Seat arrangement and manufacturing process

Abstract

A product comprises a filament mesh member, a facing, and a hook and loop fastener system. The filament mesh member comprises a set of filaments made of thermoplastic material, each member of the set of filaments being bonded to at least one other member of the set of filaments. The facing is disposed over the filament mesh member. The hook and loop fastener system comprises a loop portion and a hook portion. One of the loop portion and the hook portion is attached to the filament mesh member. The other of the loop portion and the hook portion is attached to the facing. The loop portion and the hook portion cooperate to secure the facing to the filament mesh member.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Patent Application Serial No. 18 / 968,723, filed December 4, 2024, which in turn claims the benefit of U.S. Provisional Application Serial No. 63 / 619,049, filed January 9, 2024, and priority to Danish Application Serial No. PA 2024 70209, filed August 9, 2024, the disclosures of which are hereby incorporated by reference in their entirety. This application further claims priority to Danish Application Serial No. PA 202470209, filed August 9, 2024, which in turn claims priority to U.S. Provisional Application Serial No. 63 / 619,049, filed January 9, 2024, the disclosures of which are hereby incorporated by reference in their entirety. This application also claims priority to U.S. Provisional Application Serial No. 63 / 619,049, filed January 9, 2024, the disclosures of which are hereby incorporated by reference in their entirety. Technical field

[0002] This relates to a seat assembly with a cushion comprising a filament mesh structure and a manufacturing method. Short description of the drawings Fig. 1 is a perspective view of an example of a seat assembly having a filament mesh structure; Fig. 2 is a schematic view of an example of a manufacturing system for producing the filament mesh structure; Fig. 3A is an exploded view of examples of a cover and a cushion, the cushion comprising a filament mesh structure; Fig. Figure 3B is an enlarged view of area 3B of the Fig. 3A; Fig. Figure 4 is a perspective view of a portion of the trim panel separated from a portion of the cushion, showing a hook and loop fastener system for securing the trim panel to the cushion; Fig. 5 is a schematic view of a first system for attaching a first portion of the hook and loop fastener system to the panel and for attaching a second portion of the hook and loop fastener system to the cushion; Fig. 6 is a schematic view of a second system for attaching a first portion of the hook and loop fastener system to the panel and for attaching a second portion of the hook and loop fastener system to the cushion; Fig. 7 and Fig. 8 are schematic views of a retainer assembly used to secure the second portion of the hook and loop fastener system to the cushion; Fig. 9 is a schematic view of a third system for attaching a first portion of the hook and loop fastener system to the trim panel and for attaching a second portion of the hook and loop fastener system to the cushion; Fig. 10 is a perspective view of a clip for attaching the second portion of the hook and loop fastener system to the pillow; Fig. 11 is an end view of the Fig. 10 clips shown; Fig. 12 is a plan view of a portion of the Fig. 10 clips shown; Fig. 13 is a side view of a portion of the Fig. 10 clips shown; Fig. 14 is a flow diagram of a method for securing the cover to the cushion; Fig. 15 is a schematic view of a fourth system for attaching a first portion of the hook and loop fastener system to the trim panel and for attaching a second portion of the hook and loop fastener system to the cushion; and Fig. Figure 16 is a perspective view of the second portion of the hook and loop closure system as attached to the pillow. 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, processes, 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 minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art 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, e.g., in a distributed manner, 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 in some instances herein 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 similarly, 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 illustrated 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 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 elements.It is further to be understood that the terms "includes", "including", "comprises" and / or "comprising", when used in this specification, indicate 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] As used herein, the term "if" will be optionally interpreted to mean "when" or "after" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if determined" or "when [a specified condition or event] is detected" will be optionally interpreted to mean "after determining" or "in response to determining," or "after determining [the specified condition or event]" or "in response to detecting [the specified condition or event]," depending on the context.

[0009] With reference to the Fig. 1, an example of a seating assembly 10 is shown. In some embodiments, the seating assembly 10 is a vehicle seating assembly, for example, 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. For example, a seating assembly 10 for a land vehicle may 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 types. Furthermore, the seating assembly 10 may be a non-stowable seat or a stowable seat that may be 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 in the Fig. 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, for example, when the seat assembly 10 is configured as a motorcycle seat or as a stool.

[0011] The seat base 20 is configured to accommodate a seated user and support the pelvis and thighs of the seat user. The seat base 20 includes a seat base frame 30, a cushion 32, and a trim panel 34.

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

[0013] The cushion 32 is located on the seat base frame 30. The cushion 32 is made of a resilient material that supports the seat occupant and distributes loads from the seat occupant to the seat base frame 30. The cushion 32 and the related manufacturing processes are explained in more detail below.

[0014] The trim panel 34 covers at least a portion of the cushion 32. The trim panel 34 also provides one or more visible exterior surfaces of the seat back 22. The seat occupant may be located on the trim panel 34 when seated on the seat assembly 10. The trim panel 34 is constructed from one or more suitable materials, such as fabric, leather, leatherette, vinyl, or combinations thereof. The trim panel 34 may include a plurality of trim elements joined together in any suitable manner, such as by fusing or stitching. The trim panel 34 is attached to the seat bottom frame 30, the cushion 32, or both.For example, the trim panel 34 may include trim attachment features secured to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim panel 34 and to help conform the trim panel 34 to the contour of the seat bottom frame 30, the cushion 32, or both. The trim panel 34 may also be secured 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 located adjacent the seat bottom 20. For example, the seatback 22 may be located above the seat bottom 20 and near the rear of the seat bottom 20. The seatback 22 generally extends upwardly away from the seat bottom 20. In some configurations, the seatback 22 is mounted to the seat bottom 20 and may be pivotable with respect to the seat bottom 20. In other configurations, the seatback 22 is not mounted to the seat bottom 20. For example, a vehicle seatback may be mounted to the vehicle body, such as in some second-row seating assemblies. The seatback 22 includes a seatback frame 40, a cushion 42, a trim panel 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 members and may be constructed from any suitable material, such as a metal alloy, a polymeric material, a fiber-reinforced polymeric 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 located. It is also contemplated that the seatback frame 40 may be integrally formed with the seat bottom frame 30 in some configurations.

[0017] The cushion 42 is located on the seat back frame 40. The cushion 42 is made of a resilient material that supports the seat occupant and distributes load forces from the seat occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally molded 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 processes are discussed in more detail below.

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

[0019] The headrest 46, if present, is configured to support the head of a seat occupant. The headrest 46 is located 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. 2, the material feeder 70 contains a material supply to be extruded, such as solid beads, flakes, granules, pellets, or powder of the material. In some configurations, the material feeder 70 is configured as a container or hopper. The material feeder 70 supplies the material supply to the extruder 72.

[0021] The extruder 72 melts the material supply and extrudes the material supply 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 rotating screw and heating elements. The rotation of the screw forces the material to move through the barrel and, due to the friction created by the rotation of the screw, contributes to heating the material. 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.

[0022] The nozzle 80, which may also be referred to as a nozzle plate or extrusion nozzle, has several through-holes or filament formation orifices through which the molten material flows. A single filament 52 is extruded from each through-hole. The filaments 52 fall under gravity from the nozzle 80 down into the hopper 74.

[0023] The hopper 74 compacts or groups the filaments 52 into a more compact arrangement in which the filaments bend, curl, or loop, 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, separated filaments 52 enter the hopper inlet. The filaments 52 bend, curl, or loop, coming into contact 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 located on the hopper 74 as the filaments move toward the hopper outlet.At the contact points, bonds form between the filaments 52, while at other locations where one filament 52 is not touching or bonded to another filament 52, openings or voids exist between the filaments 52. The entangled and bonded filaments 52 pass through the hopper outlet of the hopper 74 and enter the cooling tank 76. For simplicity, the bonded filaments 52 are referred to as a mesh element or filament mesh structure 90.

[0024] The cooling tank 76 contains a liquid, such as water or a mixture of water and another liquid. The liquid in the 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 maintains a desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or drag, which may result in additional bending, curling, or looping of the filaments 52 adjacent to the surface of the liquid or within the hopper 74 to further build 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 externally to solidify the filaments 52 and prevent the filaments 52 from bonding at further locations. At this point, the filaments 52 are relatively stiff and no longer in a plastic state, and thus generally retain a shape and are not moldable or reshapable without reheating.

[0025] 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.

[0026] 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 may guide the filament mesh structure 90 to a conveyor 96 and a shaker table 98 located outside the cooling tank 76. The shaker table 98 shakes the filament mesh structure 90 while it is on the conveyor 96 to remove liquid. Alternatively or additionally, the filament mesh structure 90 may be compressed to remove liquid, air may be blown toward the filament mesh structure 90 to remove liquid from the filament mesh structure 90, or both. It is also contemplated that the filament mesh structure 90 may also be allowed to drain or dry in ambient air.

[0027] 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. After leaving the cooling tank 76, the filament mesh structure 90 is further processed to cut the filament mesh structure 90 into individual pieces or blanks for individual pillows. Such processing is performed by a cutting subsystem of the manufacturing system 60. 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.It is also contemplated that a blank may be further shaped or contoured by other manufacturing processes, such as by forming the entire blank or a portion thereof.

[0028] Referring to the Fig. 3A and Fig. 3B, an example of a cushion 50 is shown. The cushion is generally designated by reference numeral 50 for convenience. It should be understood that the structure and description of the cushion 50 is applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[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 mesh element, but may also be referred to as a strand element, loop element, entangled element, filament mesh structure, mesh structure, strand weave, loop weave, entangled mesh, or woven cushion. The cushion 50 will be described hereinafter in the context of a cushion 50 that does not include foam material. In this context, the cushion 50 is comprised of filaments 52 of polymeric material that are randomly looped, bent, crimped, or entangled and bonded together. One filament 52 is directly bonded to another filament 52 rather than indirectly bonded with a resin or other intermediate material.

[0030] The filaments 52, which may also be referred to as strands or threads, are made of any suitable material or materials. In some configurations, the filaments 52 are made of a polymeric material or thermoplastic material, such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin (e.g., polypropylene, polyethylene, etc.), polystyrene, or a combination thereof. As one example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material, unlike foam material, may be recyclable or more easily recyclable than foam material. It is also contemplated that a filament 52 may include reinforcing fibers, and that the reinforcing fibers may not be made of a thermoplastic material.

[0031] In some configurations, a filament 52 may be a monofilament composed of a single material. In some configurations, a filament 52 may be composed of multiple materials. For example, a multi-material filament 52 may include a core composed of a first thermoplastic material and a sheath surrounding the core composed of 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 multi-material filaments that are not monofilaments.

[0032] Filaments 52 that are randomly looped, bent, curled, or entangled are bonded together where one filament 52 contacts another filament 52, thereby forming a lightweight, breathable cushion (e.g., cushion 32 and / or 42) or a 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 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.

[0033] Referring to the Fig. 3A shows an exploded view of a portion of the seat assembly 10, including an example of the cushion 50 and an example of a trim panel 100. The trim panel 100 may be made of a fabric, textile, or woven material. The trim panel 100 may also be referred to as a cloth or fabric cover. The cushion 50 includes the filament mesh structure 90. Fig. 3A, the cushion 50 is shown without illustrating individual filaments 52 of the filament mesh structure 90 for clarity. In some configurations, the cushion 50 has a contoured outer surface 110. The contoured outer surface 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 outer surface 110 is concave or partially concave. The contoured outer surface 110 faces the trim panel 100. Furthermore, the contoured outer surface 110 may face a seat occupant. The contoured outer surface 110 may contact a portion of the trim panel 100 in one or more regions.

[0034] The trim panel 100 is generally designated by the reference numeral 100 for convenience. It is understood that the trim panel 100 may be the trim panel 34 of the seat bottom 20 or the trim panel 44 of the seat back 22, as previously described. A portion of the trim panel 100 is shown in the Fig. 3A to better visualize other features in this figure. The trim panel 100 is located over the cushion 50 comprising the filament mesh structure 90 and can generally follow the curvature or contour of the cushion 50 when attached thereto. The trim panel 100 and the cushion can together form a manufactured product, such as the vehicle seat bottom 20 or the vehicle seat back 22.

[0035] Referring to the Fig. 4, the cushion 50 comprising the filament mesh structure 90 and the panel 100 are shown separately to illustrate a fastening system 112 for securing the panel 100 to the filament mesh structure 90. More specifically, the fastening system 112 may be one or more hook and loop fastener systems (e.g., Velcro®). Each hook and loop fastener system includes a loop portion 114 and a hook portion 116. One of the loop portion 114 and the hook portion 116 is attached to the filament mesh structure 90, while the other of the loop portion 114 and the hook portion 116 is attached to the panel 100. The loop portion 114 and the hook portion 116 cooperate to secure the trim panel 100 to the filament mesh structure 90 to collectively form a product (e.g., the seat bottom 20 or the seat back 22).

[0036] It should be noted that the loop portion 114 is shown as being attached to the trim panel 100, while the hook portion 116 is shown as being attached to the filament mesh structure 90. This configuration may be preferred because the loop portion 114 (i) feels softer to a user contacting a product formed from the filament mesh structure 90 and the trim panel 100 (e.g., the seat bottom 20 or the seat back 22) and (ii) does not increase the rigidity of the trim panel 100. However, the alternative configuration may be used if desired (e.g., the hook portion 116 may be attached to the trim panel 100 and the loop portion 114 may be attached to the filament mesh structure 90).

[0037] The loop portion 114 may be attached to the liner 100 and the hook portion 116 may be attached to the filament mesh structure 90, or vice versa, using several systems or methods. In the descriptions of the various attachment systems or methods below, reference will be made to the loop portion 114 being attached to the liner 100 and the hook portion 116 being attached to the filament mesh structure 90. However, it should be understood that references to the loop portion 114 may be interchanged with references to the hook portion 116, and references to the hook portion 116 may be interchanged with references to the loop portion 114 for the alternative configuration in which the loop portion 114 may be attached to the filament mesh structure 90 and the hook portion 116 is attached to the liner 100.

[0038] In a first example of a fastening system or method disclosed in the Fig. 5, the loop portion 114 is attached to the panel 100 by a first adhesive 118, and the hook portion 116 is attached to the filament mesh structure 90 by a second adhesive 120. The first adhesive 118 and the second adhesive 120 may be spray adhesives, heat-activated adhesives, pressure-activated adhesives, epoxies, resins, light-curing adhesives (e.g., ultraviolet light-curing adhesives), or any other type of adhesive known in the art. For example, the adhesive may be the same material as the filament mesh structure 90 or another compatible material. Alternatively, the loop portion 114 may be attached to the panel 100, and the hook portion 116 may be attached to the filament mesh structure 90 by lamination or ultrasonic welding.The first adhesive 118 and the second adhesive 120 may be located along surfaces of the loop portion 114 and the hook portion 116, respectively, that engage the panel 100 and the filament mesh structure 90, respectively, opposite the surfaces of the loop portion 114 and the hook portion 116 that are configured to engage each other to secure the loop portion 114 to the hook portion 116.

[0039] A removable film of material may be applied over the first adhesive 118 and the second adhesive 120 on the loop portion 114 and the hook portion 116, respectively. Such removable films may protect the first adhesive 118 and the second adhesive 120 before the loop portion 114 and the hook portion 116 are secured to the panel 100 and the filament mesh structure 90, respectively. Before securing the loop portion 114 and the hook portion 116 to the panel 100 and the filament mesh structure 90, respectively, the removable films can be removed to expose the first adhesive 118 and the second adhesive 120, so that the first adhesive 118 and the second adhesive 120 can engage the panel 100 and the filament mesh structure 90, respectively, to secure the loop portion 114 and the hook portion 116 to the panel 100 and the filament mesh structure 90, respectively.

[0040] In a second example of a fastening system or method disclosed in the Fig. 6, the hook portion 116 is attached to the filament mesh structure 90 by means of one or more combinations of retainer 122 and connector 124. A single combination of retainer 122 and connector 124 may be referred to as a retainer assembly 130. Each of the connectors 124 extends from a back side of the hook portion 116 through the filament mesh structure 90 to a corresponding retainer 122. The retainers 122 engage an opposite side 126 of the filament mesh structure 90 relative to the fastening system 112 (e.g., the hook and loop fastener system). The fastening system 112 is disposed along a side 128 of the filament mesh structure 90 that is opposite the opposite side 126 of the filament mesh structure 90. The loop portion 114 may be in the Fig. 6 can be attached to the casing 100 in the same way as described above with respect to the Fig. 5 (e.g., the loop portion 114 may be attached to the panel 100 by any adhesive known in the art, by lamination, ultrasonic welding, etc.).

[0041] The Fig. 7 and Fig. 8 show a retainer assembly 130 in more detail. The retainer assembly 130 can be placed within the cushion 50 comprising the filament mesh structure 90. In the illustrated embodiment, the hook portion 116 can be attached to the retainer assembly 130, while the loop portion 114 can be attached to the panel 110. The connector 124 can be sewn to the hook portion 116. The connector 124 can also be sewn to the retainer 122. The connector 124 can be provided with a width that is less than the width of the hook portion 116. The retainer 122 can have a thickness that is less than the width of the retainer 122. The connector 124 extends through a slot 132 in the cushion 50 comprising the filament mesh structure 90. The connector 124 can be made of a textile material such as fabric, cloth, or the like.

[0042] The backside of the hook portion 116 may be connected to a plate (e.g., similar to the plate 404 discussed in relation to the fourth example of a fastening system or method) that serves to increase the rigidity of the hook portion 116. The hook portion 116 may be connected to such a plate by means of an adhesive or by means of threads (e.g., the hook portion 116 may be sewn to the plate). The plate, in turn, may be connected to the connector 124. Once installed, the plate may engage an exterior side (e.g., side 128) of the filament mesh structure 90.

[0043] The holder 122 may be provided with a width that is greater than the width of the connector 124. The holder 122 may be pivotally attached to the connector 124 and spaced from the hook portion 116. For example, the holder 122 and the hook portion 116 may be secured to opposite ends of the connector 124. The holder 122 may pivot outwardly of the cushion 50 comprising the filament mesh structure 90 such that the width of the holder 122 engages the seat of the cushion 50 comprising the filament mesh structure 90. The holder 122 holds the hook portion 116 on the cushion 50 comprising the filament mesh structure 90. The holder 122 may be made of a polymeric material.

[0044] Referring to the Fig. 7, the retainer assembly 130 is shown partially inserted into the cushion 50 comprising the filament mesh structure 90. The retainer 122 of the retainer assembly 130 collapses along the connector 124 of the retainer assembly 130. The retainer 122 and the connector 124 are then inserted into the slot 132 formed by the cushion 50 comprising the filament mesh structure 90. The retainer 122 can be slid through the cushion 50 comprising the filament mesh structure 90 with the connector 124 still at least partially located in the slot 132. The retainer 122 can then be expanded relative to the connector 124 into contact with a portion of the cushion 50 comprising the filament mesh structure 90 adjacent the slot 132 to retain the connector 124 in the slot 132. Fig. 8 shows the retainer assembly 130 fully inserted into the cushion 50 comprising the filament mesh structure 90, with the hook portion 116 and the retainer 122 disposed on and engaging opposite sides (e.g., side 128 and opposite side 126, respectively) of the cushion 50 comprising the filament mesh structure 90. Fig. 8 also shows the engagement between the loop portion 114 and the hook portion 116 to secure the cover 100 to the cushion 50 comprising the filament mesh structure 90.

[0045] In a third example of a fastening system or method disclosed in the Fig. 9, the hook portion 116 is attached to the filament mesh structure 90 by means of one or more hooks 233 that extend from a back side of the hook portion 116 into the filament mesh structure 90 and engage at least one filament 52 of the set of filaments 52. More specifically, the hooks 233 may extend from an opposite side of the hook portion 116 relative to the hooks configured to engage the loops of the loop portion 114. More specifically, the hooks 233 may be attached to and extend from a backing 235. The hook portion 116 is, in turn, connected to the backing 235. The hook portion 116 may be attached to the backing 235 by an adhesive (e.g., any adhesive described herein or known in the art), lamination, ultrasonic welding, etc.A surface of the carrier 235 opposite the hook 233 may be flush with an outer surface of the filament mesh structure 90 once installed thereon. The loop portion 114 may be in the . Fig. 9 can be attached to the casing 100 in the same way as described above with respect to the Fig. 5 (e.g., the loop portion 114 may be attached to the panel 100 by any adhesive known in the art, by lamination, ultrasonic welding, etc.). The hooks 233 and the carrier 235 may form portions of a clip 200 configured to secure the hook portion 116 to the filament mesh structure 90.

[0046] In the Fig. 10-13, the clip 200 is shown in more detail. The clip 200 includes a plurality of hooks 233 and supports 235. The clip 200 is configured to attach the hook portion 116 to a pad, such as a pad 50 comprising the filament mesh structure 90. The clip 200 is made of one or more suitable materials. In some configurations, the clip 200 is made of a polymeric material. The clip 200 may be made of the same material as the filaments 52 or a different material than the filaments 52. The polymeric material may be recyclable. The clip 200 is manufactured using any suitable method. For example, the clip 200 may be molded or manufactured using an additive manufacturing method such as 3D printing. It is contemplated that the clip 200 will be manufactured as a unitary one-piece component that can be cut to a suitable length for incorporation into the filament mesh structure 90.

[0047] The clip 200 includes one or more clip segments 210. In a configuration with multiple clip segments 210, a spine 212 is provided with the clip 200. In such a configuration, the spine 212 interconnects the clip segments 210. The clip segments 210 are spaced apart such that a gap 214 exists between one clip segment 210 and an adjacent clip segment 210. The clip 200 will be described primarily in the context of a clip 200 with multiple clip segments 210.

[0048] Referring to the Fig. 10 and Fig. 11, an example of a spine 212 is shown. The spine 212 is flexible and allows the positioning of the clip segments 210 in various orientations relative to one another. The spine 212 may be linear or extend along a linear spine axis 220 when the spine 212 is in a free state, as shown in FIG. Fig. 10. The spine 212 includes a bottom surface 230 and a top surface 232. The bottom surface 230 faces away from the clip segments 210. In some configurations, the bottom surface 230 extends the length of the clip 200. The top surface 232 is disposed opposite the bottom surface 230. Thus, the top surface 232 may face the clip segments 210. In some configurations, the top surface 232 is segmented and extends from one clip segment 210 to an adjacent clip segment 210 or is visible between adjacent clip segments 210, 210.

[0049] In the Fig. 10 and Fig. 11, the spine 212 is positioned below the clip segments 210. It is also contemplated that the spine 212 may be positioned at a higher level than shown in these figures. For example, the spine 212 may extend from a side of a first clip segment 210 facing an adjacent second clip segment 210 to a corresponding side of the adjacent clip segment 210 facing the first clip segment 210, rather than being disposed below one or more clip segments 210. For example, the spine 212 may extend from the Fig. 11 shown position so that the upper surface 232 in the Fig. 11 becomes the lower surface 230 and the upper surface 232 may be hidden behind the clip segment 210 from the perspective shown.

[0050] Mainly referring to the Fig. 11, a clip segment 210 includes at least one retention feature, such as one of the supports 235. The support 235 extends upwardly from the spine 212. In some configurations, the support 235 extends from a top surface 232 of the spine 212. The support 235 extends upwardly from the spine 212 over two posts 237, creating a cavity 239. In some configurations, the support 235 may extend directly upwardly from the spine 212, filling the cavity 239 and eliminating the posts 237.

[0051] The carrier 235 may extend away from the spine 212 in a first direction 252 along or relative to a center plane 254 of the clip segment 210. The center plane 254 may bisect the clip segment 210. The first direction 252 extends away from the spine 212 or from the Fig. 11 in an upward direction. The center plane 254 may extend through the spine 212. For example, the center plane 254 may bisect the spine 212. The center plane 254 may also bisect the carrier 235. The spine axis 220 may be arranged in the center plane 254 of a clip segment 210, for example, when the clip 200 is in a free state.

[0052] One or more barbs 242 are provided with a clip segment 210. The barbs 242 may correspond to the hooks 233. The barbs 242 extend from a carrier 235, the back 212, or both. Fig. 11, two barbs 242, 242 are shown, each barb 242 extending from the support 235 and the spine 212. In some configurations, the barbs 242 are spaced apart from the spine 212 and do not extend therefrom. In such a configuration, a barb 242 extends from a corresponding support 235 in a direction away from the central plane 254. Similarly, a barb 242 extending from the spine 212 may also extend in a direction away from the central plane 254.

[0053] A barb 242 is disposed in a non-parallel and non-perpendicular relationship to the medial plane 254. In addition, a barb 242 is oriented to extend away from the underside 230 of the spine 212 or out of the Fig. 11. Thus, a barb 242 extends in the first direction 252 as the distance from the ridge 212 increases. Thus, a barb 242 may extend farther from the bottom surface 230 as the barb 242 extends away from the ridge 212 and the midplane 254. In the configuration shown, the first barb 242 extends away from the second barb 242. Thus, the first barb 242 and the second barb 242 may extend in opposite directions to each other or with respect to the midplane 254.

[0054] A barb 242 may extend in a linear or non-linear manner from the bottom surface 230. In the Fig. 11, each barb 242 is shown extending along a respective barb axis 270. The barb axis 270 intersects the medial plane 254 at an acute angle 272, as shown in the Fig. 11 and can be viewed from above or in a plan view, as in the Fig. 12, be arranged substantially perpendicular to the midplane 254. The term "substantially perpendicular" is used herein to refer to features or axes that are perpendicular or nearly perpendicular, and includes features that are perpendicular to each other within ±3°. In some configurations, the barb axis 270 intersects the midplane 254 at a location that does not intersect the ridge 212, such as at a location along the beam 235. It is also contemplated that a barb 242 may be curved or extend in a non-linear manner. For example, a barb 242, or a portion thereof, may extend along an arc or curve that may be curved upward from the perspective shown or may be convex with respect to the ridge 212.

[0055] In some configurations, the barb 242 includes a top surface 280, a bottom surface 282, a first lateral side 284, and a second lateral side 286.

[0056] The top surface 280 faces away from the spine 212. In some configurations, the top surface 280 extends from a corresponding support 235. For example, the top surface 280 may intersect or extend from a corresponding support 235. The top surface 280 extends further away from the spine 212 the further the top surface 280 extends from a corresponding support 235 from which it originates. The top surface 280 may have a planar or a non-planar configuration.

[0057] The top surface 282 is opposite the bottom surface 280. Thus, the bottom surface 282 faces the spine 212. In some configurations, the bottom surface 282 extends from a corresponding support 235. In some configurations, the bottom surface 282 intersects or extends from the spine 212. The bottom surface 282 may have a planar or non-planar configuration. The bottom surface 282 extends farther from the spine 212 the farther the bottom surface 282 extends from a corresponding support 235 from which it originates. In some configurations, the bottom surface 282 is longer than the top surface 280.

[0058] In some configurations, the bottom surface 282 is substantially parallel to the top surface 280. As used herein, the term "substantially parallel" means the same as parallel or nearly parallel and includes features or axes that are within ±3° of each other. The bottom surface 282 does not intersect the top surface 280 when the bottom surface 282 is substantially parallel to the top surface 280. In some configurations, the bottom surface 282 and the top surface 280 are arranged in a non-parallel relationship. For example, the bottom surface 282 and the top surface 280 may become closer together as the distance from the midplane 254 increases. In some configurations, it is contemplated that the bottom surface 282 may intersect the top surface 280, for example, at a distal end of the barb 242.

[0059] With reference to the Fig. 11-13, the first lateral side 284 extends from a corresponding support 235. The first lateral side 284 extends from the top side 280 to the bottom side 282. As best shown in the Fig. 12, the first lateral side 284 extends toward the second lateral side 286 as the distance from the midplane 254 increases. For example, the first lateral side 284 may extend toward or approach a corresponding barb axis 270 as the distance from the midplane 254 increases. It is contemplated that the first lateral side 284 may be planar or non-planar.

[0060] The second lateral side 286 extends from a corresponding support 235 and is opposite the first lateral side 284. The second lateral side 286 extends from the top surface 280 to the bottom surface 282. The second lateral side 286 extends toward the first lateral side 284 as the distance from the midplane 254 increases. For example, the second lateral side 286 may extend toward or approach a corresponding barb axis 270 as the distance from the midplane 254 increases. Such a configuration facilitates installation of the clip 200 in the cushion 50. It is contemplated that the second lateral side 286 may be planar or non-planar.

[0061] In some configurations, the first lateral side 284 intersects the second lateral side 286 at a distal end 292 of the barb 242. This may result in a barb 242 having a triangular configuration when viewed from above if the first lateral side 284 and the second lateral side 286 have planar configurations that are vertically oriented, as best shown in the Fig. 12. It is also contemplated that the distal end 292 may be rounded or radiused rather than meeting along a linear edge.

[0062] Insertion of the clip 200 into the filament mesh structure 90 causes the barbs 242 to engage the filaments 52 such that at least some of the filaments 52 contact a barb 242 and the barb 242 becomes entangled in the filaments 52 such that the clip 200 is retained in the filament mesh structure 90. At least a portion of a barb 242 is received in a cavity or gap between members of the set of filaments 52. The barb 242 contacts one or more members of the set of filaments 52.

[0063] Due to the looping or crimping of the filaments 52, a filament 52 may contact the clip 200 at various locations. In some configurations, at least one member of the set of filaments 52 contacts the first and second barbs 242, 242 of a clip segment 210.

[0064] In some configurations, at least one member of the set of filaments 52 contacts more than one clip segment 210. For example, a clip segment 210 may be inserted into a slot defined by the filament mesh structure 90. At least one member of the set of filaments 52 contacts a first clip segment 210 and a second clip segment 210. The filaments 52 may loop or curl around and contact a barb 242 of the first clip segment 210 and a barb 242 of the second clip segment 210; however, it should be understood that the filaments 52 need not form a closed loop around or enclose one or both of the barbs 242. For example, a filament 52 may extend over a barb 242 and engage the top surface 280, may contact another side of a barb 242, or combinations thereof.For example, a filament contacting the bottom surface 282 of a barb 242 may help limit downward movement or tilting of the clip 200, a filament contacting a lateral side of a barb 242, such as the first lateral side 284 or the second lateral side 286, may prevent or limit movement of the clip 200 in at least one direction along or within the slot.

[0065] Referring to the Fig. 14 is a flowchart of a method 300 for securing the trim panel 100 to the cushion 50 comprising the filament mesh structure 90. The method 300 begins at block 302, where a first portion (e.g., one of the loop portion 114 and the hook portion 116) of a hook and loop fastener system (e.g., the fastening system 112) is attached to a filament mesh element (e.g., the filament mesh structure 90). Next, the method 300 proceeds to block 304, where a second portion (e.g., the other of the loop portion 114 and the hook portion 116) of the hook and loop fastener system is attached to a trim panel (e.g., the trim panel 100). The method 300 then proceeds to block 306 in which the first portion (e.g., one of the loop portion 114 and the hook portion 116) of the hook and loop fastener system is connected to the second portion (e.g.,the other of the loop portion 114 and the hook portion 116) of the hook and loop fastener system to secure the panel (e.g., panel 100) to the filament mesh member (e.g., filament mesh structure 90) to form a product (e.g., seat bottom 20 or seat back 22). It is understood that the flowchart in FIG. Fig. 14 is for illustrative purposes only and that the method 300 is not to be considered as limited to the flowchart in the Fig. 14 should be interpreted in a limited manner. Some of the steps of method 300 may be rearranged, while others may be omitted entirely.

[0066] In a fourth example of a fastening system or method disclosed in the Fig. 15 and Fig. 16, the hook portion 116 is attached to the filament mesh structure 90 by means of a clip 400. The clip 400 includes one or more first hooks 402 extending from a rear side of the hook portion 116 into the filament mesh structure 90 and engaging at least one filament 52 of the set of filaments 52. More specifically, the one or more first hooks 402 may extend from an opposite side of the hook portion 116 relative to the hooks configured to engage the loops of the loop portion 114. The rear side of the hook portion 116 may be connected to a plate 404 that serves to increase the rigidity of the hook portion 116. The hook portion 116 may be connected to the plate 404 by means of an adhesive or by means of a thread (e.g., the hook portion 116 may be sewn to the plate 404).The plate 404 may in turn be connected to a connector 406 containing a bead 408. The connector 406 may in turn be connected to the clip 400 to secure the hook portion 116 to the clip 400 connected to the filament mesh structure 90. The connector 406 extends through a slot 407 in the pad 50 encompassing the filament mesh structure 124.

[0067] Once installed, the plate 404 may engage an outer surface 410 of the filament mesh structure 90. The connector 406 may be directly connected to the plate 404 and may be secured to the clip 400 by one or more second hooks 412 extending from the clip 400. More specifically, the one or more second hooks 412 may engage the bead 408 on the connector 406. The connector may be made of a plastic material (e.g., Duon® with beads). The clip 400 may include a series of one or more first hooks 402 and one or more second hooks 412 connected together by a spine 414 to form a rattlesnake configuration.

[0068] The loop section 114 can be in the Fig.15 may be attached to the panel 100 in the same manner as described above with respect to Figure 100 (e.g., the loop portion 114 may be attached to the panel 100 by any adhesive known in the art, by lamination, ultrasonic welding, etc.).

[0069] Set 1. A product comprising: a filament mesh member comprising a set of filaments of thermoplastic material, each member of the set of filaments being bonded to at least one other member of the set of filaments; a facing disposed over the filament mesh member; and a hook and loop fastening system comprising a loop portion and a hook portion, wherein (i) one of the loop portion and the hook portion is attached to the filament mesh member and (ii) the other of the loop portion and the hook portion is attached to the facing, the loop portion and the hook portion cooperating to secure the facing to the filament mesh member.

[0070] Clause 2. The product according to clause 1, wherein one of the loop portion and the hook portion is attached to the filament mesh member by means of an adhesive.

[0071] Clause 3. The product of any one of clauses 1 to 2, wherein the other of the loop portion and the hook portion is attached to the panel by means of an adhesive.

[0072] Clause 4. The product of clause 1, wherein the one of the loop portion and the hook portion is attached to the filament mesh member by means of one or more hooks extending from a back side of the one of the loop portion and the hook portion into the filament mesh member and engaging at least one filament of the set of filaments.

[0073] Clause 5. The product of any one of clauses 1 to 4, wherein the other of the loop portion and the hook portion is attached to the panel by means of an adhesive.

[0074] Clause 6. The product of clause 1, wherein the one of the loop portion and the hook portion is attached to the filament mesh member via a retainer and a connector, wherein (i) the connector extends from a back side of the one of the loop portion and the hook portion (ii) through the filament mesh member and (iii) to the retainer which engages an opposite side of the filament mesh member relative to the hook and loop fastener system.

[0075] Clause 7. The product of any one of clauses 1 or 6, wherein the other of the loop portion and the hook portion is attached to the panel by means of an adhesive.

[0076] Sentence 8. The product according to any one of sentences 1 to 7, wherein the product is a vehicle seat bottom.

[0077] Sentence 9. The product according to any one of sentences 1 to 7, wherein the product is a vehicle seat back.

[0078] Set 10. A fastening system comprising: a hook portion attached to one of the filament mesh member and a sheet, the filament mesh structure comprising a set of filaments, each member of the set of filaments being connected to at least one other member of the set of filaments; and a loop portion attached to the other of the filament mesh member and the sheet, the loop portion and the hook portion cooperating to secure the sheet to the filament mesh member.

[0079] Clause 11. The fastening system of clause 10, wherein (i) the hook portion is attached to one of the filament mesh member and the sheet by a first adhesive and (ii) the loop portion is attached to the other of the filament mesh member and the sheet by a second adhesive.

[0080] Clause 12. The fastening system of clause 10, wherein the one of the loop portion and the hook portion is attached to the filament mesh member by means of one or more hooks extending from a back side of the one of the loop portion and the hook portion into the filament mesh member and engaging at least one filament of the set of filaments.

[0081] Clause 13. The fastening system of clause 10, wherein the one of the loop portion and the hook portion is attached to the filament mesh member via a retainer and a connector, wherein (i) the connector extends from a back side of the one of the loop portion and the hook portion (ii) through the filament mesh member and (iii) to the retainer which engages an opposite side of the filament mesh member relative to the hook and loop fastener system.

[0082] Clause 14. The fastening system of any one of clauses 10 to 13, wherein the filament mesh member and the sheet together form a vehicle seat bottom.

[0083] Clause 15. The fastening system of any one of clauses 10 to 13, wherein the filament mesh member and the sheet together form a vehicle seat back.

[0084] Clause 16. A method comprising: engaging a first portion of a hook and loop fastener system with a second portion of the hook and loop fastener system to secure a fabric cover to a filament mesh member comprising a set of filaments of thermoplastic material, each member of the set of filaments being connected to at least one other member of the set of filaments.

[0085] Clause 17. The method of clause 16 further comprising attaching the first portion of the hook and loop fastener system to the filament mesh member prior to engaging the first portion with the second portion.

[0086] Clause 17. The method of any one of clauses 16 to 17 further comprising attaching the second portion of the hook and loop fastener system to the fabric cover prior to engaging the first portion with the second portion.

[0087] Clause 19. The method of any one of clauses 16 to 18, wherein the method comprises forming a vehicle seat bottom by the engagement between the first portion of the hook and loop fastener system and the second portion of the hook and loop fastener system.

[0088] Clause 20. The method of any one of clauses 16 to 18, wherein the method comprises forming a vehicle seat back by the engagement between the first portion of the hook and loop fastener system and the second portion of the hook and loop fastener system.

[0089] It is understood that the designations "first," "second," "third," "fourth," etc., for each component, state, or condition described herein may be rearranged in the claims so that they are in chronological order with respect to the claims. Furthermore, it is understood that each component, state, or condition described herein that does not have a numerical designation may be designated "first," "second," "third," "fourth," etc., in the claims if one or more of the specific components, states, or conditions are claimed.

[0090] Although exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms according to the disclosure. In this regard, 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 disclosure. Furthermore, the features of various implementing embodiments may be combined to form further embodiments according to the disclosure. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 18 / 968,723

[0001] US 63 / 619.049

[0001] PA 2024 70209

[0001]

Claims

[1] A product comprising: a filament mesh element comprising a set of filaments of thermoplastic material, each member of the set of filaments being connected to at least one other member of the set of filaments; a covering disposed over the filament mesh element; and a hook and loop fastener system comprising a loop portion and a hook portion, wherein (i) one of the loop portion and the hook portion is attached to the filament mesh member and (ii) the other of the loop portion and the hook portion is attached to the panel, the loop portion and the hook portion cooperating to secure the panel to the filament mesh member. [2] The product according to claim 1, wherein one of the loop portion and the hook portion is fixed to the filament mesh member by means of an adhesive. [3] The product according to claim 1 or 2, wherein the other of the loop portion and the hook portion is attached to the panel by means of an adhesive. [4] The product according to any one of the preceding claims, wherein one of the loop portion and the hook portion is attached to the filament mesh element by means of one or more hooks extending from a rear side of one of the loop portion and the hook portion into the filament mesh element and engaging at least one filament of the set of filaments. Preferably, the other of the loop portion and the hook portion is attached to the liner by means of an adhesive. [5] The product according to any one of the preceding claims, wherein the one of the loop portion and the hook portion is attached to the filament mesh member via a retainer and a connector, wherein (i) the connector extends from a rear side of the one of the loop portion and the hook portion (ii) through the filament mesh member and (iii) to the retainer which engages an opposite side of the filament mesh member relative to the hook and loop fastener system, preferably the other of the loop portion and the hook portion is attached to the panel by means of an adhesive. [6] The product according to any one of the preceding claims, wherein the product is a vehicle seat bottom, or wherein the product is a vehicle seat back. [7] A fastening system comprising: a hook portion attached to one of the filament mesh element and a sheet, wherein the filament mesh structure comprises a set of filaments, each element of the set of filaments being connected to at least one other element of the set of filaments; and a loop portion attached to the other of the filament mesh member and the sheet, the loop portion and the hook portion cooperating to secure the sheet to the filament mesh member. [8] The fastening system of claim 7, wherein (i) the hook portion is attached to one of the filament mesh member and the sheet by a first adhesive and (ii) the loop portion is attached to the other of the filament mesh member and the sheet by a second adhesive. [9] The fastening system according to claim 7 or 8, wherein the one of the loop portion and the hook portion is attached to the filament mesh member by means of one or more hooks extending from a back side of the one of the loop portion and the hook portion into the filament mesh member and engaging at least one filament of the set of filaments. [10] The fastening system according to any one of claims 7 to 9, wherein the one of the loop portion and the hook portion is attached to the filament mesh member via a retainer and a connector, wherein (i) the connector extends from a back side of the one of the loop portion and the hook portion (ii) through the filament mesh member and (iii) to the retainer which engages an opposite side of the filament mesh member relative to the hook and loop fastener system. [11] The fastening system according to any one of claims 7 to 10, wherein the filament mesh element and the sheet together form a vehicle seat bottom, or wherein the filament mesh element and the sheet together form a vehicle seat back. [12] A method comprising: engaging a first portion of a hook and loop fastener system with a second portion of the hook and loop fastener system to secure a fabric cover to a filament mesh member comprising a set of filaments of thermoplastic material, each member of the set of filaments being connected to at least one other member of the set of filaments. [13] The method of claim 12, further comprising attaching the first portion of the hook and loop fastener system to the filament mesh member prior to engaging the first portion with the second portion. [14] The method of claim 12 or 13, further comprising attaching the second portion of the hook and loop fastener system to the fabric cover prior to engaging the first portion with the second portion. [15] The method of any one of claims 12 to 14, wherein the method comprises forming a vehicle seat bottom by the engagement between the first portion of the hook and loop fastener system and the second portion of the hook and loop fastener system, or wherein the method comprises forming a vehicle seat back by the engagement between the first portion of the hook and loop fastener system and the second portion of the hook and loop fastener system.

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