Seat assembly and method of assembly

Abstract

The invention relates to a seat assembly and a method of assembly. Seat assemblies and methods of manufacture. A seat assembly includes a cushion, an attachment pad, and a trim cover. The liner includes a wire mesh structure including a set of wires. The attachment pad is coupled to the wire mesh structure. The trim cover is attached to the attachment pad.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 603,686, filed on November 29, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0003] This application relates to seat assemblies and assembly methods. Brief Description of the Drawings

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

[0005] Figure 2 is a schematic view of an example of a manufacturing system for manufacturing a filament mesh structure.

[0006] Figure 3 is an exploded view of an example of a trim cover, an attachment pad, and a cushion that includes a filament mesh structure.

[0007] Figure 4 is Figure 3 a plan view of the attachment pad of

[0008] Figure 5 is a perspective view showing the attachment pad fixed to the cushion.

[0009] Figures 6 - 9 is a partial cross - sectional view showing steps associated with an assembly method. Detailed Description

[0011] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well - known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0012] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. These drawings are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one of ordinary skill in the art to practice the embodiments according to the present disclosure in various ways.

[0013] "One or more" includes functions performed by one element, functions performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0014] 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 can be referred to as a second contact, and similarly, a second contact can be referred to as a first contact, without departing from the scope of the various described embodiments. Both the first contact and the second contact are contacts, but they are not the same contact.

[0015] The terms used in the description of the various embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the various embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated 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 stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0016] As used herein, the term "if" is optionally interpreted to mean "when", "upon", "in response to determining", or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the condition or event]" is optionally interpreted to mean "when determining", "in response to determining", "when detecting [the condition or event]", or "in response to detecting [the condition or event]", depending on the context.

[0017] Reference Figure 1, an example of the seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly, such as for a land vehicle (e.g., a car, a truck, a bus, etc.) or for a non-land vehicle (e.g., an aircraft or a ship). For example, the seat assembly 10 for a land vehicle can be shaped and sized to be a front-row driver or passenger seat, a second-row seat, a third-row seat, or other rear-row seat, and can include a bucket seat, a bench seat, or other seat styles as shown. Additionally, the seat assembly 10 can be a non-stowable seat or a stowable seat, and the stowable seat can be foldable and stowable in a cavity in the vehicle floor. Further, the seat assembly 10 can be configured for non-vehicle applications, such as furniture.

[0018] In Figure 1 the configuration shown, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that in some configurations, the seat back 22 can be omitted, such as when the seat assembly 10 is configured as a motorcycle seat or a stool.

[0019] 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, padding 32, and a trim cover 34.

[0020] The seat bottom frame 30 is a structure that supports the padding 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 some configurations, the seat bottom frame 30 includes a panel on which the padding 32 is disposed, a seat pan, a suspension pad, or a suspension wire.

[0021] The padding 32 is disposed on the seat bottom frame 30. The padding 32 is made of a flexible material that supports the seat occupant and distributes the load forces from the seat occupant to the seat bottom frame 30. The padding 32 and related manufacturing methods will be discussed in more detail below.

[0022] The trim cover 34 covers at least a portion of the cushion 32. Additionally, the trim cover 34 provides one or more visible outer surfaces of the seat back 22. When seated on the seat assembly 10, the seat occupant may rest on the trim cover 34. The trim cover 34 is made of any suitable one or more materials, such as fabric, leather, faux leather, vinyl material, or combinations thereof. The trim cover 34 may include a plurality of trim panels assembled in any suitable manner, such as by fusing or stitching. The trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim attachment features that attach to the seat bottom frame 30, the cushion 32, or both to inhibit removal of the trim cover 34 and to help the trim cover 34 conform to the profile of the seat bottom frame 30, the cushion 32, or both. The trim cover 34 may also be attached to an attachment backing plate, which will be discussed in more detail below.

[0023] 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 near 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 the 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 trim cover 44, and an optional head restraint 46.

[0024] 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 may be made of any suitable material, such as a metal alloy, a polymeric material, a fiber-reinforced polymeric material, or combinations thereof. In some configurations, the seat back frame 40 includes a panel, a bottom plate, a suspension pad, or suspension wires on which the cushion 42 is disposed. It is also contemplated that in some configurations, the seat back frame 40 may be integrally formed with the seat bottom frame 30.

[0025] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a flexible material that supports the seat occupant and distributes the 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 may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods will be discussed in more detail below.

[0026] The trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible outer surfaces of the seat back 22. When seated on the seat assembly 10, the seat occupant may rest on the trim cover 44. The trim cover 44 is made of any suitable material or combination of materials (e.g., fabric, leather, faux leather, vinyl material, or a combination thereof). The trim cover 44 may include one trim panel or multiple trim panels, which are assembled in any suitable manner (e.g., by fusing or stitching). The trim cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include decorative attachment features that attach to the seat back frame 40, the cushion 42, or both to inhibit removal of the trim cover 44 and to help the trim cover 44 conform to the contour of the seat back frame 40, the cushion 42, or both. The trim cover 44 may also be attached to an attachment backing plate, which will be discussed in more detail below.

[0027] The headrest 46 (if provided) is configured to support the head of the seat occupant. The headrest 46 is disposed at the top of the seat back 22 or at an end of the seat back 22 that is opposite the seat bottom 20. The headrest 46 may be movable relative to the seat back 22 in one or more directions or may be integrally formed with the seat back 22.

[0028] Reference Figure 3 , an example of a cushion 50 is shown. For ease of reference, the cushion is generally denoted by reference numeral 50. It should be understood that the structure and description of the cushion 50 apply to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0029] 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 wire mesh structure but may also be referred to as a mesh cushion, a mesh structure, or a stranded mesh. In Figure 3 , 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 in addition to the non-foam component, the cushion 50 may also include a foam component or foam material to provide additional cushioning or localized cushioning for the seat occupant. For example, the foam material may be disposed between the cushion 50 and the trim cover (e.g., trim covers 34, 44), on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided for the cushion 50 or removing the foam material from the cushion 50 can reduce weight and can improve the support and comfort of the seat occupant. Additionally, removing the foam material can facilitate recycling of the cushion 50.

[0030] The gasket 50 is described below without including the foam material. In this case, the gasket 50 is made of filaments 52 of a polymeric material, which filaments 52 are randomly looped, bent, curled or entangled and bonded together, as will be discussed in more detail below. An example of the filaments 52 is Figures 6 to 9 as shown. The filaments 52 are bonded directly to another filament 52, rather than indirectly bonded with a resin or other intermediate material.

[0031] The filaments 52 can also be referred to as strands or threads and are made of any suitable one or more materials. In some configurations, the filaments 52 are made of a polymeric material or a thermoplastic material, such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin (e.g., based on polypropylene, polyethylene, etc.), polystyrene or a combination thereof. As an example, polyethylene-based filaments can be made of linear low density polyethylene (LLPDE). Different from the foam material, the filament material can be recyclable or easier to recycle than the foam material. It is also contemplated that the filaments 52 can include reinforcing fibers, and the reinforcing fibers can be made of a material other than a thermoplastic material.

[0032] In some configurations, the filaments 52 can be monofilaments made of a single material. In some configurations, the filaments 52 are made of multiple materials. For example, the filaments 52 made of multiple materials can include a core made of a first thermoplastic material and a sheath made of a second thermoplastic material different from the first thermoplastic material and surrounding the core. It is contemplated that the gasket 50 can include a combination of monofilaments and filaments that are made of multiple materials and are not monofilaments.

[0033] The randomly looped, bent, curled or entangled filaments 52 are bonded together where one filament 52 contacts another filament 52, thereby producing a lightweight, breathable gasket (e.g., gasket 32 and / or gasket 42) or a mesh structure having openings or voids between the filaments 52. Figure 2 An example of a manufacturing system 60 for manufacturing a gasket or a wire mesh structure is also shown. In this example, the manufacturing system 60 includes a material feeder 70, an extruder 72 and a hopper 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0034] Referring to Figure 2 , the material feeder 70 holds the raw material to be extruded, such as solid beads, flakes, granules, pellets or powders made of the material. In some configurations, the material feeder 70 is configured as a container or a hopper. The material feeder 70 supplies the raw material to the extruder 72.

[0035] Extruder 72 melts the material stock and extrudes the material stock into a set of filaments 52. Extruder 72 can have any suitable configuration. In some configurations, extruder 72 includes a barrel that receives a rotatable screw and a heating element. Rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction generated as the screw rotates. The material exits the barrel under pressure and in a molten state and is conveyed under pressure to die 80 of extruder 72.

[0036] Die 80 (which can also be referred to as a die plate or extrusion die) has a plurality of through-holes or filament-forming openings through which the molten material passes. A single filament 52 is extruded from each through-hole. Filaments 52 fall downward from die 80 under the force of gravity into funnel 74.

[0037] Funnel 74 combines or groups the filaments 52 into a more compact arrangement in which the filaments bend, curl, or loop, and filaments 52 contact and bond to at least one other filament 52. Funnel 74 has an inlet opening or funnel inlet and an outlet opening or funnel outlet that is smaller than the funnel inlet. Individually separated filaments 52 enter the funnel inlet. As filaments 52 accumulate, the filaments bend, curl, or loop and move into contact. Filaments 52 move through funnel 74 toward the funnel outlet. As the filaments move toward the funnel outlet, some filaments may slide along funnel 74 or along an intervening sheet disposed on funnel 74. A bond forms between filaments 52 at the contact points, while openings or voids between filaments 52 exist at other locations where one filament 52 does not contact or bond to another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of funnel 74 and enter cooling tank 76. For ease of reference, the bonded filaments 52 are referred to as wire mesh structure 90.

[0038] Cooling tank 76 contains a liquid, such as water or a mixture of water and another fluid. The liquid in cooling tank 76 helps support the entangled and bonded filaments 52 to limit further compaction or consolidation of the filaments 52 into a less open or less porous arrangement and maintain the desired porosity and density of wire mesh structure 90. Thus, the liquid provides some buoyancy or drag that can cause additional bending, curling, or looping of filaments 52 adjacent to the surface of the liquid or within funnel 74 to further construct wire mesh structure 90. When filaments 52 are in the liquid, the liquid also cools the filaments 52. For example, the liquid cools the filaments 52 from the outside to solidify the filaments 52 and prevent the filaments 52 from bonding at additional locations. At this time, filaments 52 are relatively rigid and no longer in a plastic state, so they generally maintain their shape and cannot be plastified or reformed without being reheated.

[0039] The material handling subsystem 78 conveys the wire mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that assist in moving the wire mesh structure 90 through and out of the liquid. In some configurations, a tractor conveyor 92 is disposed within the cooling tank 76 to help pull the wire mesh structure 90 from the funnel 74 and counteract the buoyancy of the filaments 52.

[0040] One or more other rollers (such as roller 94) hold the wire mesh structure 90 submerged in the liquid and guide the wire mesh structure 90 through the cooling tank 76. For example, roller 94 can guide the wire mesh structure 90 toward a conveyor belt 96 and a shaker table 98 disposed outside the cooling tank 76. When the wire mesh structure 90 is on the conveyor belt 96, the shaker table 98 shakes the wire mesh structure 90 to remove the liquid. Alternatively or additionally, the wire mesh structure 90 can be squeezed to remove the liquid, air can be blown onto the wire mesh structure 90 to remove the liquid, or both. It is also contemplated that the wire mesh structure 90 can also be allowed to dry, or dry in ambient air.

[0041] The manufacturing system 60 described above is a continuous flow process in which the wire mesh structure 90 is formed as a continuous structure when the filament extrusion is not interrupted. After leaving the cooling tank 76, further processing of the wire mesh structure 90 is provided to cut the wire mesh structure 90 into individual pieces or blanks for individual pads. This processing is performed by the cutting subsystem of the manufacturing system 60. The cutting system can be of any suitable type. For example, the cutting system can use blades, knives, hot knives, saws, fluid jets, etc. to cut the filaments 52 of the wire mesh structure 90 into blanks. The cutting system can be used to shape or contour the blanks. It is also contemplated that the blanks can be further shaped or contoured using other manufacturing processes, such as molding the entire blank or a portion thereof.

[0042] Reference Figure 3 shows an exploded view of a portion of the seat assembly 10, including an example of a pad 50, an example of a trim cover 100, and an example of an attachment backing plate 102.

[0043] The pad 50 includes the wire mesh structure 90. In Figure 3In [the figure], for clarity, the gasket 50 is shown without depicting the individual wires 52 of the wire mesh structure 90. In some configurations, the gasket 50 has a contoured exterior side 110. The contoured exterior side 110 may have a partially or fully non-planar profile and may include one or more curved surfaces or curved regions. In some configurations, the contoured exterior side 110 is concave or partially concave. The contoured exterior side 110 faces the trim cover 100 and the attachment backing plate 102. Additionally, the contoured exterior side 110 may face the seat occupant. The contoured exterior side 110 may contact a portion of the trim cover 100 in one or more regions where the attachment backing plate 102 is not sandwiched between the trim cover 100 and the gasket 50 and the trim cover 100 is not separate from the gasket 50.

[0044] For ease of reference, the trim cover 100 is generally denoted by the reference numeral 100. It should be understood that the trim cover 100 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22 as described above. Figure 3 A portion of the trim cover 100 is shown in [the figure] to make other features in the figure more visible. The trim cover 100 may be attached to the attachment backing plate 102 and may generally follow the curvature or profile of the attachment backing plate 102, or the side of the attachment backing plate 102 facing away from the gasket 50.

[0045] The attachment backing plate 102 is disposed between the gasket 50 and the trim cover 100. In some configurations, the attachment backing plate 102 extends from the gasket 50 to the trim cover 100. For example, the attachment backing plate 102 may extend from the contoured exterior side 110 to the side of the trim cover 100 facing the contoured exterior side 110. Other components (such as a heating backing plate) that may be disposed between the trim cover 100 and the attachment backing plate 102 are also contemplated.

[0046] Reference Figure 4 , a plan view of an example of the attachment backing plate 102 is shown. The attachment backing plate 102 includes a body 120 and a set of hooks 122.

[0047] The body 120 is configured to support a seat occupant and facilitate the installation of the trim cover 100 onto the cushion 50. The body 120 can be a panel, layer, or assembled layer having a solid or hollow structure. The body 120 can be made of multiple pieces or be configured as a unitary one-piece component that can be made of any suitable one or more materials. For example, the body 120 can be made of a polymeric material such as a thermoplastic material such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin (e.g., based on polypropylene, polyethylene, etc.), polystyrene, or a combination thereof. In some configurations, the body 120 is made of the same material as the filaments 52. In other configurations, the body 120 is made of a material different from the filaments 52, but the material is similar enough to the material of the cushion 50 to allow the cushion 50 and the attachment backing plate 102 to be recycled together without disassembly. For example, the attachment backing plate 102 can be separated from the trim cover 100, and the cushion 50 and the body 120 can be ground or shredded together for recycling without having to separate the cushion 50 from the attachment backing plate 102.

[0048] Reference Figure 3 and Figure 4 , in some configurations, the body 120 is disposed on the outer side 110 of the shaping of the cushion 50. For example, the body 120 can engage or contact the filaments 52 of the wire mesh structure 90 of the cushion 50 along the outer side 110 of the shaping and can be not disposed inside the wire mesh structure 90. The body 120 can extend along one side of the filaments 52 that constitutes the contour and the outer side 110 of the shaping of the cushion 50 and can extend across multiple filaments 52, thereby bridging the gaps between adjacent filaments 52 and following the outer contour of the cushion 50 without extending into the wire mesh structure 90. In some configurations, the body 120 can be not disposed inside trenches, holes, or recesses (such as trenches, holes, or recesses cut into the wire mesh structure 90 or formed as local recesses extending from the outer side 110 of the shaping into the wire mesh structure 90) that extend from the outer side 110 of the shaping to the wire mesh structure 90. In some configurations, the body 120 includes a first side 130, a second side 132, and a plurality of apertures 134 and / or 134’.

[0049] Main reference Figure 3, the first side 130 faces the gasket 50. For example, the first side 130 may face the outer side 110 of the shaped gasket 50. Thus, the first side 130 faces away from the decorative cover 100 and may engage or contact the outer side 110 of the shape. The first side 130 may follow the contour of the outer side 110 of the shape. Thus, the first side 130 may be disposed substantially parallel to the outer side 110 of the shape. As used herein, the term "substantially parallel" means the same as or very close to parallel and includes features or axes within ±3° of being parallel to each other. In some configurations, the first side 130 or a portion thereof may be non-planar.

[0050] The second side 132 is disposed opposite the first side 130. In some configurations, the second side 132 engages or contacts the decorative cover 100. The second side 132 may also follow the contour of the outer side 110 of the shaped gasket 50. For example, the second side 132 may be disposed substantially parallel to the outer side 110, the first side 130, or both.

[0051] Main reference Figure 4 , the body 120 defines a plurality of apertures 134, 134'. The apertures 134, 134' extend from the first side 130 to the second side 132 and may be referred to as openings, holes, or windows. In some configurations, the aperture 134 may be configured as a through-hole surrounded by the body 120. In Figure 4 , nine apertures 134 of this configuration are shown; however, it is contemplated that more or fewer apertures 134 may be provided. These apertures 134 are spaced from the perimeter of the body 120. In some configurations, the apertures 134' may be disposed along the perimeter of the body 120. In such a configuration, the apertures 134' may extend from the first side 130 to the second side 132 but may not be surrounded by the body 120 since the apertures 134' are disposed along the perimeter. In Figure 4 , twelve apertures 134' along the perimeter of the body 120 are shown; however, it is contemplated that more or fewer apertures 134' may be provided. In some configurations, the body 120 is solid except for the apertures 134, 134'.

[0052] The apertures 134, 134' may have any suitable configuration. In Figure 4In the depicted configuration, the orifice 134, which is configured as a through-hole, is depicted as having a generally rectangular configuration, where a first pair of sides or a pair of first sides 140, which are disposed opposite one another, have a greater length than a second pair of sides or a pair of second sides 142, which are disposed opposite one another and interconnect the pair of first sides 140. It is also contemplated that the orifice 134 can have a non-rectangular configuration, including but not limited to circular, oval, ovoid, triangular, or various other polygonal shapes. The orifice 134' disposed along the perimeter can have fewer sides. For example, such an orifice 134' can have a single first side 140' that has a length greater than a second pair of sides 142' that extend from two opposite ends of the first side 140' to the outer perimeter. Such an orifice 134' can be a recess that extends along the perimeter towards the center of the body 120. It is also contemplated that the second pair of sides 142' can be omitted, and the single first side 140' can extend along an arc.

[0053] This set of hooks 122 can also be referred to as barbs, latches, clasps, or clips and assist in attaching the attachment pad 102 to the cushion 50. For example, the hooks in this set of hooks 122 are configured to extend into the wire mesh structure 90 and engage, hook onto, grip, or couple to at least one wire 52 of the wire mesh structure 90, as will be discussed in more detail below. This set of hooks 122 extends from the body 120. For example, the hooks 122 can be integrally formed with the body 120 as a single-piece unitary component. In some configurations, each hook in this set of hooks 122 can extend from the body 120 at different locations. Thus, the hooks in this set of hooks 122 can be spaced apart from one another and can not contact one another or extend from one another.

[0054] Main reference Figure 6 , the hooks 122 can be disposed adjacent the associated orifice 134 or 134'. For example, the hooks 122 can extend from the first side 140 or 140' in a direction towards the associated orifice 134, 134'. In some configurations, one hook 122 is associated with and disposed adjacent each orifice 134, 134'.

[0055] In some configurations, some or all of the hooks in this set of hooks 122 can face in opposite directions relative to one another. In Figure 4 an example of a pair of hooks 122 extending in two opposite directions is shown in dashed boxes. For example, the free end 160 of one hook 122 can face away from or be directed away from the free end 160 of the other hook 122. Orienting the hooks 122 in opposite directions allows the hooks 122 to better secure the body 120 to the wire mesh structure 90, such as during dynamic loading when a seat occupant moves or bounces on the cushion 50. In Figure 4Similar hook arrangements are provided at the upper left and upper right corners of , where a pair of hooks 122, 122 disposed along the perimeter face away from the hook 122 disposed adjacent to the orifice 134, which orifice 134 is configured as a through-hole and is oriented at an angle of approximately 45° with respect to the horizontal line extending from left to right in the perspective view shown. Thus, the perimeter hooks 122, 122 generally extend away from the center of the body 120, while the hook 122 visible through the angled orifice 134 extends toward the center of the body 120. Thus, the hooks 122 disposed along or adjacent to the perimeter of the attachment pad 102 may face in a different direction or extend in a different direction compared to the nearest hook 122 that is not disposed along the perimeter, to help the attachment pad 102 conform to the profile of the gasket 50 and hold the attachment pad 102 against the profile of the gasket 50, and to help prevent the attachment pad 102 from separating or disengaging from the wire mesh structure 90 of the gasket 50.

[0056] As Figure 5 Best shown in , the perimeter of the attachment pad 102 may be disposed at a greater height than the central region of the attachment pad 102. Thus, compared to the hooks 122 that are not disposed along the perimeter of the attachment pad 102, the perimeter hooks 122 or the hooks positioned adjacent to the perimeter of the attachment pad 102 may be disposed at a greater height or at a position higher than the horizontal plane located below the gasket 50. Additionally, the attachment pad 102 may have a curved profile that extends downward from the perimeter to the hooks 122 that are not disposed along the perimeter of the attachment pad 102.

[0057] As Figure 4 Shown, the hooks 122 may taper or narrow as the hooks 122 extend away from the body 120 and toward the associated orifices 134, 134'. In some configurations, the hooks 122 may taper and narrow as the hooks 122 extend toward the distal or free end 160 of the hooks 122.

[0058] Referring Figure 6 , in some configurations, the hook 122 includes a first section 150, a second section 152, and a bend 154.

[0059] The first section 150 extends from the body 120. For example, the first section 150 may extend from the first side 130 of the body 120. The first section 150 may extend in a direction away from the decorative cover 100. For example, the first section 150 may extend from the first side 130 in a direction away from the second side 132. In some configurations, the first section 150 or a portion thereof may be disposed substantially perpendicular to an adjacent region of the second side 132.

[0060] The second section 152 can extend from the end of the first section 150. For example, the second section 152 can extend from the end of the first section 150 that is disposed opposite to the body 120. The second section 152 extends in a direction different from that of the first section 150. In some configurations, the first section 150 and the second section 152 are in contact at the bend 154 and are disposed in a non-parallel relationship. In some configurations, the second section 152 extends at an acute angle α1 with respect to the first section 150 such that the second section 152 extends toward the adjacent apertures 134, 134' in the body 120 or extends in an upward direction toward the second side 132.

[0061] The second section 152 has a free end 160. The free end 160 is disposed at the end of the second section 152 that is opposite to the first section 150 and the bend 154 (if provided). The free end 160 is configured to be positioned within the wire mesh structure 90 or, when the attachment pad 102 is installed and coupled to the wire mesh structure 90, may not extend beyond the outer contour 110 of the molding. When installed, the free end 160 can be disposed below the second side 132 such that the free end 160 does not poke the seat occupant, does not create a bulge or deformation in the trim cover, or neither pokes the seat occupant nor creates a bulge or deformation in the trim cover. For example, the free end 160 or a portion thereof can protrude into the apertures 134, 134' as shown, or can be entirely disposed below the second side 132 and within the wire mesh structure 90 such that the free end 160 does not poke the seat occupant.

[0062] The first section 150 and the second section 152 can cooperate to form the bend 154. When the hook 122 is in the nominal or default position as Figure 6 shown, the bend 154 can have an arcuate or curved profile. The hook 122 can be configured to flex or bend at the bend 154.

[0063] Reference Figures 6 - 9 , an example of steps associated with the assembly method is shown. Figures 6 - 9 is a cross-sectional view taken through the hook 122 of the attachment pad 102 and the adjacent aperture 134 and through the wire mesh structure 90 of the liner 50. The wire mesh structure 90 is shown in a simplified form, where various wires 52 disposed behind the cross-sectional plane are omitted for clarity. Additionally, for simplicity, some of the wires 52 that intersect the cross-sectional plane are shown as cross-sections and more specifically as cross-sectional circles. It should be understood that the wires 52 can intersect the cross-sectional plane in a non-vertical manner and thus the cross-sections of the wires 52 can be more accurately depicted as non-circular (such as oval, elliptical, or other non-circular shapes).

[0064] The installation of the attachment backing plate 102 onto the wire mesh structure 90 will be described primarily in the context of attachment using a single hook 122; however, it should be understood that some or all of the hooks 122 of the attachment backing plate 102 may be installed in a similar manner, and the hooks may be installed simultaneously or sequentially.

[0065] Reference Figure 6 shows the gasket 50 and the attachment backing plate 102 prior to assembly. The attachment backing plate 102 is aligned with the desired installation location on the gasket 50, where the first side 130 faces the outer side 110 of the gasket 50, and the hooks 122 extend toward the outer side 110 of the gasket 50. The bend 154 of the hook 122 may engage or contact the outer side 110, while the remaining portion of the attachment backing plate 102 may be spaced apart from or disposed above the gasket 50.

[0066] Reference Figure 7 shows the attachment backing plate 102 being actuated toward the wire mesh structure 90 of the gasket 50. The attachment backing plate 102 may be actuated toward the wire mesh structure 90 by moving the body 120 of the attachment backing plate 102 toward the outer side 110, by moving the gasket 50 and its outer side 110 toward the attachment backing plate 102, or a combination thereof. In the example shown, the attachment backing plate 102 is depicted as being actuated against the gasket 50 such that the first side 130 of the body 120 engages or contacts the outer side 110 of the gasket 50 in response to a downward force applied against the second side 132 of the attachment backing plate 102 as represented by the vertical arrow line. The force may be applied in any suitable manner. For example, the force may be applied manually or with a machine or device such as a press.

[0067] The force applied against the attachment backing plate 102 forces the hooks 122 through the outer side 110 and into the wire mesh structure 90. When the hooks 122 are inserted into the wire mesh structure 90, the wires 52 of the wire mesh structure 90 that engage or contact the hooks 122 may be moved or displaced by the hooks 122. The movement or displacement of the wires 52 may be restricted by the bonding between the wires 52. Accordingly, the wires 52 provide some resistance to the insertion of the hooks 122. In response, the hooks 122 flex. For example, the first segment 150, the second segment 152, or both may bend or flex relative to their initial configuration in Figure 6 In Figure 7In [the figure], the hook 122 is shown as being flexed mainly at the bend 154 such that the second section 152 is flexed or bent upward relative to the body 120 and extends toward, into, or through the aperture 134 provided in the body 120 adjacent to the hook 122. As a result, the angle α2 between the first section 150 and the second section 152 can be less than the angle α1 before insertion. In the example shown, the hook 122 is flexed such that the free end 160 is pushed upward into and through the aperture 134, such that the free end 160 protrudes beyond the aperture 134 and is disposed above the second side 132 of the body 120. In some configurations, the free end 160 moves upward beyond the first side 130 of the body 120 and into the aperture 134 without protruding above the second side 132. In other configurations, the free end 160 can move upward but may not enter the aperture 134.

[0068] The first section 150 and the second section 152 can act like a wedge, forcing one or more filaments 52 around the hook 122. Accordingly, the filaments 52 can be moved away from the gap 170 located between the first section 150 and the second section 152, which can be above the bend 154, resulting in no filaments 52 being disposed in the gap 170, or fewer filaments 52 being disposed in the gap 170 compared to the adjacent regions of the wire mesh structure 90.

[0069] Reference Figure 8 , the hook 122 is actuated (e.g., pushed, pulled, moved, flexed, bent, positioned) relative to the body 120 into the gasket 50. Actuation of the hook 122 can occur while the body 120 remains against the outer side 110 of the gasket 50. Actuating the hook 122 flexes the hook away from the body 120 and toward the wire mesh structure 90. For example, actuating the hook 122 can include pushing a portion of the hook 122 into the wire mesh structure 90, pulling the hook into the wire mesh structure 90, or a combination thereof. Actuation of the hook 122 will be discussed mainly in the case of pushing the hook 122 into the wire mesh structure 90.

[0070] In some configurations, a force is applied to the hook 122 using a tool 180, such as a shaft, rod, lever, strip, wedge, etc. As an example, the tool 180 can be aligned with a portion of the hook 122, such as the second segment 152. The tool 180 can then engage the second segment 152. For example, the tool 180 can engage or contact the second segment 152 between the free end 160 and the bend 154. Depending on the positioning of the tool 180, the tool can enter or pass through the aperture 134 before or after the tool 180 engages the second segment 152. A force can be applied using the tool 180 to push the second segment 152 downward and into the wire mesh structure 90. The force can be applied against the second segment 152 using the tool 180 in a manner that causes the hook 122 to bend or flex away from the first segment 150. The hook 122 can bend or flex at the bend 154. Some or all of the force applied using the tool 180 can be directed toward the wire mesh structure 90.

[0071] Sufficient force is applied using the tool 180 to push the second segment 152 deeper into the wire mesh structure 90. As a result, flexure or bending can occur along the first segment 150, the second segment 152, the bend 154, or a combination thereof. The second segment 152 can bend, flex, or otherwise move away from the body 120 and the second side 132 such that the free end 160 moves into the wire mesh structure 90 or is pushed deeper into the wire mesh structure 90 and further away from the outer side 110. In some configurations, a force can be applied such that the angle α3 between the first segment 150 and the second segment 152 increases and is greater than Figure 6 the angle α1 shown in. For example, the angle α3 can be greater than 90°, such as between 90° and 180°. As a result, the second segment 152 can extend away from the body 120, allowing one or more wires 52 to enter the gap 170 between the first segment 150 and the second segment 152. In some configurations, when pushed into the wire mesh structure 90, the free end 160 is disposed below the first segment 150, the bend 154, or both, or is further away from the first side 130 than the first segment 150, the bend 154, or both.

[0072] Referring to Figure 9 , the hook 122 after being released is shown. Releasing the hook 122 can allow the hook 122 to flex back toward Figure 6 its initial position as shown, or back to Figure 6its initial position as shown. The hook 122 can be released by retracting the tool 180 and / or disengaging the tool 180 from the hook 122. Releasing the hook 122 allows the hook 122 to capture, hook, grip, or otherwise engage one or more of the filaments 52 in the set of filaments 52, thereby coupling the attachment pad 102 to the wire mesh structure 90. In the illustrated configuration, releasing the hook 122 allows the second segment 152 to move upwardly toward the body 120 and the orifice 134 such that one or more filaments 52 are positioned in the gap 170 and captured between the first segment 150 and the second segment 152 of the hook 122. Thus, at least one filament in the set of filaments 52 can engage the hook 122 and be received between the first segment 150 and the second segment 152. After being released, the second segment 152 can extend toward the orifice 134 or into the orifice 134 and extend toward the decorative cover 100 when the decorative cover 100 is installed.

[0073] The filaments in the set of filaments 52 can engage the first side 130 of the body 120 and the hook 122. For example, filament 52’ is shown engaging the first side 130 and at least one of the first segment 150 and the second segment 152 of the hook 122. Figure 5 An example of the resulting assembly with the attachment pad 102 coupled to the gasket 50 is shown.

[0074] The decorative cover 100 can be attached to the body 120 before or after the attachment pad 102 is secured or coupled to the wire mesh structure 90. In some configurations, after the hook 122 is released and the attachment pad 102 is coupled to the gasket 50, the decorative cover 100 is attached to the attachment pad 102. It is also contemplated that the decorative cover 100 can be attached to the attachment pad 102 before the hook 122 is inserted into the wire mesh structure 90, which can be achieved in a configuration where the attachment pad 102 is pulled against the wire mesh structure 90.

[0075] Reference Figure 3 , the decorative cover 100 can be attached to the second side 132 of the body 120. The decorative cover 100 can be attached to the body 120 in any suitable manner. For example, the decorative cover 100 can be attached to the attachment pad 102 by adhering or bonding the decorative cover 100 to the body 120, such as by using an adhesive 190 disposed between the lower side of the decorative cover 100 and the second side 132. It is also contemplated that the decorative cover 100 can be attached to the attachment pad 102 using fasteners (such as hook-and-loop fasteners).

[0076] The present invention allows the cushion to be provided with an attachment backing plate, which helps to better fix the decorative cover at a position near the center of the cushion, without providing grooves or trenches for setting decorative clips in the cushion. The present invention allows the use of an attachment backing plate to fix the decorative cover. Compared with using a separate decorative clip, the attachment backing plate can provide a larger surface area for attaching the decorative cover, which can provide a larger surface area along which the decorative cover and the attachment backing plate can be attached, so as to fix the decorative cover at more positions compared with the decorative clip. The present invention allows the attachment backing plate to be reliably fixed to the wire mesh structure, which has a plurality of hooks that can be arranged in different directions, such that the plurality of hooks are oriented to counteract the load force and inhibit the separation of the attachment backing plate. Additionally, the attachment backing plate and the wire mesh structure can be recycled together, thus avoiding disassembly during the recycling process.

[0077] Clause 1. A seat assembly, comprising: a cushion including a wire mesh structure, the wire mesh structure including a set of filaments of a thermoplastic material, wherein each filament in the set of filaments is looped and joined to at least one other filament of the set of filaments; an attachment backing plate including a body and a set of hooks extending from the body and coupling the attachment backing plate to the wire mesh structure, wherein the body is disposed on an outer side of a profiling of the wire mesh structure; and a decorative cover attached to the attachment backing plate.

[0078] Clause 2. The seat assembly according to Clause 1, wherein each hook in the set of hooks extends from the body at different positions.

[0079] Clause 3. The seat assembly according to any one of the preceding clauses, wherein the hooks in the set of hooks extend into the wire mesh structure and grip at least one filament of the wire mesh structure.

[0080] Clause 4. The seat assembly according to any one of the preceding clauses, wherein each hook in the set of hooks further includes a first section and a second section, wherein the first section extends from the body and extends away from the decorative cover, and the second section extends from an end of the first section toward the decorative cover.

[0081] Clause 5. The seat assembly according to Clause 4, wherein the second section further includes a free end disposed opposite to the first section, wherein the free end is positioned in the wire mesh structure.

[0082] Clause 6. The seat assembly according to any one of the preceding clauses, wherein the body further includes a first side and a second side disposed opposite to the first side, wherein the first side engages an outer side of a profiling of the cushion, and the second side engages the decorative cover.

[0083] Clause 7. The seat assembly according to Clause 6 when dependent on Clause 4, wherein the body defines an orifice extending from the first side of the body to the second side, and the second segment extends from the end of the first segment towards the orifice.

[0084] Clause 8. The seat assembly according to Clause 4, Clause 5, Clause 6 when dependent on Clause 4, or Clause 7, wherein a wire in the set of wires engages a hook in the set of hooks and is received between the first segment and the second segment.

[0085] Clause 9. The seat assembly according to Clause 6, Clause 7, or Clause 8 when dependent on Clause 6, wherein a wire in the set of wires engages at least one of the first side of the body and the first and second segments of the hook in the set of hooks.

[0086] Clause 10. The seat assembly according to any of the preceding clauses, wherein the set of hooks includes a first hook and a second hook, wherein the body further includes a first orifice and a second orifice extending from the first side of the body to the second side, wherein the first hook is disposed adjacent to the first orifice, and the second hook is disposed adjacent to the second orifice.

[0087] Clause 11. The seat assembly according to Clause 10, wherein the first hook and the second hook extend in opposite directions.

[0088] Clause 12. The seat assembly according to Clause 10 or Clause 11, wherein the first orifice is a through-hole surrounded by the body, and the second orifice is disposed along the perimeter of the body and is not surrounded by the body.

[0089] Clause 13. A method, comprising: joining an attachment backing and a gasket, the attachment backing including a body and hooks extending from the body, and the gasket including a wire mesh structure including a set of wires of a thermoplastic material, wherein each wire in the set of wires is looped and bonded to at least one other wire in the set of wires; actuating the hooks relative to the body; and releasing the hooks, thereby allowing the hooks to grip at least one wire in the set of wires and couple the attachment backing to the wire mesh structure.

[0090] Clause 14. The method according to Clause 13, wherein actuating the hooks causes at least a portion of the hooks to flex away from the body, and releasing the hooks allows at least a portion of the hooks to flex towards the body.

[0091] Clause 15. The method according to Clause 13 or Clause 14, wherein joining the attachment pad and the gasket further includes joining a first side of the body to the wire mesh structure and actuating the hook when the first side of the body is joined to the wire mesh structure.

[0092] Clause 16. The method according to any one of Clauses 13 to 15, wherein actuating the hook further includes pushing the hook into the wire mesh structure.

[0093] Clause 17. The method according to any one of Clauses 13 to 16, wherein actuating the hook further includes applying a force to the hook using a tool.

[0094] Clause 18. The method according to Clause 17, wherein releasing the hook further includes disengaging the tool from the hook.

[0095] Clause 19. The method according to any one of Clauses 13 to 18, further including attaching a decorative cover to the attachment pad after releasing the hook.

[0096] Clause 20. The method according to Clause 19, wherein attaching the decorative cover to the attachment pad further includes adhering the decorative cover to the body using an adhesive.

[0097] Although the exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in this specification are illustrative rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. In addition, the features of different implementation embodiments can be combined to form additional embodiments of the invention.

Claims

1. A seat assembly, comprising: a liner comprising a wire mesh structure comprising a set of filaments of a thermoplastic material, wherein each filament of the set of filaments is looped and bonded to at least one other filament of the set of filaments; an attachment plate including a body and a set of hooks extending from the body and coupling the attachment plate to the wire mesh structure, wherein the body is disposed on an outside of the molding of the wire mesh structure; and A trim cover is attached to the attachment plate.

2. The seat assembly according to claim 1, wherein: Each hook in the set of hooks extends from the body at a different location.

3. The seat assembly of claim 1, wherein: Hooks in the set of hooks extend into the wire mesh structure and grasp at least one wire of the wire mesh structure.

4. The seat assembly of claim 1, wherein: Each hook in the set of hooks further includes a first segment and a second segment, wherein the first segment extends from the body and away from the trim cover, and the second segment extends from an end of the first segment toward the trim cover.

5. The seat assembly of claim 4, wherein: The second section further includes a free end portion disposed opposite to the first section, wherein the free end portion is positioned in the wire mesh structure.

6. The seat assembly of claim 4, wherein: The body also includes a first side and a second side disposed opposite the first side, wherein the first side engages an outer side of the contour of the cushion and the second side engages the trim cover.

7. The seat assembly of claim 6, wherein: The body defines an aperture extending from the first side to the second side of the body, and the second segment extends from an end of the first segment toward the aperture.

8. The seat assembly of claim 7, wherein: A wire from the set of wires engages a hook from the set of hooks and is received between the first segment and the second segment.

9. The seat assembly of claim 7, wherein: A wire in the set of wires engages the first side of the body and engages at least one of the first segment and the second segment of a hook in the set of hooks.

10. The seat assembly of claim 1, wherein: The set of hooks includes a first hook and a second hook, wherein the body further includes a first aperture and a second aperture extending from a first side to a second side of the body, wherein the first hook is disposed adjacent to the first aperture and the second hook is disposed adjacent to the second aperture.

11. The seat assembly of claim 10, wherein: The first hook and the second hook extend in opposite directions.

12. The seat assembly of claim 10, wherein: The first aperture is a through hole surrounded by the body, and the second aperture is disposed along a perimeter of the body and is not surrounded by the body.

13. A method comprising: engaging an attachment pad and a cushion, the attachment pad comprising a body and hooks extending from the body, and the cushion comprising a wire mesh structure comprising a set of wires of a thermoplastic material, wherein each wire of the set of wires is looped and bonded to at least one other wire of the set of wires; actuating the hook relative to the body; and The hook is released, allowing the hook to grab at least one wire of the set of wires and couple the attachment pad to the wire mesh structure.

14. The method according to claim 13, wherein: Actuating the hook flexes at least a portion of the hook away from the body, and releasing the hook allows at least a portion of the hook to flex toward the body.

15. The method according to claim 13, wherein: Engaging the attachment plate and the pad also includes engaging the first side of the body with the wire mesh structure, and actuating the hook when the first side of the body is engaged with the wire mesh structure [the hook is actuated when the attachment plate is flush with the pad, so the attachment plate is tightly fixed].

16. The method according to claim 13, wherein: Actuating the hook further includes pushing the hook into the wire mesh structure.

17. The method according to claim 13, wherein: Actuating the hook further comprises applying a force to the hook using a tool.

18. The method according to claim 17, wherein: Releasing the hook further includes disengaging the tool from the hook.

19. The method of claim 13, further comprising attaching a trim cover to the attachment plate after releasing the hook.

20. The method according to claim 19, wherein: Attaching the trim cover to the attachment plate further includes adhering the trim cover to the body using an adhesive.

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