the third clip segment. In addition, the second clip segment is shown to be disposed at an angle relative to the horizontal reference plane 260 and the first and third clip segments. It is also contemplated that adjacent clip segments 110 may be disposed at different elevations, but may be disposed in a common relationship to the horizontal reference plane 260. Thus, the present invention allows the clip segments 110 to be positioned relative to each other at different elevations, along curved paths, straight paths, to follow the contour of the pad, and allows the clip segments 110 to be positioned at the same or different depths relative to the first side 212. This possibility may allow the clip segment 110 to be inserted into the cushion to a sufficient depth to help keep the occupant comfortable while following the contours of the cushion.

[0090] Use of the above-described clips with a gasket helps to securely anchor the clip in the gasket, thereby allowing the clip and associated trim cover to remain in a desired position, which helps to keep the trim cover taut and avoid wrinkling or bunching that may provide an undesirable appearance. When used with a gasket having a filament mesh structure, the clip can be removed and replaced, thereby facilitating rework and reducing waste.

[0091] Clause 1. A clip comprising: a ridge including a bottom side; a first retention feature and a second retention feature extending from the ridge; and a first barb extending from at least one of the first retention feature and the ridge, wherein the first barb extends away from the bottom side of the ridge.

[0092] Clause 2. The clip of clause 1, wherein the first and second retention features extend from a top side of the spine, the top side being disposed opposite a bottom side of the spine.

[0093] Clause 3. The clip of clause 1 or clause 2, further comprising a second barb extending from at least one of the second retention feature and the ridge, the second barb extending away from a bottom side of the ridge.

[0094] Clause 4. The clip of Clause 3, wherein the first barb and the second barb are spaced apart from the ridge and do not extend to the ridge.

[0095] Clause 5. The clip of clause 3 or clause 4, wherein the first barb extends away from the second barb.

[0096] Clause 6. A clip according to any of the preceding clauses, wherein the first barb includes a first lateral side and a second lateral side, wherein the first lateral side and the second lateral side are arranged opposite to each other and extend from the first retaining feature, wherein when the first lateral side and the second lateral side extend away from the first retaining feature, the first lateral side and the second lateral side become closer.

[0097] Clause 7. The clip of Clause 6, wherein the first lateral side intersects the second lateral side at a distal end of the first barb.

[0098] Clause 8. A clip according to any of the preceding clauses, wherein the first barb includes an upper side and a lower side, wherein the upper side and the lower side are arranged opposite to each other and extend from the first retaining feature, wherein when the upper side and the lower side extend away from the first retaining feature, the upper side and the lower side extend farther from the ridge.

[0099] Clause 9. The clip of clause 8, wherein the upper side does not intersect the lower side.

[0100] Item 10. A seat assembly comprising: a filament mesh structure including a group of filaments, wherein each member in the group of filaments is looped and bonded to at least one other member in the group of filaments, the filament mesh structure including a first side; a decorative cover; and a clip disposed in the filament mesh structure, the clip including a spine and a first clip segment, the first clip segment including a first retaining feature and a second retaining feature extending from the spine and securing the decorative cover to the clip, and a first barb and a second barb securing the first clip segment to the filament mesh structure, wherein the first barb and the second barb extend away from the spine and toward the first side of the filament mesh structure.

[0101] Clause 11. The seat assembly of Clause 10, wherein the first barb is received in a gap between members in the set of filaments.

[0102] Clause 12. The seat assembly of Clause 10 or Clause 11, wherein a member of the set of filaments contacts the first barb and the second barb of the first clip segment.

[0103] Clause 13. The seat assembly of any of Clauses 10 to 12, wherein a member of the set of filaments contacts the first barb and the first retaining feature of the first clip segment.

[0104] Clause 14. The seat assembly of any one of clauses 10 to 13, wherein the first barb and the second barb each extend from the first retention feature and the second retention feature.

[0105] Clause 15. The seat assembly of any one of clauses 10 to 14, wherein the filament mesh structure further comprises a slit extending from the first side, wherein the clip is disposed in the slit and is spaced apart from and does not extend to the first side.

[0106] Clause 16. The seat assembly of Clause 15, wherein the filament mesh structure further comprises a second side disposed opposite the first side, wherein the slits and the clips are spaced apart from and do not extend to the second side.

[0107] Clause 17. The seat assembly of any one of clauses 10 to 16, wherein the ridge is linear when the ridge is in a free state, and at least a portion of the ridge is non-linear when the ridge is disposed in the filament mesh structure.

[0108] Clause 18. The seat assembly of any one of Clauses 10 to 17, wherein the clip further comprises a second clip segment extending from the spine and separate from the first clip segment.

[0109] Clause 19. The seat assembly of Clause 17, wherein a member of the set of filaments contacts the first clamp segment and the second clamp segment.

[0110] Clause 20. The seat assembly of Clause 18 or Clause 19, wherein the ridge extends along an arc such that the first clip segment and the second clip segment are positioned at different heights in the filament web relative to each other.

[0111] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms of the present invention. Rather, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present invention. In addition, the features of various implementation embodiments may be combined to form additional embodiments of the present invention.

Claims

1. A clip, comprising: a spine, the spine comprising a bottom side; a first retention feature and a second retention feature, the first retention feature and the second retention feature extending from the spine; as well as A first barb extends from at least one of the first retention feature and the ridge, wherein the first barb extends away from the bottom side of the ridge.

2. The clip according to claim 1, wherein: The first and second retention features extend from a top side of the ridge, the top side being disposed opposite the bottom side of the ridge.

3. The clip of claim 1 further comprising a second barb extending from at least one of the second retention feature and the ridge, the second barb extending away from the bottom side of the ridge.

4. The clip according to claim 3, wherein: The first barb and the second barb are spaced apart from the ridge and do not extend to the ridge.

5. The clip according to claim 3, wherein: The first barb extends away from the second barb.

6. The clip according to claim 1, wherein: The first barb includes a first lateral side and a second lateral side, the first lateral side and the second lateral side are arranged opposite to each other and extend from the first retention feature, wherein the first lateral side and the second lateral side become closer as they extend away from the first retention feature.

7. The clip according to claim 6, wherein: The first lateral side intersects the second lateral side at a distal end of the first barb.

8. The clip according to claim 1, wherein: The first barb includes an upper side and a lower side disposed opposite each other and extending from the first retention feature, wherein the upper side and the lower side extend further away from the ridge as the upper side and the lower side extend away from the first retention feature.

9. The clip according to claim 8, wherein: The upper side does not intersect the lower side.

10. A seat assembly comprising: a filament mesh structure comprising a set of filaments, wherein each member of the set of filaments is looped and bonded to at least one other member of the set of filaments, the filament mesh structure comprising a first side; Decorative hood; as well as A clip is provided in the filament mesh structure, the clip comprising: spine; and A first clamp section, the first clamp section comprising: first and second retention features extending from the spine and securing the trim cover to the clip; and A first barb and a second barb securing the first clip segment to the filament mesh structure, wherein the first barb and the second barb extend away from the spine and toward the first side of the filament mesh structure.

11. The seat assembly of claim 10, wherein: The first barbs are received in gaps between members in the set of filaments.

12. The seat assembly of claim 10, wherein: A member of the set of filaments contacts the first barb and the second barb of the first clamp segment.

13. The seat assembly of claim 10, wherein: A member of the set of filaments contacts the first barb and the first retaining feature of the first clip segment.

14. The seat assembly of claim 10, wherein: The first barb and the second barb each extend from the first retention feature and the second retention feature.

15. The seat assembly of claim 10, wherein: The filament mesh structure further includes a slit extending from the first side, wherein the clip is disposed in the slit and is spaced apart from and does not extend to the first side.

16. The seat assembly of claim 15, wherein: The filament mesh structure also includes a second side disposed opposite the first side, wherein the slits and the clips are spaced apart from and do not extend to the second side.

17. The seat assembly of claim 10, wherein: The ridges are linear when the ridges are in a free state, and at least a portion of the ridges are non-linear when the ridges are disposed in the filament web structure.

18. The seat assembly of claim 10, wherein: The clip also includes a second clip segment extending from the spine and separate from the first clip segment.

19. The seat assembly of claim 18, wherein: A member of the set of filaments contacts the first clamp segment and the second clamp segment.

20. The seat assembly of claim 18, wherein: The ridge extends along an arc such that the first and second clip segments are positioned at different heights in the filament web relative to each other.

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