Seat arrangement and assembly method

Abstract

A seat assembly and manufacturing method. The seat assembly includes a cushion, a mounting pad, and a trim cover. The cushion includes a filament mesh structure comprising a set of filaments. The mounting pad is coupled to the filament mesh structure. The trim cover is attached to the mounting pad.

Description

Cross-reference to related applications

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 603,686, filed November 29, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Technical field

[0002] This relates to a seat arrangement and a method of assembly. Short description of the drawings Fig. 1 is a perspective view of an example of a seating arrangement. Fig. Figure 2 is a schematic diagram of an example of a manufacturing system for producing the filament mesh structure. Fig. 3 is an exploded view of examples of a trim cover, a mounting pad, and a cushion, wherein the cushion includes a filament mesh structure. Fig. 4 is a top view of the mounting pad of Fig. 3. Fig. 5 is a perspective view showing the fixing pad attached to the cushion. The Fig. 6-9 are fragmentary sectional views showing the steps associated with a method of assembly. Detailed description

[0003] Reference will now 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 one skilled 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 in order not to unnecessarily obscure aspects of the embodiments.

[0004] It should be understood that the disclosed embodiments are merely exemplary, and that various and alternative forms are possible. The figures are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be construed as limiting, but merely as a representative basis for teaching one skilled in the art how to variously employ embodiments in accordance with the disclosure.

[0005] “One or more” includes a function performed by one element, a function performed by more than one element, such as in a distributed form, multiple functions performed by one element, multiple functions performed by multiple elements, or any combination of the above.

[0006] It should also be understood that although the terms "first," "second," etc., are used herein in some instances to describe various elements, those elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact could be referred to as a second contact, and likewise, a second contact could be referred to as a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0007] The terminology used in the description of the various embodiments described herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various embodiments described 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 is also to be understood that the term "and / or," as used herein, refers to and includes all possible combinations of one or more of the associated listed items.Furthermore, the terms "includes", "containing", "comprises" and / or "comprising", when used in this specification, are understood to specify the presence of the specified 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.

[0008] The term "if" can be understood as "when" or "at" or "in response to noting" or "in response to detecting," depending on the context. Similarly, the expression "when it is detected" or "when [a particular condition or event] is detected" can be understood as "at the detection" or "in response to the detection" or "upon detecting [the particular condition or event]" or "in response to detecting [the particular condition or event]," depending on the context.

[0009] Referring to Fig. 1, an example of a seating assembly 10 is shown. In some embodiments, the seating assembly 10 is a vehicle seating assembly, e.g., for a land vehicle such as a car, truck, bus, or the like, or for a non-land vehicle such as an aircraft or a watercraft. A seating assembly 10 for a land vehicle may, for example, have the shape and size of a front-row driver or passenger seat, a second, third, or other rear-row seat, and may include bucket seats as shown, bench seats, or other seating configurations. Furthermore, the seating assembly 10 may be a non-stowable seat or a stowable seat that is foldable and stowable in a cavity in the vehicle floor. Furthermore, the seating assembly 10 may be configured for non-vehicle applications, such as furniture.

[0010] In the Fig. 1, the seat assembly 10 includes a seat base 20 and a seat back 22. 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.

[0011] The seat base 20 is configured to accommodate a seat occupant and support the pelvic and thigh areas of the seat occupant. The seat base 20 includes a seat base frame 30, a cushion 32, and a trim cover 34.

[0012] The seat frame 30 is a structure that supports the cushion 32. The seat frame 30 includes one or more structural elements and may be constructed of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or combinations thereof. In some configurations, the seat frame 30 includes a panel, a seat pan, a suspension mat, or suspension wires upon which the cushion 32 is disposed.

[0013] The cushion 32 is disposed on the seat frame 30. The cushion 32 is made of a resilient material that supports the seat occupant and distributes the load forces from the seat occupant to the seat frame 30. The cushion 32 and the associated manufacturing processes are discussed in more detail below.

[0014] The trim cover 34 covers at least a portion of the cushion 32. In addition, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. The seat occupant may be positioned on the trim cover 34 when seated on the seat assembly 10. The trim cover 34 is constructed of one or more suitable materials, such as fabric, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 34 may include a plurality of trim panels assembled together 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 attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to assist in conforming the trim cover 34 to the contour of the seat bottom frame 30, the cushion 32, or both. The trim cover 34 may also be attached to a mounting pad, as explained in more detail below.

[0015] The seatback 22 is configured to support the back of a seated occupant. The seatback 22 is disposed adjacent the seat bottom 20. For example, the seatback 22 may be disposed above the seat bottom 20 and near the rear of the seat bottom 20. The seatback 22 extends substantially upwardly away from the seat bottom 20. In some configurations, the seatback 22 is attached to the seat bottom 20 and may be pivotable with respect to the seat bottom 20. In other configurations, the seatback 22 is not attached to the seat bottom 20. For example, a vehicle seatback may be attached to the body structure of the vehicle, as in some second-row seating assemblies. The seatback 22 includes a seatback frame 40, a cushion 42, a trim cover 44, and optionally, a headrest 46.

[0016] The seatback frame 40 is a structure that supports the cushion 42. The seatback frame 40 includes one or more structural elements and may be constructed of any suitable material, such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or combinations thereof. In some configurations, the seatback frame 40 includes a panel, a tray, a suspension mat, or suspension wires upon which the cushion 42 is disposed. It is also contemplated that the seatback frame 40 may be integrally molded with the seat bottom frame 30 in some configurations.

[0017] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a resilient material that supports the seat occupant and distributes the loading forces from the seat occupant to the seat back frame 40. It is conceivable that the cushion 42 is molded integrally with the cushion 32 of the seat bottom 20 or is disposed separately from the cushion 32 of the seat bottom 20. The cushion 42 and the associated manufacturing processes are explained in more detail below.

[0018] The trim cover 44 covers at least a portion of the cushion 42. In addition, the trim cover 44 provides one or more visible exterior surfaces of the seatback 22. The seat occupant may be positioned on the trim cover 44 when seated on the seat assembly 10. The trim cover 44 is constructed of one or more suitable materials, such as fabric, leather, synthetic leather, vinyl, or combinations thereof. The trim cover 44 may include one or more trim panels assembled together in a suitable manner, such as by fusing or sewing. The trim cover 44 is attached to the seatback frame 40, the cushion 42, or both.For example, the trim cover 44 may include trim attachment features secured to the seatback frame 40, the cushion 42, or both to prevent removal of the trim cover 44 and to assist in conforming the trim cover 44 to the contour of the seatback frame 40, the cushion 42, or both. The trim cover 44 may also be secured to a mounting pad, as explained in more detail below.

[0019] The headrest 46, if provided, is configured to support the head of a seat occupant. The headrest 46 is disposed at the top of the seatback 22 or at an end of the seatback 22 opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seatback 22 or may be integrally formed with the seatback 22.

[0020] Referring to Fig. 3 shows an example of a cushion 50. For convenience, the cushion is designated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 are applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0021] The cushion 50 consists of a non-foam component or contains 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, mesh structure, or stranded mesh. Fig. 3, the cushion 50 is illustrated 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 50 may also include a foam component or foam material in addition to a non-foam component to provide additional padding or localized cushioning to the seat occupant. For example, foam material may be provided 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 with the cushion 50 or omitting foam material from the cushion 50 reduces weight and may improve the body support and comfort of a seat occupant.In addition, the omission of foam material can facilitate the recycling of the cushion 50.

[0022] The cushion 50 will be described below in the context of a cushion 50 that does not contain foam material. In this context, the cushion 50 consists of filaments 52 of polymeric material that are randomly looped, bent, crimped, or looped and connected to one another, as explained in more detail below. An example of filaments 52 is shown in the Fig. 6-9. A filament 52 is directly bonded to another filament 52 rather than indirectly bonded to a resin or other intermediate material.

[0023] The filaments 52, which may also be referred to as fibers or threads, are made of any suitable material or materials. In some configurations, the filaments 52 are made of a polymeric or thermoplastic material, such as a polyamide-, polyester-, polyimide-, polyolefin- (e.g., polypropylene-, polyethylene-, etc.-), polystyrene-based thermoplastic resin, or combinations thereof. A polyethylene-based filament, for example, may be made of linear low-density polyethylene (LLPDE). The filament material, unlike foam material, may be recyclable or more easily recycled than foam material. It is also contemplated that a filament 52 may include reinforcing fibers, and that the reinforcing fibers need not be made of a thermoplastic material.

[0024] In some configurations, a filament 52 may be a monofilament made from a single material. In some configurations, a filament 52 is made from multiple materials. For example, a filament 52 made from multiple materials may include a core made from a first thermoplastic material and a sheath surrounding the core made from a second thermoplastic material that is different from the first thermoplastic material. It is contemplated that the pad 50 may include a combination of monofilaments and filaments made from multiple materials that are not monofilaments.

[0025] Filaments 52 that are randomly looped, bent, looped, crimped, or looped are bonded together where one filament 52 contacts another filament 52, thereby forming a lightweight, air-permeable cushion (e.g., cushions 32 and / or 42) or a filament mesh structure with openings or voids between the filaments 52. An example of a manufacturing system 60 for producing a cushion or filament mesh structure is also shown in Fig. 2. 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.

[0026] Referring to Fig. 2, the material supply 70 contains the material to be extruded, e.g., solid beads, flakes, granules, pellets, or powder of the material. In some configurations, the material supply 70 is configured as a container or hopper. The material supply 70 provides material to the extruder 72.

[0027] The extruder 72 melts the feedstock and extrudes the feedstock into a set of filaments 52. The extruder 72 may have any suitable configuration. In some configurations, the extruder 72 includes a barrel that houses a rotatable screw and heating elements. The rotation of the screw forces the material to move through the barrel and helps heat the material due to the friction created by the rotation of the screw. The material exits the barrel under pressure and in a molten state and is transported under pressure to a nozzle 80 of the extruder 72.

[0028] The nozzle 80, which may also be referred to as a die plate or extrusion die, has multiple through-holes or filament-forming openings through which the molten material passes. A single filament 52 is extruded from each through-hole. The filaments 52 fall from the nozzle 80 by gravity into the hopper 74.

[0029] The hopper 74 compacts or groups the filaments 52 into a more compact arrangement in which the filaments bend, curl, or entangle, and one filament 52 contacts and bonds with at least one other filament 52. The hopper 74 has an inlet opening, or hopper inlet, and an outlet opening, or hopper outlet, that is smaller than the hopper inlet. Individual severed filaments 52 enter the hopper inlet. The filaments 52 bend, curl, or entangle, and contact one another as they accumulate. The filaments 52 move through the hopper 74 toward the hopper outlet. Some filaments may slide along the hopper 74 or an intermediate sheet disposed on the hopper 74 as the filaments move toward the hopper outlet.Bonds are formed between the filaments 52 at the points of contact, while at other locations where one filament 52 does not contact or bond with another filament 52, openings or voids are present between the filaments 52. The looped and interconnected filaments 52 pass through the hopper outlet of the hopper 74 and enter the cooling tank 76. For simplicity, the interconnected filaments 52 are referred to as the filament mesh structure 90.

[0030] The cooling tank 76 contains a liquid, such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 supports the looped and bonded filaments 52 to limit further compaction or solidification of the filaments 52 into a less open or less porous arrangement and to maintain a desired porosity and density of the filament mesh structure 90. Thus, the liquid provides a certain buoyancy or drag value, which may result in additional bending, curling, or entangling of the filaments 52 adjacent to the surface of the liquid or within the hopper 74 to further establish the filament mesh structure 90. The liquid also cools the filaments 52 when the filaments 52 are in the liquid.For example, the liquid cools the filaments 52 from the outside to solidify the filaments 52 and prevent the filaments 52 from bonding together at further points. At this point, the filaments 52 are relatively stiff and no longer in a plastic state, so they essentially retain their shape and are not moldable or reshapable without reheating.

[0031] 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 conveyors that assist in moving the filament mesh structure 90 through and out of the liquid. In some configurations, a tractor conveyor 92 is provided in the cooling tank 76 to assist in pulling the filament mesh structure 90 away from the hopper 74 and counteracting the buoyancy of the filaments 52.

[0032] One or more other rollers, such as roller 94, keep the filament mesh structure 90 submerged 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 vibrating table 98 located outside the cooling tank 76. The vibrating table 98 shakes the filament mesh structure 90 while it is on the conveyor belt 96 to remove liquid. Alternatively or additionally, the filament mesh structure 90 can be squeezed to remove liquid, or air can be blown toward the filament mesh structure 90 to assist in removing liquid from the filament mesh structure 90, or both. It is also conceivable to allow the filament mesh structure 90 to drain or to dry in ambient air.

[0033] The manufacturing system 60 described above is a continuous flow process in which the filament mesh structure 90 is formed as a continuous structure if the filament extrusion is not interrupted. Further processing of the filament mesh structure 90 is provided after exiting the cooling tank 76 to cut the filament mesh structure 90 into individual pieces or blanks for individual pads. This processing is performed by a cutting subsystem of the manufacturing system 60. The cutting system may be of any suitable type. For example, the cutting system may use a blade, a knife, a hot knife, a saw, a fluid jet, or the like to cut the filaments 52 of the filament mesh structure 90 into a blank. The cutting system may be used to shape or contour the blank. A blank may be further shaped or contoured by other manufacturing processes, e.g.,by forming the entire blank or part of it.

[0034] Referring to Fig. 3, an exploded view of a portion of the seat assembly 10 is shown, including an example of the cushion 50, an example of a trim cover 100, and an example of a mounting pad 102.

[0035] The cushion 50 comprises the filament mesh structure 90. In Fig. 3, the cushion 50 is shown without illustrating the individual filaments 52 of the filament mesh structure 90 for clarity. In some configurations, the cushion 50 is provided with a contoured outer surface 110. The contoured outer surface 110 may have a partially or completely non-planar profile and may include one or more curved surfaces or curved regions. In some configurations, the contoured outer surface 110 is concave or partially concave. The contoured outer surface 110 faces the trim cover 100 and the attachment pad 102. Additionally, the contoured outer surface 110 may face a seat occupant. The contoured outer surface 110 may contact a portion of the fairing cover 100 in one or more areas where the attachment pad 102 is not disposed between the fairing cover 100 and the cushion 50 and the fairing cover 100 does not separate the fairing cover 100 from the cushion 50.

[0036] For convenience, the trim cover 100 is generally designated by the reference numeral 100. It is 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 previously described. Fig. 3, a portion of the fairing cover 100 is shown to better illustrate other features in this figure. The fairing cover 100 may be attached to the mounting pad 102 and may substantially follow the curve or contour of the mounting pad 102 or a side of the mounting pad 102 facing away from the cushion 50.

[0037] The attachment pad 102 is disposed between the cushion 50 and the fairing cover 100. In some configurations, the attachment pad 102 extends from the cushion 50 to the fairing cover 100. For example, the attachment pad 102 may extend from the contoured outer surface 110 to a side of the fairing cover 100 facing the contoured outer surface 110. It is also conceivable that other components, such as a heating pad, are disposed between the fairing cover 100 and the attachment pad 102.

[0038] Referring to Fig. Figure 4 shows a top view of the example of the mounting pad 102. The mounting pad 102 includes a body 120 and a set of hooks 122.

[0039] The body 120 is configured to support a seat occupant and facilitate the attachment of the trim cover 100 to the cushion 50. The body 120 may be comprised of a panel, a layer, or assembled layers having a solid or hollow construction. The body 120 may be comprised of multiple pieces or configured as a unitary, one-piece component that may be constructed from any suitable material or materials. For example, the body 120 may be constructed from a polymeric material, such as a thermoplastic material, such as a polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.) thermoplastic resin, polystyrene-based, or combinations thereof. In some configurations, the body 120 is constructed from the same material as the filaments 52.In other configurations, the body 120 is made of a different material than the filaments 52, but is sufficiently similar to the material of the cushion 50 that the cushion 50 and the mounting pad 102 can be recycled together without disassembly. For example, the fairing cover 100 can be removed from the mounting pad 102, and the cushion 50 and the body 120 can be shredded or cut together for recycling without removing the mounting pad 102 from the cushion 50.

[0040] Referring to the Fig. 3 and Fig. 4, in some configurations, the body 120 is disposed on a contoured outer surface 110 of the cushion 50. For example, the body 120 may engage or contact the filaments 52 of the filament mesh structure 90 of the cushion 50 along the contoured outer surface 110 and may not be disposed within the filament mesh structure 90. The body 120 may extend along the side of the filaments 52 that form the profile and the contoured outer surface 110 of the cushion 50 and may extend from filament 52 to filament 52, thereby bridging the gaps between adjacent filaments 52 and following the outer profile of the cushion 50 without extending into the filament mesh structure 90. In some configurations, the body 120 may not be disposed within a trench, hole, or groove extending from the contoured outer surface 110 into the filament mesh structure 90, such asa trench, hole, or groove cut into the filament mesh structure 90 or formed as a localized depression in the filament mesh structure 90 extending from the contoured outer surface 110. In some configurations, the body 120 includes a first side 130, a second side 132, and a plurality of cutouts 134 and / or 134'.

[0041] Primarily referring to Fig. 3, the first side 130 faces the cushion 50. For example, the first side 130 may face the contoured outer surface 110 of the cushion 50. Thus, the first side 130 faces away from the trim cover 100 and may engage or contact the contoured outer surface 110. The first side 130 may follow the contour of the contoured outer surface 110. Thus, the first side 130 may be substantially parallel to the contoured outer surface 110. The term "substantially parallel," as used herein, means the same as or very close to parallel and includes features or axes that are parallel to each other within ±3°. In some configurations, the first side 130, or a portion thereof, may be non-planar.

[0042] The second side 132 is disposed opposite the first side 130. In some configurations, the second side 132 engages or contacts the trim cover 100. The second side 132 may also follow the contour of the contoured outer surface 110 of the cushion 50. For example, the second side 132 may be disposed substantially parallel to the contoured outer surface 110, the first side 130, or both.

[0043] Primarily referring to Fig. 4, a plurality of cutouts 134, 134' are defined by the body 120. A cutout 134, 134' extends from the first side 130 to the second side 132 and may be referred to as an opening, hole, or window. In some configurations, a cutout 134 may be configured as a through-hole surrounded by the body 120. In Fig. 4, nine cutouts 134 are shown having such a configuration; however, it is conceivable that a greater or fewer number of cutouts 134 may be provided. These cutouts 134 are spaced from the perimeter of the body 120. In some configurations, a cutout 134' may be disposed along the perimeter of the body 120. In such a configuration, the cutout 134' may extend from the first side 130 to the second side 132, but is not surrounded by the body 120 because the cutout 134' is disposed along the perimeter. In Fig. 4, twelve cutouts 134' are shown along the perimeter of the body 120; however, it is conceivable that a greater or fewer number of cutouts 134' may be provided. In some configurations, the body 120 is solid except for the cutouts 134, 134'.

[0044] The cutouts 134, 134' may have any suitable configuration. In the Fig. 4, the cutouts 134, which are configured as through-holes, are depicted as having a substantially rectangular configuration in which a first pair of sides or a pair of first sides 140 disposed opposite one another have a greater length than a second pair of sides or a pair of second sides 142 disposed opposite one another and interconnecting the pair of first sides 140. It is also contemplated that the cutouts 134 may have a non-rectangular configuration, including, but not limited to, circular, elliptical, oval, triangular, or various other polygonal shapes. The cutouts 134' disposed along the circumference may have fewer sides.For example, such a cutout 134' may have a single first side 140' that is longer than a second pair of sides 142' that extend from opposite ends of the first side 140' to the outer perimeter. Such a cutout 134' may be a circumferential indentation extending toward the center of the body 120. It is also conceivable that the second pair of sides 142' may be omitted and the single first side 140' may extend along an arc.

[0045] The set of hooks 122, which may also be referred to as barbs, catcher, clasp, or clip, facilitates the attachment of the attachment pad 102 to the cushion 50. For example, elements of the set of hooks 122 are configured to extend into the filament mesh structure 90 and engage, hook, grasp, or couple with at least one filament 52 of the filament mesh structure 90, as discussed in more detail below. The set of hooks 122 extends from the body 120. For example, the hooks 122 may be integrally molded with the body 120 as a unitary, one-piece component. In some configurations, each element of the set of hooks 122 may extend from the body 120 at a different location. Thus, the elements of the set of hooks 122 may be spaced apart from one another and may not touch or extend from one another.

[0046] Primarily on Fig. Referring to Figure 6, a hook 122 may be disposed adjacent to an associated cutout 134 or 134'. For example, a hook 122 may extend from the first side 140 or 140' in a direction moving toward an associated cutout 134, 134'. In some configurations, a hook 122 is associated with and disposed adjacent to each cutout 134, 134'.

[0047] In some configurations, some or all members of the set of hooks 122 may point in opposite directions relative to each other. Examples of hook pairs 122 extending in opposite directions are shown in Fig. 4 by the dashed boxes. For example, the free end 160 of one hook 122 may be facing away from or pointing away from the free end 160 of another hook 122. Orienting the hooks 122 in opposite directions allows the hooks 122 to better secure the body 120 to the filament mesh structure 90, e.g., during dynamic loading where the seat occupant moves or bounces on the cushion 50. A similar hook arrangement is shown in the upper left and right corners of Fig. 4, in which a pair of circumferentially disposed hooks 122, 122 point away from a hook 122 disposed adjacent a cutout 134 configured as a through-hole and oriented at an angle of approximately 45° with respect to a horizontal line running from left to right in the illustrated perspective. As such, the circumferential hooks 122, 122 extend substantially away from the center of the body 120, while the hook 122 visible through the angled cutout 134 extends toward the center of the body 120.For example, a hook 122 disposed along or adjacent the perimeter of the attachment pad 102 may point or extend in a different direction than the nearest hook 122 not disposed along the perimeter to help the attachment pad 102 conform to the contour of the cushion 50 and to hold the attachment pad 102 against the contour of the cushion 50 and prevent the attachment pad 102 from detaching or unlatching from the filament mesh structure 90 of the cushion 50.

[0048] As in Fig. 5, the perimeter of the attachment pad 102 may be located higher than the central region of the attachment pad 102. Thus, a perimeter hook 122, or a hook located adjacent to the perimeter of the attachment pad 102, may be located at a higher elevation or farther above a horizontal plane disposed below the cushion 50 than the hooks 122 not located along the perimeter of the attachment pad 102. Additionally, the attachment pad 102 may have a curved contour extending downward from the perimeter to a hook 122 not located along the perimeter of the attachment pad 102.

[0049] As in Fig. 4, a hook 122 may taper or narrow as the hook 122 extends away from the body 120 and toward an associated cutout 134, 134'. In some configurations, the hook 122 may taper and narrow as the hook 122 extends toward a distal end or free end 160 of the hook 122.

[0050] Referring to Fig. 6, a hook 122 includes, in some configurations, a first segment 150, a second segment 152, and a bend 154.

[0051] The first segment 150 extends from the body 120. For example, the first segment 150 may extend from the first side 130 of the body 120. The first segment 150 may extend in a direction away from the trim cover 100. For example, the first segment 150 may extend from the first side 130 in a direction away from the second side 132. In some configurations, the first segment 150, or a portion thereof, may be disposed substantially perpendicular to an adjacent region of the second side 132.

[0052] The second segment 152 may extend from an end of the first segment 150. For example, the second segment 152 may extend from an end of the first segment 150 that is disposed opposite the body 120. The second segment 152 extends in a different direction than the first segment 150. In some configurations, the first segment 150 and the second segment 152 meet at the bend 154 and are disposed in a non-parallel relationship. In some configurations, the second segment 152 extends at an acute angle α1 with respect to the first segment 150 such that the second segment 152 extends toward an adjacent cutout 134, 134' in the body 120 or upward toward the second side 132.

[0053] The second segment 152 has a free end 160. The free end 160 is disposed at an end of the second segment 152 that is opposite the first segment 150 and the bend 154, if provided. The free end 160 is configured to be positioned within the filament mesh structure 90 or may not extend beyond the contoured outer surface 110 when the attachment pad 102 is attached and coupled to the filament mesh structure 90. When attached, the free end 160 may be disposed below the second side 132 such that the free end 160 does not poke a seat occupant, create a bulge or deformation in the trim cover, or both.For example, the free end 160 or a portion thereof may protrude into the cutout 134, 134' as shown, or may be disposed entirely below the second side 132 and within the filament mesh structure 90 such that the free end 160 does not puncture a seat occupant.

[0054] The first segment 150 and the second segment 152 may cooperate to form the bend 154. The bend 154 may have an arcuate or curved profile when the hook 122 is in a nominal or standard position, as shown in Fig. 6. The hook 122 may be configured to bend or curve at the bend 154.

[0055] Referring to the Fig. 6-9 illustrate examples of steps associated with an assembly method. Fig. 6-9 are sectional views through a hook 122 and an adjacent cutout 134 of the attachment pad 102 and through the filament mesh structure 90 of the cushion 50. The filament mesh structure 90 is illustrated in a simplified form in which various filaments 52 located behind the cutting plane are omitted for clarity. Furthermore, some filaments 52 that intersect the cutting plane are illustrated with cross-sections, and more specifically, with circles in cross-section, for simplicity. It should be understood that a filament 52 may not intersect the cutting plane perpendicularly, and therefore, a cut filament 52 may be more accurately illustrated in a non-circular shape, such as an oval, ellipse, or other non-circular shape.

[0056] The attachment of the attachment pad 102 to the filament mesh structure 90 is primarily described in the context of attachment with a single hook 122; however, it is understood that some or all of the hooks 122 of the attachment pad 102 may be attached in a similar manner and that the hooks may be attached simultaneously or sequentially.

[0057] Referring to Fig. 6, the cushion 50 and the attachment pad 102 are shown prior to assembly. The attachment pad 102 is aligned with a desired installation location on the cushion 50, with the first side 130 facing the outer side 110 of the cushion 50 and the hook 122 extending toward the outer side 110 of the cushion 50. The curve 154 of the hook 122 may engage or contact the outer side 110, while the remainder of the attachment pad 102 may be spaced apart from or above the cushion 50.

[0058] Referring to Fig. 7, the attachment pad 102 is actuated toward the filament mesh structure 90 of the cushion 50. The attachment pad 102 can be actuated toward the filament mesh structure 90 by moving the body 120 of the attachment pad 102 toward the outer side 110, by moving the cushion 50 and its outer side 110 toward the attachment pad 102, or combinations thereof. In the example shown, the attachment pad 102 is illustrated as being actuated against the cushion 50 such that the first side 130 of the body 120 engages or contacts the outer side 110 of the cushion 50 in response to a downward force applied to the second side 132 of the attachment pad 102, as illustrated by the vertical arrow lines. The force can be applied in any suitable manner. For example, the force can be applied manually or with a machine or device such as a press.

[0059] A force exerted against the attachment pad 102 pushes the hook 122 through the outer surface 110 and into the filament mesh structure 90. Filaments 52 of the filament mesh structure 90 that engage or contact the hook 122 may be moved or translated by the hook 122 when the hook 122 is inserted into the filament mesh structure 90. The movement or translation of the filaments 52 may be limited by the bonds between the filaments 52. As a result, the filaments 52 provide some resistance to the insertion of the hook 122. As a result, the hook 122 bends. For example, the first segment 150, the second segment 152, or both may bend from their original configuration in Fig. 6 bend or warp. In Fig. 7, the hook 122 is illustrated as bending primarily at the bend 154 such that the second segment 152 bends or curves upwardly with respect to the body 120 and extends toward, into, or through the cutout 134 in the body 120 disposed adjacent the hook 122. As a result, the angle α2 between the first segment 150 and the second segment 152 may be smaller than the angle α1 prior to insertion. In the example shown, the hook 122 bends such that the free end 160 is pushed upwardly into and through the cutout 134 such that the free end 160 protrudes from the cutout 134 and is disposed above the second side 132 of the body 120. In some configurations, the free end 160 moves up past the first side 130 of the body 120 into the cutout 134 without protruding beyond the second side 132.In other configurations, the free end 160 can move upward but cannot enter the cutout 134.

[0060] The first segment 150 and the second segment 152 may act like a wedge, forcing one or more filaments 52 around the hook 122. As a result, the filaments 52 may be moved away from the gap 170 located between the first segment 150 and the second segment 152, which may be located 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 than in adjacent regions of the filament mesh structure 90.

[0061] Referring to Fig. 8, the hook 122 is actuated (e.g., pushed, pulled, moved, bent, curved, positioned) with respect to the body 120 into the cushion 50. Actuating the hook 122 may occur while the body 120 is held against the outer side 110 of the cushion 50. Actuating the hook 122 bends the hook away from the body 120 and toward the filament mesh structure 90. Actuating the hook 122 may include, for example, pushing a portion of the hook 122 into the filament mesh structure 90, pulling the hook into the filament mesh structure 90, or combinations thereof. Actuating the hook 122 will be discussed below primarily in the context of pressing the hook 122 into the filament mesh structure 90.

[0062] In some configurations, force is applied to the hook 122 using a tool 180, such as a shaft, rod, lever, bar, wedge, or the like. For example, the tool 180 may be aligned with a portion of the hook 122, such as the second segment 152. The tool 180 may then engage the second segment 152. For example, the tool 180 may engage or contact the second segment 152 between the free end 160 and the bend 154. Depending on the position of the tool 180, the tool may enter or pass through the cutout 134 before or after the tool 180 engages the second segment 152. A force may be applied with the tool 180 to push the second segment 152 downward and into the filament mesh structure 90. The tool 180 can exert a force on the second segment 152, causing the hook 122 to bend or curve away from the first segment 150.The hook 122 may bend or curve at the bend 154. Part or all of the force applied by the tool 180 may be directed toward the filament mesh structure 90.

[0063] The application of sufficient force with the tool 180 pushes the second segment 152 deeper into the filament mesh structure 90. As a result, bending or curving may occur along the first segment 150, the second segment 152, the curvature 154, or a combination thereof. The second segment 152 may bend, curve, or otherwise move away from the body 120 and the second side 132 such that the free end 160 moves into the filament mesh structure 90 or is pushed deeper into the filament mesh structure 90 and further away from the outer side 110. In some configurations, the force may be applied such that the angle α3 between the first segment 150 and the second segment 152 increases and is greater than that in Fig. 6. For example, the angle α3 may be greater than 90°, such as between 90° and 180°. As a result, the second segment 152 may extend away from the body 120, allowing one or more filaments 52 to enter the gap 170 between the first segment 150 and the second segment 152. In some configurations, the free end 160 is disposed below the first segment 150, the bend 154, or both, or farther from the first side 130 than the first segment 150, the bend 154, or both when pushed into the filament mesh structure 90.

[0064] In Fig. 9 shows the hook 122 after release. By releasing the hook 122, the hook 122 can move to or into its Fig. 6. The hook 122 may be released by retracting the tool 180 and / or detaching 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 members of the set of filaments 52, thereby coupling the attachment pad 102 to the filament mesh structure 90. In the configuration shown, releasing the hook 122 allows the second segment 152 to move upwardly toward the body 120 and the cutout 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 element of the set of filaments 52 can engage the hook 122 and be received between the first segment 150 and the second segment 152.Once released, the second segment 152 may extend toward the cutout 134 and toward the fairing cover 100 when the fairing cover 100 is installed.

[0065] An element of the set of filaments 52 can engage the first side 130 of the body 120 and the hook 122. For example, the 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. An example of the resulting assembly with the attachment pad 102 coupled to the cushion 50 is shown in Fig. 5 shown.

[0066] The fairing cover 100 may be attached to the body 120 before or after the attachment pad 102 is attached or coupled to the filament mesh structure 90. In some configurations, the fairing cover 100 is attached to the attachment pad 102 after the hooks 122 are released and the attachment pad 102 is coupled to the cushion 50. It is also conceivable that the fairing cover 100 is attached to the attachment pad 102 before the hooks 122 are inserted into the filament mesh structure 90, which may be realized in a configuration in which the attachment pad 102 is pulled against the filament mesh structure 90.

[0067] Referring to Fig.3, the fairing cover 100 may be attached to the second side 132 of the body 120. The fairing cover 100 may be attached to the body 120 in any suitable manner. For example, the fairing cover 100 may be attached to the attachment pad 102 by gluing or adhering the fairing cover 100 to the body 120, for example, with an adhesive 190 disposed between the underside of the fairing cover 100 and the second side 132. It is also conceivable that the fairing cover 100 is attached to the attachment pad 102 with a fastener, such as a hook-and-loop fastener.

[0068] The present invention may make it possible to provide a cushion with a fastening pad that helps to better secure a fairing cover at positions positioned near the center of the cushion without providing recesses or grooves in the cushion in which a fairing clip is disposed. The present invention may make it possible to fasten a fairing cover with a fastening pad that can provide a larger area for fastening the fairing cover compared to using individual fairing clips, thereby providing a larger area to which the fairing cover and the fastening pad can be fastened, allowing the fairing cover to be fastened in more locations compared to fairing clips.The present invention can enable a fastening pad to be reliably attached to a filament mesh structure with multiple hooks that can be arranged in different directions, so that multiple hooks are aligned to counteract loading forces and prevent the fastening pad from detaching. Furthermore, the fastening pad and the filament mesh structure can be recycled together, thus avoiding disassembly during the recycling process.

[0069] Clause 1. A seating assembly comprising: a cushion comprising a filament mesh structure, the filament mesh structure comprising a set of filaments of thermoplastic material, each member of the set of filaments being looped and connected to at least one other member of the set of filaments; an attachment pad comprising a body and a set of hooks extending from the body and coupling the attachment pad to the filament mesh structure, the body being disposed on a contoured exterior of the filament mesh structure; and a trim cover attached to the attachment pad.

[0070] Clause 2. The seating arrangement according to Clause 1, wherein each element of the set of hooks extends from the body at a different location.

[0071] Clause 3. The seating assembly of any preceding clause, wherein the members of the set of hooks extend into the filament mesh structure and engage at least one filament of the filament mesh structure.

[0072] Clause 4. The seat assembly of any preceding clause, wherein each member of the set of hooks further comprises a first segment and a second segment, the first segment extending away from the body and the trim cover, and the second segment extending from an end of the first segment toward the trim cover.

[0073] Clause 5. The seat assembly of clause 4, wherein the second segment further comprises a free end disposed opposite the first segment, the free end being positioned in the filament mesh structure.

[0074] Clause 6. The seat assembly of any preceding clause, wherein the body further comprises a first side and a second side disposed opposite the first side, the first side engaging the contoured outer surface of the cushion and the second side engaging the trim cover.

[0075] Clause 7. The seating arrangement of Clause 6 when dependent on Clause 4, wherein the body defines a cutout extending from the first side to the second side of the body, and the second segment extends from one end of the first segment towards the cutout.

[0076] Clause 8. The seat assembly of clause 4, clause 5, clause 6 when dependent on claim 4, or clause 7, wherein a member of the set of filaments engages a member of the set of hooks and is received between the first segment and the second segment.

[0077] Clause 9. The seating arrangement of Clause 6, Clause 7 or Clause 8 when dependent on Clause 6, wherein an element of the set of filaments engages the first side of the body and at least one of the first segments and second segments of an element of the set of hooks.

[0078] Clause 10. The seat assembly of any preceding clause, wherein the set of hooks comprises a first hook and a second hook, the body further comprising first and second cutouts extending from a first side to a second side of the body, the first hook being disposed adjacent to the first cutout and the second hook being disposed adjacent to the second cutout.

[0079] Clause 11. The seating arrangement according to Clause 10, wherein the first hook and the second hook extend in opposite directions.

[0080] Clause 12. The seat assembly of Clause 10 or Clause 11, wherein the first cutout is a through-hole surrounded by the body and the second cutout is arranged along a perimeter of the body and is not surrounded by the body.

[0081] Clause 13. A method comprising: engaging a fastening pad and a cushion, the fastening pad comprising a body and a hook extending from the body, and the cushion comprising a filament mesh structure, the filament mesh structure comprising a set of filaments of thermoplastic material, each member of the set of filaments being entangled and connected to at least one other member of the set of filaments; actuating the hook with respect to the body; and releasing the hook, thereby allowing the hook to engage at least one member of the set of filaments and couple the fastening pad to the filament mesh structure.

[0082] Clause 14. The method of Clause 13, wherein actuating the hook bends the hook away from the body and releasing the hook allows the hook to bend towards the body.

[0083] Clause 15. The method of clause 13 or clause 14, wherein engaging the attachment pad and the cushion further comprises engaging a first side of the body with the filament mesh structure, and actuating the hook occurs when the first side of the body engages the filament mesh structure.

[0084] Clause 16. The method of any one of clauses 13 to 15, wherein actuating the hook further comprises pressing the hook into the filament mesh structure.

[0085] Clause 17. The method of any one of clauses 13 to 16, wherein actuating the hook further comprises applying a force to the hook with a tool.

[0086] Clause 18. The method of Clause 17, wherein releasing the hook further comprises disengaging the tool from the hook.

[0087] Clause 19. The method of any one of clauses 13 to 18, further comprising securing a trim cover to the securing pad after releasing the hook.

[0088] Clause 20. The method of Clause 19, wherein securing the fairing cover to the mounting pad further comprises adhering the fairing cover to the body with an adhesive.

[0089] While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the words used in the description are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Furthermore, the features of the various embodiments may be combined to form further embodiments of the invention.

Claims

A seating assembly comprising:a cushion comprising a filament mesh structure, the filament mesh structure comprising a set of filaments of thermoplastic material, each member of the set of filaments being looped and connected to at least one other member of the set of filaments;a mounting pad comprising a body and a set of hooks extending from the body and coupling the mounting pad to the filament mesh structure, the body being disposed on a contoured exterior of the filament mesh structure; anda trim cover attached to the mounting pad. The seat assembly of claim 1, wherein each member of the set of hooks extends from the body at a different location. The seat assembly of claim 1, wherein members of the set of hooks extend into the filament mesh structure and engage at least one filament of the filament mesh structure. The seat assembly of claim 1, wherein each member of the set of hooks further comprises a first segment and a second segment, the first segment extending from the body and away from the trim cover and the second segment extending from an end of the first segment toward the trim cover. The seat assembly of claim 4, wherein the second segment further comprises a free end disposed opposite the first segment, the free end being positioned in the filament mesh structure. The seat assembly of claim 4, wherein the body further comprises a first side and a second side disposed opposite the first side, the first side engaging the contoured outer surface of the cushion and the second side engaging the trim cover. The seat assembly of claim 6, wherein the body defines a cutout 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 cutout. The seat assembly of claim 7, wherein a member of the set of filaments engages a member of the set of hooks and is received between the first segment and the second segment. The seat assembly of claim 7, wherein a member of the set of filaments engages the first side of the body and at least one of the first segment and the second segment of a member of the set of hooks. The seat assembly of claim 1, wherein the set of hooks comprises a first hook and a second hook, the body further comprising first and second cutouts extending from a first side to a second side of the body, the first hook being disposed adjacent the first cutout and the second hook being disposed adjacent the second cutout. The seat assembly of claim 10, wherein the first hook and the second hook extend in opposite directions. The seat assembly of claim 10, wherein the first cutout is a through-hole surrounded by the body, and the second cutout is disposed along a perimeter of the body and is not surrounded by the body. A method comprising: engaging a fastening pad and a cushion, the fastening pad comprising a body and a hook extending from the body, and the cushion comprising a filament mesh structure, the filament mesh structure comprising a set of filaments of thermoplastic material, each member of the set of filaments being looped and connected to at least one other member of the set of filaments; actuating the hook with respect to the body; and releasing the hook, thereby allowing the hook to engage at least one member of the set of filaments and couple the fastening pad to the filament mesh structure. The method of claim 13, wherein actuating the hook bends at least a portion of the hook away from the body and releasing the hook allows at least a portion of the hook to bend toward the body. The method of claim 13, wherein engaging the attachment pad and the cushion further comprises engaging a first side of the body with the filament mesh structure and actuating the hook when the first side of the body engages the filament mesh structure [hooks are actuated when the attachment pad is flush with the cushion such that the attachment pad is firmly secured]. The method of claim 13, wherein actuating the hook further comprises pressing the hook into the filament mesh structure. The method of claim 13, wherein actuating the hook further comprises applying a force against the hook with a tool. The method of claim 17, wherein releasing the hook further comprises disengaging the tool from the hook. The method of claim 13, further comprising attaching a trim cover to the attachment pad after releasing the hook. The method of claim 19, wherein attaching the fairing cover to the attachment pad further comprises adhering the fairing cover to the body with an adhesive.

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