Cushion assembly

Abstract

The invention relates to a cushion assembly. The assembly is provided with a monolithic web of expanded thermoplastic resin strands having pores formed therein. The assembly is further provided with decorative ropes inserted into the holes of the integral net. The decorative cord is mounted into the aperture by one or more of inserting the decorative cord into the aperture, joining the decorative cord to an integral web of expanded thermoplastic resin strands, or joining a first section of expanded thermoplastic resin strands to a second section of expanded thermoplastic resin strands at least partially over the aperture.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Application No. 18 / 980,826, filed on December 13, 2024, which claims priority to Danish Application No. PA202470202, filed on July 30, 2024, which claims priority to U.S. Provisional Application No. 63 / 613,925, filed on December 22, 2023. The disclosures of these applications are hereby incorporated by reference in their entirety.

[0003] This application claims priority to Danish Application No. PA202470202, filed on July 30, 2024, which claims priority to U.S. Provisional Application No. 63 / 613,925, filed on December 22, 2023. The disclosures of these applications are hereby incorporated by reference in their entirety.

[0004] This application claims priority to U.S. Provisional Application No. 63 / 613,925, filed on December 22, 2023. The disclosure of this U.S. Provisional Application is hereby incorporated by reference in its entirety. Technical Field

[0005] Various embodiments relate to cushions formed from a unitary mesh of expanded thermoplastic resin strands. Brief Description of the Drawings

[0006] Figure 1 is a front perspective view of a seat assembly according to an embodiment;

[0007] Figure 2 is according to an embodiment Figure 1 of a seat assembly of a cushion assembly looking down perspective view;

[0008] Figure 3 is according to another embodiment Figure 1 of a seat assembly of a cushion assembly looking down perspective view;

[0009] Figure 4 is according to another embodiment Figure 1 of a seat assembly of a cushion assembly manufacturing process front perspective view;

[0010] Figure 5 is Figure 2 of a cushion assembly manufacturing process side view, showing an intermediate manufacturing step;

[0011] Figure 6 is Figure 2Side view of the manufacturing process of the gasket assembly, illustrating another manufacturing step;

[0012] Figure 7 is Figure 5 Side view of the assembled gasket assembly;

[0013] Figure 8 is Figure 7 Front view of the gasket assembly;

[0014] Figure 9 is according to an embodiment Figure 1 Front view of the trim cover of the gasket assembly; and

[0015] Figure 10 is Figure 9 Exploded front perspective view of the gasket assembly. Detailed description

[0016] Now, reference will be made in detail to 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.

[0017] It should be understood that the disclosed embodiments are merely exemplary, and that various forms and alternative forms are possible. These drawings need not be 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 those skilled in the art to implement the embodiments according to the present disclosure in various ways.

[0018] "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.

[0019] It should also be understood that although in some instances 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, without departing from the scope of the various described embodiments, a first section may be referred to as a second section, and similarly, a second section may be referred to as a first section. Both the first section and the second section are sections, but they are not the same section.

[0020] The terms used in the description of the various embodiments described 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, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" are intended to include the plural forms as well. 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 also be 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.

[0021] As used herein, the term "if" is optionally construed to mean "when" or "upon" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the stated condition or event]" is optionally construed to mean "when determining" or "in response to determining" or "when detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]", depending on the context.

[0022] Figure 1 The figure shows a seat assembly 20 as a vehicle seat assembly 20 according to an embodiment. Although the vehicle seat assembly 20 is illustrated and described, any seat assembly 20 may be employed. The seat assembly 20 may be used in land vehicles, aircraft, watercraft, etc. The seat assembly 20 may also be used as an office chair, a comfort chair, etc.

[0023] The depicted seat assembly 20 includes a seat bottom 22, a seat back 24, and a head restraint 26. The seat bottom 22 is provided with a seat bottom cushion 28 to support the pelvis and thighs of a seated occupant. The seat back 24 includes a seat back cushion 30 to support the back and shoulders of a seated occupant. A trim cover 32 is disposed over the seat cushions 28, 30 to hide the cushions 28, 30 and to provide a uniform and smooth contact surface for the occupant.

[0024] Generally referring to Figure 2, the figure shows a cushion assembly 34 removed from the seat assembly 20. In the illustrated embodiment, the cushion assembly 34 includes a cushion body 35 formed by an integral network 36 of expanded thermoplastic resin strands. The cushion body 35 can be manufactured according to the teachings of U.S. Patent Application Publication No. US2023 / 0191678 A1 of Lear Corporation, published on June 22, 2023 by Blair et al. According to another embodiment, the cushion body 35 can also be formed of a foam material. The cushion assembly 34 provides support for the occupant on the seat assembly 20. The cushion assembly 34 is elastically deformable and provides comfort to the occupant while supporting the occupant.

[0025] The cushion component 34 is a non-foam component or includes at least one non-foam component. The non-foam component is mainly referred to as a mesh member, but may also be referred to as a stranded member, a looped member, a wound member, a filament mesh structure, a mesh structure, a stranded mesh, a looped mesh, a wound mesh, or a mesh cushion. Figure 2 , the cushion assembly 34 is depicted as a non-foam component that does not include a foam component or foam material such as urethane or polyurethane foam; however, it is contemplated that the cushion assembly 34 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or partial cushioning for the seat occupant. For example, the foam material may be disposed between the cushion assembly 34 and the trim cover 32, on the cushion assembly 34, within the cushion assembly 34, or a combination thereof. Reducing the amount of foam material provided to the cushion assembly 34 or removing foam material from the cushion assembly 34 reduces weight and can improve support and comfort for the seat occupant. In addition, removing the foam material can facilitate recycling of the cushion assembly 34.

[0026] The cushion component 34 is described below without including a cushion component 34 of foam material. In this case, the cushion component 34 is made of filaments 36 of polymer material that are randomly looped, bent, curled or twisted and bonded together, as will be discussed in more detail below. The filaments 36 are directly bonded to one another filament 36, rather than indirectly bonded with resin or other intermediate materials.

[0027] The filament 36, which may also be referred to as a strand or thread, is made of any suitable one or more materials. In some configurations, the filament 36 is made of a polymeric material or a thermoplastic material, such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene, or a combination thereof. As an example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). Different from foam materials, the filament material may be recyclable or easier to recycle than foam materials. It is also contemplated that the filament 36 may include reinforcement fibers, and the reinforcement fibers may not be made of a thermoplastic material.

[0028] In some configurations, the filament 36 may be a monofilament made of a single material. In some configurations, the filament 36 is made of multiple materials. As an example, the filament 36 made of multiple materials may include a core made of a first thermoplastic material and a sheath made of a second thermoplastic material different from the first thermoplastic material that surrounds the core. It is contemplated that the cushion assembly 34 may include a combination of monofilaments and filaments that are made of multiple materials and are not monofilaments.

[0029] The filaments 36 that are randomly looped, bent, looped, curled, or wound are joined together where one filament 36 contacts another filament 36, thereby producing a lightweight, breathable cushion assembly 34 having openings or voids between the filaments 36.

[0030] The cushion assembly 34 is installed within the trim cover ( Figure 1 ). To attach the cushion assembly 34 to other seat components, the cushion assembly includes a trim cord 40. The trim cord 40 may be attached to other seat components, such as a seat frame, a seat suspension, etc. The trim cord 40 may also be used to attach other components, such as the trim cover 32, to the cushion assembly 34. The trim cord 40 may be formed of any suitable material, such as a structural and flexible material, e.g., a polyethylene material. Alternatively, the trim cord 40 may be formed of a steel wire.

[0031] The gasket assembly 34 is provided with a hole 38 formed therein. In the depicted embodiment, the hole 38 is a slot or groove 38 formed along the length of the body 35. If another gasket body 35 is stacked on the gasket body 35, then the groove 38 can be hidden along its length, having a hole opening at the distal end of the groove 38. The decorative cord 40 is inserted into the groove 38. According to the depicted embodiment, in order to hold the decorative cord 40 within the gasket body 35, the decorative cord 40 is joined to the body 35 at a joint (weld) 39 within the groove 38. The decorative cord 40 can be joined by friction joining, ultrasonic joining, heat staking, etc., such that the decorative cord 40 is bonded to the body 35 and integrated with the body 35. Alternatively, additional joint 39 material can be melted and deposited to cool the decorative cord 40 and bond the decorative cord 40 to the body 35. According to another embodiment, the decorative cord 40 is joined to the gasket body 35 without additional adhesive.

[0032] Reference Figure 3 , another gasket assembly 56 removed from the seat assembly 20 is illustrated. The gasket assembly 56 includes a gasket body 60 formed of an integral web 36 of expanded thermoplastic resin strands. According to another embodiment, the gasket body 60 can also be formed of a general foam material. The gasket assembly 56 can be the same as the Figure 2 gasket assembly 34, or can be another gasket assembly 56 as depicted.

[0033] The gasket assembly 56 includes a decorative cord 58 joined to the gasket body 60 at a connection 62. According to one embodiment, the connection 62 is a heat stake that partially melts the decorative cord 58 and the gasket body 60 to bond the decorative cord 58 to the gasket body 60. According to another embodiment, the connection 62 is a joint 62.

[0034] The gasket assembly 56 is provided with a hole 64 formed therein and a decorative cord 66 inserted into the hole 64. The decorative cord 66 can be formed of a polyethylene material. The hole 64 is depicted as a groove 64. Figure 3 Another method of installing the decorative cord 66 into the hole 64 according to an embodiment is illustrated. A section 42 of the expanded thermoplastic resin strands is joined at least partially above the hole 64 to the integral web 36 of the expanded thermoplastic resin strands. In the illustrated embodiment, a first section 52 of the expanded thermoplastic resin strands is joined at least partially above the hole 64 to a second section 54 of the expanded thermoplastic resin strands.

[0035] Figures 4 - 6The figure shows a method and system for inserting a decorative cord 68 into a hole 70 of a cushion body 72. The cushion body 72 can be formed of foam, an integral web of extruded thermoplastic resin, or any suitable material. A linear actuator assembly 74 is provided to install the decorative cord 68 into the cushion body 72. The linear actuator assembly 74 can be used without engaging the decorative cord 68 to the cushion body 72. The linear actuator assembly 74 includes a pair of bases 76 that provide a pair of guides. A pair of sliders 78 are mounted in the bases 76 for translation relative to the bases 76. A pair of linear actuators, such as pneumatic cylinders 80, are mounted on the bases 76 and are connected to the distal ends of the sliders 78 to extend and retract the sliders 78 relative to the bases 76. An elongate end effector 82 is mounted to each slider 78. Although a pair of bases 76, sliders 78, linear actuators 80, and end effectors 82 are illustrated and described, any number can be employed to install any number of decorative cords 68.

[0036] Figure 4 and Figure 5 The figure shows the linear actuator assembly 74 in an idle position, where the cushion body 72 is presented near the distal end of the end effector 82. In Figure 6 this, the linear actuator 80 extends the slider 78 from the base 76 such that the end effector 82 is inserted into the cushion body 72. In Figure 6 the extended position, the end effector 82 releases the decorative cord 68 into the cushion body 72. Then, the linear actuator 80 retracts to Figure 4 and Figure 5 the idle position.

[0037] Figure 7 and Figure 8 The figure shows the cushion body 72 with the decorative cord 68 installed. The holes 70 of the integral web 36 have internal dimensions, and the decorative cord 68 has external dimensions, such as a cross-section, that are less than the internal dimensions of the holes 70. In some embodiments, the cross-section of the decorative cord 68 is greater than three millimeters and less than five millimeters. In some embodiments, the internal dimension of the hole 70 is at least five millimeters greater than the cross-section of the decorative cord 68. Additionally, in some embodiments, the internal dimension of the hole 70 is less than ten millimeters. In some embodiments, the internal dimension of the hole 70 is 100% - 166% greater than the cross-section of the decorative cord 68.

[0038] Figure 9 The figure shows the decorative cover 32 of the seat assembly 20 according to various embodiments. Figure 10The figure shows a cushion body 72 of the seat assembly 20 with a trim cover 32. The trim cover 32 can be attached to a trim cord 68. In some embodiments, the trim cover 32 is provided with more than one clip 48 stitched to the trim cover 32. The clip 48 is sized to receive the trim cord 68 and hold the trim cord 68 to the integral web 36. The trim cover 32 can also be provided with a fastener assembly 50 attached to the trim cover 32. The fastener assembly 50 is sized to receive the trim cord 68 and hold the trim cord 68 to the integral web 36.

[0039] The fastener assembly 50 includes a strip or thread 44 stitched to the trim cover 32. According to some embodiments, the thread 44 can be a wire thread 44. The fastener assembly 50 also includes more than one hog ring 46, which are rings with a discontinuous loop that are deformed by a tool to close the loop and provide a fastening connection. The hog ring 46 connects the thread 44 to the trim cord 68. The hog ring 46 is installed and closed around the thread 44 and the trim cord 68. According to another embodiment, the hog ring 46 can be installed and closed around the thread 44, and then the trim cord 68 can subsequently be installed into the closed hog ring 46.

[0040] According to a first clause (which can be combined with any one of the subsequent clauses or can be not combined with any one of the subsequent clauses), the assembly is provided with an integral web of expanded thermoplastic resin strands having holes formed therein. The trim cord is inserted into the holes of the integral web. The trim cord is installed into the holes by one or more of the following: inserting the trim cord into the holes, joining the trim cord to the integral web of expanded thermoplastic resin strands, or joining at least a first section of the expanded thermoplastic resin strands above the holes to a second section of the expanded thermoplastic resin strands.

[0041] According to a second clause, there is provided an assembly according to any one of the preceding or subsequent clauses, wherein the trim cord is joined to a region of the integral web of expanded thermoplastic resin strands within a groove formed in the integral web.

[0042] According to a third clause, there is provided an assembly according to any one of the preceding or subsequent clauses, wherein the trim cord is joined to the integral web of expanded thermoplastic resin strands.

[0043] According to a fourth clause, there is provided an assembly according to any one of the preceding or subsequent clauses, wherein the trim cord is joined without an adhesive.

[0044] According to a fifth clause, there is provided an assembly according to any one of the preceding or subsequent clauses, wherein a section of the expanded thermoplastic resin strands is joined at least partially above the holes to the integral web of expanded thermoplastic resin strands.

[0045] According to Clause 6, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the holes in the overall net have internal dimensions, and wherein the decorative cord has a cross-section smaller than the internal dimensions of the holes.

[0046] According to Clause 7, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the cross-section of the decorative cord is greater than three millimeters.

[0047] According to Clause 8, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the cross-section of the decorative cord is smaller than five millimeters.

[0048] According to Clause 9, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the internal dimension of the holes in the overall net is at least five millimeters larger than the cross-section of the decorative cord.

[0049] According to Clause 10, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the internal dimension of the holes in the overall net is smaller than ten millimeters.

[0050] According to Clause 11, there is provided a component as described in any one of the foregoing or subsequent clauses, wherein the internal dimension of the holes in the overall net is 100% - 166% larger than the cross-section of the decorative cord.

[0051] According to Clause 12, there is provided a component as described in any one of the foregoing or subsequent clauses, the component having a decorative cover and at least one clip stitched to the decorative cover, wherein the clip is sized to receive the decorative cord and hold the decorative cover to the overall net.

[0052] According to Clause 13, there is provided a component as described in any one of the foregoing or subsequent clauses, the component having a decorative cover, a thread stitched to the decorative cover, and at least one loop for attaching the decorative cord to the thread.

[0053] According to Clause 14, there is provided a component as described in any one of the foregoing or subsequent clauses, the component having a decorative cover and at least one fastener stitched into the decorative cover, wherein the fastener is sized to receive the decorative cord and hold the decorative cover to the overall net.

[0054] According to Clause 15 (which may or may not be combined with any one of the foregoing or subsequent clauses), the component is provided with an overall net of expanded thermoplastic resin strands having holes formed therein. The decorative cord is inserted into the holes of the overall net, wherein a first section of the expanded thermoplastic resin strands is joined at least partially above the holes to a second section of the expanded thermoplastic resin strands.

[0055] According to Article 16, a component as described in any one of the foregoing or subsequent articles is provided, wherein a decorative cord is joined to an integral web of expandable thermoplastic resin strands.

[0056] According to Article 17, a component as described in any one of the foregoing or subsequent articles is provided, wherein the decorative cord is joined without an adhesive.

[0057] According to Article 18 (which may or may not be combined with any one of the foregoing or subsequent articles), a component is provided with an integral web of expandable thermoplastic resin strands. A decorative cord is attached to the integral web, wherein the decorative cord is joined to the integral web of expandable thermoplastic resin strands.

[0058] According to Article 19, a component as described in any one of the foregoing or subsequent articles is provided, wherein the decorative cord is joined without an adhesive.

[0059] According to Article 20, a component as described in any one of the foregoing or subsequent articles is provided, the component having a decorative cover and at least one clip stitched to the decorative cover, wherein the clip is sized to receive a decorative cord and hold the decorative cover to the integral web.

[0060] According to Article 21, a component as described in any one of the foregoing or subsequent articles is provided, the component having a decorative cover and at least one fastener stitched into the decorative cover, wherein the fastener is sized to receive a decorative cord and hold the decorative cover to the integral web.

[0061] According to Article 22, a component as described in any one of the foregoing or subsequent articles is provided, the component having a decorative cover, a thread stitched to the decorative cover, and at least one loop for attaching a decorative cord to the thread.

[0062] According to Article 23, any combination of any one of the foregoing articles is provided.

[0063] Although multiple embodiments have been described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in this specification are descriptive rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. Additionally, the features of multiple implementation embodiments can be combined to form additional embodiments according to the present disclosure.

Claims

1. A component comprising: an integral web of expanded thermoplastic resin strands having pores formed therein; as well as A decorative rope, the decorative rope being inserted into the holes of the integral net; and The decorative rope is installed in the hole by one or more of the following items: inserting the decorative rope into the hole, joining the decorative rope to the overall network of expanded thermoplastic resin strands, or joining a first segment of the expanded thermoplastic resin strands to a second segment of the expanded thermoplastic resin strands at least partially above the hole.

2. The assembly of claim 1, wherein the decorative cord is joined to a region of the integral web of expanded thermoplastic resin strands within a groove formed in the integral web.

3. An assembly according to claim 1 or 2, wherein the decorative cord is joined to the integral web of expanded thermoplastic resin strands.

4. An assembly according to any one of the preceding claims, wherein the decorative cord is joined without adhesive.

5. An assembly according to any one of the preceding claims, wherein sections of expanded thermoplastic resin strands are joined to the integral web of expanded thermoplastic resin strands at least partially over the apertures.

6. The assembly of any one of the preceding claims, wherein the apertures of the integral mesh have an inner dimension, and wherein the decorative cord has a cross-section that is smaller than the inner dimension of the apertures.

7. The assembly of claim 6, wherein the cross-section of the decorative cord is greater than three millimeters.

8. An assembly according to claim 6 or 7, wherein the cross-section of the decorative cord is less than five millimeters.

9. The assembly of any one of claims 6-8, wherein the inner dimension of the holes in the integral mesh is at least five millimeters larger than the cross-section of the decorative cord.

10. The assembly of any one of claims 6-9, wherein the inner dimension of the holes in the integral web is less than ten millimeters.

11. The assembly of any one of claims 6-10, wherein the inner dimensions of the apertures in the integral mesh are 100%-166% larger than the cross-section of the decorative cord.

12. The assembly of any of the preceding claims, further comprising a decorative cover and at least one clip sewn to the decorative cover, wherein the clip is sized to receive the decorative cord and retain the decorative cover to the integral net.

13. The assembly of any one of the preceding claims, further comprising a decorative cover, a cord sewn to the decorative cover, and at least one loop for attaching the decorative cord to the cord.

14. The assembly of any of the preceding claims, further comprising a decorative cover and at least one fastener sewn into the decorative cover, wherein the fastener is sized to receive the decorative cord and retain the decorative cover to the integral net.

15. A component comprising: an integral web of expanded thermoplastic resin strands having pores formed therein; as well as A decorative cord is inserted into the hole of the integral net, wherein a first section of an expanded thermoplastic resin strand is joined to a second section of an expanded thermoplastic resin strand at least partially over the hole.

16. The assembly of claim 15, wherein the decorative cord is joined to the integral web of expanded thermoplastic resin strands.

17. An assembly according to claim 15 or 16, wherein the decorative cord is joined without adhesive.

18. An assembly comprising: an integral web of expanded thermoplastic resin strands; as well as A decorative cord is attached to the integral web, wherein the decorative cord is joined to the integral web of expanded thermoplastic resin strands.

19. The assembly of claim 18, wherein the decorative cord is joined without adhesive.

20. The assembly of claim 18 or 19, further comprising a decorative cover and at least one clip sewn to the decorative cover, wherein the clip is sized to receive the decorative cord and retain the decorative cover to the integral net.

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