Seat assembly and seat assembly method

Abstract

To provide a seat assembly and a seat assembly method.SOLUTION: A seat assembly comprises a cushion, an attachment pad, and a trim cover. The cushion has a filament mesh structure having a set of filaments. The attachment pad is connected to the filament mesh structure. The trim cover is attached to the attachment pad.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] This application claims the benefit of U.S. Patent Application No. 18 / 952,450, filed on November 19, 2024, which claims the benefit of U.S. Provisional Application No. 63 / 603,686, filed on November 29, 2023, the entire disclosure of which is incorporated herein by reference. This application relates to a sheet assembly and an assembly method.

Summary of the Invention

Means for Solving the Problems

[0002] According to one aspect of the present invention, there is provided a cushion comprising a filament mesh structure having a set of filaments of a thermoplastic material, each member of the set of filaments being looped and coupled to at least one other member of the set of filaments, a body, and a set of hooks extending from the body and coupled to the filament mesh structure, wherein the body is disposed on a contoured outer portion of the filament mesh structure, and a trim cover attached to the attachment pad.

[0003] According to another aspect of the present invention, there is provided an engaging step of engaging an attachment pad and a cushion, the attachment pad comprising a body and a hook extending from the body, the cushion comprising a filament mesh structure having a set of filaments of a thermoplastic material, each member of the set of filaments being looped and coupled to at least one other member of the set of filaments, an operating step of operating the hook with respect to the body, and a releasing step of releasing the hook, whereby the hook captures at least one member of the set of filaments and attaches the attachment pad to the filament mesh structure.

Brief Description of the Drawings

[0004]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

DETAILED DESCRIPTION OF THE INVENTION

[0005] Here, embodiments will be referred to in detail, and examples of the embodiments are shown in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments can be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks are not described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0006] It should be understood that the disclosed embodiments are merely illustrative and that various alternatives are possible. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but should be interpreted only as a representative basis for one of ordinary skill in the art to variously practice embodiments in accordance with the disclosure.

[0007] "One or more" includes functions performed by one element, functions performed by a plurality of elements, e.g., in a distributed fashion, some functions performed by one element, some functions performed by a plurality of elements, or any combination of the above.

[0008] The terms first, second, etc. are used herein in some instances to describe various elements, but it should also be understood that these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of the various embodiments described, a first contact can be referred to as a second contact, and similarly, a second contact can be referred to as a first contact. The first contact and the second contact are both contacts, but they are not the same contact.

[0009] In the description of the various embodiments described herein, the terms are used for the purpose of describing only specific embodiments and are not intended to be limiting. As used in the description of the various embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and / or" as used herein refers to any and all possible combinations of one or more of the associated listed items and is also to be understood to encompass such combinations. The terms "includes", "including", "comprises", and / or "comprising", when used herein, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0010] As used herein, the term "if" is optionally interpreted, depending on the context, to mean "when" or "in response to a determination" or "in response to a detection". Similarly, the phrases "if determined" or "if [stated condition or event] is detected" are optionally interpreted, depending on the context, to mean "in response to a determination" or "in response to a determination" or "when [stated condition or event] is detected" or "when [stated condition or event] is detected".

[0011] Referring to FIG. 1, an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for a land vehicle such as an automobile, truck, bus, or a non-land vehicle such as an aircraft or a ship. For example, the seat assembly 10 for a land vehicle can have a shape and size as a front-row driver's seat or passenger seat, a second-row, third-row, or other rear-row seat, and can include a bucket-style seat, a bench-style seat, or other seat styles as shown. Further, the seat assembly 10 can be a non-foldable seat or a foldable and stowable seat that can be stowed in a cavity within the vehicle floor. Additionally, the seat assembly 10 can be configured for non-vehicle applications such as furniture.

[0012] In the configuration shown in FIG. 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. In some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or a stool, it is conceivable that the seat back 22 may be omitted.

[0013] The seat bottom 20 is configured to receive a seated occupant and support the occupant's pelvis and thighs. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover 34.

[0014] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 can include one or more structural members and can be made of any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In some configurations, the seat bottom frame 30 includes a panel on which the cushion 32 is disposed, a seat pan, a suspension mat, or a suspension wire.

[0015] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made of a flexible material that supports the seat occupant and distributes the load from the seat occupant to the seat bottom frame 30. The cushion 32 and related manufacturing methods are described in more detail below.

[0016] The trim cover 34 covers at least a portion of the cushion 32. Further, the trim cover 34 provides one or more visible outer surfaces of the seat back 22. The seat occupant can be disposed on the trim cover 34 when seated on the seat assembly 10. The trim cover 34 is made of any suitable material or materials such as cloth, leather, leatherette, vinyl, or combinations thereof. The trim cover 34 can include a plurality of trim panels assembled by any suitable method such as 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 can include trim attachment features that are attached to the seat bottom frame 30, the cushion 32, or both to prevent removal of the trim cover 34 and to help conform the trim cover 34 to the contours of the seat bottom frame 30, the cushion 32, or both. The trim cover 34 can also be attached to an attachment pad as described in more detail below.

[0017] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat bottom 20. For example, the seat back 22 may be disposed above the seat bottom 20 and near the rear side of the seat bottom 20. The seat back 22 extends generally upwardly away from the seat bottom 20. In some configurations, the seat back 22 may be attached to the seat bottom 20 and be rotatable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, a vehicle seat back may be attached to the vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a trim cover 44, and optionally a headrest 46.

[0018] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and may be made of any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In some configurations, the seat back frame 40 includes a panel, pan, suspension mat, or suspension wire on which the cushion 42 is disposed. Also, the seat back frame 40 may be integrally formed with the seat bottom frame 30 in some configurations.

[0019] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made of a flexible material that supports the seat occupant and distributes the load from the seat occupant to the seat back frame 40. The cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separated from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods are described in more detail below.

[0020] The trim cover 44 covers at least a portion of the cushion 42. Further, the trim cover 44 provides one or more visible outer surfaces of the seat back 22. A seat occupant may be disposed on the trim cover 44 when seated on the seat assembly 10. The trim cover 44 is made of any suitable material or combination of materials, such as cloth, leather, leatherette, vinyl, or combinations thereof. The trim cover 44 may include one or more trim panels assembled in any suitable manner, such as by fusing or stitching. The trim cover 44 is attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include trim attachment features attached to the seat back 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 contours of the seat back frame 40, the cushion 42, or both. The trim cover 44 may be attached to the attachment pad as described in more detail below.

[0021] The headrest 46, when provided, is configured to support the head of a seat occupant. The headrest 46 is located at the top of the seat back 22 or at an end of the seat back 22 on the side opposite the seat bottom 20. The headrest 46 may be movable relative to the seat back 22 in one or more directions or may be integrally formed with the seat back 22.

[0022] Referring to FIG. 3, an example of a cushion 50 is shown. The cushion is generically designated by reference numeral 50 for convenience of reference. 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.

[0023] The cushion 50 is either a non-foamed component or includes at least one non-foamed component. The non-foamed component is mainly called a filament mesh structure, but may also be called a mesh cushion, a mesh structure, or a more chain-like mesh. In FIG. 3, the cushion 50 is shown as a non-foamed component that does not include a foamed component or foamed material such as urethane foam or polyurethane foam. However, the cushion 50 may include a foamed component or foamed material in addition to the non-foamed component to provide additional cushioning or local cushioning for the seat occupant. For example, the foamed material may be provided between the cushion 50 and a trim cover (e.g., trim covers 34, 44) disposed on the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foamed material provided to the cushion 50 or removing the foamed material from the cushion 50 can reduce weight and improve the support and comfort of the seat occupant. Further, removing the foamed material can facilitate the recycling of the cushion 50.

[0024] The cushion 50 is described below in relation to a cushion 50 that does not include a foamed material. In this context, the cushion 50 is made of filaments 52 of a polymeric material that are randomly looped, bent, curled, or intertwined and bonded to each other as described in detail below. Examples of the filaments 52 are shown in FIGS. 6-9. The filaments 52 are directly bonded to another filament 52 rather than indirectly bonded to a resin or other intermediate material.

[0025] The filament 52, also referred to as a strand or thread, is made of any suitable material or materials. In some configurations, the filament 52 is made of a polymeric material or a thermoplastic material such as a thermoplastic resin based on polyamide, polyester, polyimide, polyolefin (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene, or combinations thereof. As an example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material is recyclable, unlike the foamed material, or may be recycled more easily than the foamed material. It is also conceivable that the filament 52 includes reinforcing fibers and the reinforcing fibers need not be made of a thermoplastic material.

[0026] In some configurations, the filament 52 may be a monofilament made of a single material. In some configurations, the filament 52 is made of multiple materials. As an example, the filament 52 made of multiple materials can include a core made of a first thermoplastic material and a sheath that surrounds the core and is made of a second thermoplastic material different from the first thermoplastic material. The cushion 50 can include a combination of a monofilament and a filament made of multiple materials and not a monofilament.

[0027] The randomly looped, bent, looped, curled, or intertwined filaments 52 are joined together where one filament 52 contacts another filament 52, thereby creating a lightweight and air-permeable cushion (e.g., cushions 32 and / or 42) or a mesh structure having openings or voids between the filaments 52. An example of a manufacturing system 60 for manufacturing a cushion or a 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 funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0028] Referring to FIG. 2, the material supply 70 holds the material stock to be extruded, such as solid beads, flakes, granules, pellets, or powder made from the material. In some configurations, the material supply 70 is configured as a container or hopper. The material supply 70 supplies the material stock to the extruder 72.

[0029] The extruder 72 melts the material stock and extrudes the material stock into a set of filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel that receives a rotatable screw and a heating element. The rotation of the screw moves the material through the barrel and helps heat the material by the friction generated as the screw rotates. The material exits the barrel in a molten state under pressure and is transported under pressure to the die 80 of the extruder 72.

[0030] The die 80, also referred to as a die plate or extrusion die, has a plurality of through holes or filament-forming openings through which the molten material passes. A single filament 52 is extruded from each through hole. The filaments 52 fall downward from the die 80 into the funnel 74 under gravity.

[0031] The funnel 74 integrates or groups the filaments 52 into a more compact arrangement where the filaments bend, curl, or loop and where the filament 52 contacts and bonds to at least one other filament 52. The funnel 74 has an inlet opening or funnel inlet and an outlet opening or funnel outlet that is smaller than the funnel inlet. The individual separate filaments 52 enter the funnel inlet. The filaments 52 bend, curl, or loop and move so as to contact as they accumulate. The filaments 52 move through the funnel 74 toward the funnel outlet. As the filaments move toward the funnel outlet, some of the filaments can slide along the funnel 74 or an intervening sheet disposed on the funnel 74. Bonds are formed between the filaments 52 at the contact points while openings or voids between the filaments 52 are present at other locations where one filament 52 does not contact or bond to another filament 52. The intertwined and bonded filaments 52 enter the cooling tank 76 through the funnel outlet of the funnel 74. For purposes of reference, the bonded filaments 52 are referred to as a filament mesh structure 90.

[0032] The cooling tank 76 holds a liquid such as water or a mixture of water and another fluid. The liquid within the cooling tank 76 serves to support the intertwined and bonded filaments 52, limit further compression or consolidation of the filaments 52, and maintain the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance that can further bend, curl, or loop the filaments 52 adjacent to the surface of the liquid or within the funnel 74 to further build the filament mesh structure 90. Also, the liquid cools the filaments 52 when the filaments 52 are within 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 at additional locations. At this point, the filaments 52 are relatively rigid and no longer in a plastic state and thus generally maintain their shape and cannot be molded or remolded without reheating.

[0033] 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 in and out of the liquid. In some configurations, a tractor conveyor 92 is provided within the cooling tank 76 to help pull the filament mesh structure 90 away from the funnel 74 and counteract the buoyancy of the filament 52.

[0034] 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, roller 94 can guide the filament mesh structure 90 towards a conveyor belt 96 and a shaker table 98 disposed outside the cooling tank 76. The shaker table 98 shakes the filament mesh structure 90 while it is on the conveyor belt 96 to remove the liquid. Alternatively, or in addition, the filament mesh structure 90 can be squeezed to remove the liquid, air can be blown towards the filament mesh structure 90 to help remove the liquid from the filament mesh structure 90, or both. Also, the filament mesh structure 90 can be drip-dried or dried in the ambient air.

[0035] The above manufacturing system 60 is a continuous flow process, and when the extrusion of the filament is not interrupted, the filament mesh structure 90 is formed as a continuous structure. Further processing of the filament mesh structure 90 is performed after exiting the cooling tank 76, and the filament mesh structure 90 is cut into individual pieces or blanks for individual cushions. Such processing is performed by the cutting subsystem of the manufacturing system 60. The cutting system may be of any suitable type. For example, the cutting system can use a blade, knife, hot knife, saw, fluid jet, etc. to cut the filaments 52 of the filament mesh structure 90 into blanks. The cutting system may be used to shape or contour the blanks. The blanks may be further shaped or contoured by other manufacturing processes such as shaping the entire blank or a part thereof.

[0036] Referring to FIG. 3, an exploded view of a portion of a seat assembly 10 including an example of a cushion 50, an example of a trim cover 100, and an example of a mounting pad 102 is shown.

[0037] The cushion 50 includes a filament mesh structure 90. In FIG. 3, for clarity, the cushion 50 is shown without showing the individual filaments 52 of the filament mesh structure 90. In some configurations, the cushion 50 has a contoured outer portion 110. The contoured outer portion 110 can have a partially or fully non-planar shape and can include one or more curved surfaces or curved surface regions. In some configurations, the contoured outer portion 110 is concave or partially concave. The contoured outer portion 110 faces the trim cover 100 and the mounting pad 102. Further, the contoured outer portion 110 may face the seat occupant. The contoured outer portion 110 may contact a part of the trim cover 100 in one or more regions where the mounting pad 102 is not sandwiched between the trim cover 100 and the cushion 50 and the trim cover 100 is not separated from the cushion 50.

[0038] The trim cover 100 is generally denoted by reference numeral 100 for convenience of reference. It should be understood that the trim cover 100 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22 as described above. A part of the trim cover 100 is shown in FIG. 3 to make other features of this figure clearer. The trim cover 100 may be attached to the attachment pad 102, and generally, it may be along the curvature or contour of the attachment pad 102, or the side surface of the attachment pad 102 facing away from the cushion 50.

[0039] The attachment pad 102 is disposed between the cushion 50 and the trim cover 100. In some configurations, the attachment pad 102 extends from the cushion 50 to the trim cover 100. For example, the attachment pad 102 may extend from the contoured outer portion 110 to the side surface of the trim cover 100 facing the contoured outer portion 110. Also, other components such as a heating pad may be disposed between the trim cover 100 and the attachment pad 102.

[0040] Referring to FIG. 4, a plan view of an example of the attachment pad 102 is shown. The attachment pad 102 includes a body 120 and a set of hooks 122.

[0041] The body 120 is configured to support the seat occupant and facilitate attachment of the trim cover 100 to the cushion 50. The body 120 may be a solid or hollow panel, layer, or assembled layers. The body 120 may be composed of multiple parts or may be configured as a single one-piece component made of any suitable material or materials. For example, the body 120 may be composed of a polymeric material such as a thermoplastic resin, such as polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or combinations thereof. In some configurations, the body 120 is composed of the same material as the filament 52. In other configurations, the body 120 is composed of a material different from the filament 52 but is sufficiently similar to the material of the cushion 50 so that the cushion 50 and the attachment pad 102 can be recycled together without disassembling. For example, the trim cover 100 may be removed from the attachment pad 102, and the cushion 50 and the body 120 may be ground or shredded together for recycling without removing the attachment pad 102 from the cushion 50.

[0042] Referring to FIGS. 3 and 4, in some configurations, the body 120 is disposed on the contoured outer portion 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 portion 110 and may not be disposed inside the filament mesh structure 90. The body 120 may extend along the side surfaces of the filaments 52 that constitute the contour of the cushion 50 and the contoured outer portion 110, and may extend from filament 52 to filament 52, thereby bridging the gaps between adjacent filaments 52 and following the outer contour of the cushion 50 without extending into the filament mesh structure 90. In some configurations, the body 120 may not be disposed inside a groove, hole, or groove extending from the contoured outer portion 110 into the filament mesh structure 90, for example, a groove, hole, or groove cut into the filament mesh structure 90, or a groove, hole, or groove formed as a local depression in the filament mesh structure 90 extending from the contoured outer portion 110. In some configurations, the body 120 includes a first side 130, a second side 132, and a plurality of openings 134 and / or 134'.

[0043] Primarily referring to FIG. 3, the first side 130 faces the cushion 50. For example, the first side 130 may face the contoured outer portion 110 of the cushion 50. As such, the first side 130 faces away from the trim cover 100 and may engage or contact the contoured outer portion 110. The first side 130 may follow the contour of the contoured outer portion 110. As such, the first side 130 may be disposed substantially parallel to the contoured outer portion 110. As used herein, the term "substantially parallel" means the same as or very nearly parallel, including features or axes within ±3° of being parallel to each other. In some configurations, the first side 130 or a portion thereof may be non-planar.

[0044] The second side 132 is disposed on the opposite side of the first side 130. In some configurations, the second side 132 engages or contacts the trim cover 100. The second side 132 can also follow the contour of the outer portion 110 having the contour of the cushion 50. For example, the second side 132 may be disposed substantially parallel to the contoured outer portion 110, the first side 130, or both.

[0045] Referring mainly to FIG. 4, a plurality of openings 134, 134' are defined by the body 120. The openings 134, 134' extend from the first side 130 to the second side 132 and may be referred to as openings, holes, or windows. In some configurations, the opening 134 may be configured as a through-hole surrounded by the body 120. In FIG. 4, nine openings 134 having such a configuration are illustrated. However, it is contemplated that more or fewer openings 134 may be provided. These openings 134 are spaced apart from around the body 120. In some configurations, the opening 134' may be disposed along the perimeter of the body 120. In such a configuration, the opening 134' may extend from the first side 130 to the second side 132, but since the opening 134' is disposed along the perimeter, it may not be surrounded by the body 120. In FIG. 4, twelve openings 134' are shown along the perimeter of the body 120. However, it is contemplated that more or fewer openings 134' may be provided. In some configurations, the body 120 is solid except for the openings 134, 134'.

[0046] The openings 134, 134’ can have any suitable configuration. In the configuration shown in FIG. 4, the opening 134 configured as a through-hole is generally shown in a rectangular configuration where a first pair of sides or a pair of first sides 140 arranged opposite to each other are arranged opposite to each other and have a length longer than that of a second pair of sides or a pair of second sides 142 that interconnect the pair of first sides 140. Also, the opening 134 can have a non-rectangular configuration including, but not limited to, circular, oval, elliptical, triangular, or various other polygonal shapes. The opening 134’ arranged along the periphery can have fewer sides. For example, such an opening 134’ can have a single first side 140’ that has a length longer than that of a second pair of sides 142’ extending from both ends of the first side 140’ to the outer periphery. Such an opening 134’ can be a recess along the periphery extending towards the center of the body 120. The second pair of sides 142’ may be omitted, and it is also conceivable that the single first side 140’ may extend along an arc.

[0047] A set of hooks 122, also referred to as barbs, catches, clasps, or clips, facilitates the attachment of the attachment pad 102 to the cushion 50. For example, the members of the set of hooks 122 extend within the filament mesh structure 90 and are configured to catch, hook, grip, or connect at least one filament 52 of the filament mesh structure 90. The set of hooks 122 extends from the body 120. For example, the hooks 122 may be integrally formed with the body 120 as an integral one-piece component. In some configurations, each member of the set of hooks 122 may extend from the body 120 at different positions. As such, the members of the set of hooks 122 may be spaced apart from each other and may not contact or extend with each other.

[0048] Referring mainly to FIG. 6, hook 122 may be disposed adjacent to the associated opening 134 or 134'. For example, hook 122 may extend from the first side 140 or 140' in a direction extending toward the associated opening 134, 134'. In some configurations, one hook 122 is associated with each opening 134, 134' and is disposed adjacent thereto.

[0049] In some configurations, some or all of the members of a set of hooks 122 may face in opposite directions. An example of a pair of hooks 122 extending in opposite directions is shown by the dashed boxes in FIG. 4. For example, the free end 160 of one hook 122 may face away from or be directed away from the free end 160 of another hook 122. By orienting the hooks 122 in opposite directions, the hooks 122 can better secure the body 120 to the filament mesh structure 90, such as during dynamic loads when a seat occupant moves or bounces on the cushion 50. Similar hook arrangements are also provided in the upper left and right corners of FIG. 4, and a pair of hooks 122, 122 disposed along the outer periphery are configured as through-holes and face away from the hook 122 disposed adjacent to the opening 134 oriented at an angle of approximately 45° with respect to the horizontal line extending from left to right in the illustrated perspective view. Thus, the outer peripheral hooks 122, 122 generally extend away from the center of the body 120, while the hooks 122 visible through the angled opening 134 extend toward the center of the body 120. Thus, the hooks 122 disposed along or adjacent to the outer periphery of the attachment pad 102 face or extend in a different direction from the nearest hook 122 not disposed along the outer periphery, helping the attachment pad 102 to conform to the contour of the cushion 50, holding the attachment pad 102 against the contour of the cushion 50, and helping to prevent the attachment pad 102 from coming off the filament mesh structure 90 of the cushion 50.

[0050] As best shown in FIG. 5, the perimeter of the attachment pad 102 may be disposed at a height greater than that of the central region of the attachment pad 102. Accordingly, the peripheral hooks 122 or hooks disposed adjacent to the perimeter of the attachment pad 102 may be disposed at a height greater than that of the hooks 122 that are not disposed along the perimeter of the attachment pad 102 or further above the horizontal plane disposed under the cushion 50. Further, the attachment pad 102 may have a curved profile that extends downward from the perimeter to the hooks 122 that are not disposed along the perimeter of the attachment pad 102.

[0051] As shown in FIG. 4, the hook 122 can taper or narrow as the hook 122 extends away from the body 120 towards the associated openings 134, 134'. In some configurations, the hook 122 can taper or narrow as the hook 122 extends towards the distal end or free end 160 of the hook 122.

[0052] Referring to FIG. 6, in some configurations, the hook 122 includes a first segment 150, a second segment 152, and a bend 154.

[0053] The first segment 150 extends from the body 120. For example, the first segment 150 can extend from the first side 130 of the body 120. The first segment 150 can extend in a direction away from the trim cover 100. For example, the first segment 150 can 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 the adjacent region of the second side 132.

[0054] The second segment 152 can extend from the end of the first segment 150. For example, the second segment 152 can extend from the end of the first segment 150 that is disposed opposite to the body 120. The second segment 152 extends in a direction different from that of the first segment 150. In some configurations, the first segment 150 and the second segment 152 meet at a 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 in an upward direction towards the adjacent openings 134, 134' within the body 120 or towards the second side 132.

[0055] The second segment 152 has a free end 160. The free end 160 is disposed at the end of the second segment 152 that is on the opposite side when the first segment 150 and the bend 154 are provided. The free end 160 is configured to be disposed within the filament mesh structure 90 or not to extend beyond the contoured outer portion 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 under the second side 132 such that the free end 160 does not poke the occupant of the seat, does not bulge or distort the trim cover, or both. For example, the free end 160 or a part thereof may protrude into the openings 134, 134' as shown, or may be disposed completely under the second side 132 and inside the filament mesh structure 90 such that the free end 160 does not poke the occupant of the seat.

[0056] The first segment 150 and the second segment 152 can cooperate to form a bend 154. The bend 154 can have an arcuate or curved shape when the hook 122 is in its nominal or default position as shown in FIG. 6. The hook 122 can be configured to bend or flex at the bend 154.

[0057] Referring to FIGS. 6-9, examples of steps related to the assembly method are shown. FIGS. 6-9 are cross-sectional views taken through the adjacent openings 134 of the hook 122 and the attachment pad 102, and through the filament mesh structure 90 of the cushion 50. The filament mesh structure 90 is shown in a simplified form with various filaments 52 located behind the cross-sectional plane omitted for clarity. Further, some filaments 52 that intersect the cross-sectional plane are sectioned and more specifically are shown as circles sectioned for simplicity. The filaments 52 can intersect the cross-sectional plane in a non-vertical manner, and thus it should be understood that the sectioned filaments 52 can be depicted more accurately in a non-circular manner such as an ellipse, oval, or other non-circular shape.

[0058] The attachment of the attachment pad 102 to the filament mesh structure 90 is mainly described in the context of attachment by a single hook 122. However, it should be understood that some or all of the hooks 122 of the attachment pad 102 may be attached in a similar manner, and the hooks may be attached simultaneously or sequentially.

[0059] Referring to FIG. 6, the cushion 50 and the attachment pad 102 are shown before assembly. The attachment pad 102 is aligned with a desired installation position on the cushion 50, the first side 130 faces towards the outer portion 110 of the cushion 50, and the hook 122 extends towards the outer portion 110 of the cushion 50. The bent portion 154 of the hook 122 can engage or contact the outer side 110, while the remaining portion of the attachment pad 102 can be spaced from the cushion 50 or disposed above the cushion.

[0060] 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 outwardly 110, moving the cushion 50 and its outer side 110 toward the attachment pad 102, or a combination thereof. In the illustrated example, the attachment pad 102 is shown to be actuated with respect to 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 represented by the vertical arrow line. The force may be applied in any suitable manner. For example, the force may be applied manually or by a machine or device such as a press.

[0061] The force applied to the attachment pad 102 pushes the hook 122 through the outer side 110 into the filament mesh structure 90. The filaments 52 of the filament mesh structure 90 that engage or contact the hook 122 may be moved or displaced by the hook 122 when the hook 122 is inserted into the filament mesh structure 90. The movement or displacement of the filaments 52 may be restricted by the bonds between the filaments 52. As a result, the filaments 52 provide some resistance to the insertion of the hook 122. In response thereto, the hook 122 bends. For example, the first segment 150, the second segment 152, or both may bend or flex with respect to its initial configuration in FIG. 6.

[0062] In FIG. 7, hook 122 is shown to be bent mainly at bend 154 such that second segment 152 bends upward relative to body 120 and extends toward, into, or through opening 134 of body 120 disposed adjacent to hook 122. As a result, the angle α2 between first segment 150 and second segment 152 may be smaller than angle α1 before insertion. In the illustrated example, hook 122 bends such that free end 160 is pushed upward into opening 134 such that free end 160 protrudes from opening 134 and is disposed above second side 132 of body 120. In some configurations, free end 160 moves upward through first side 130 of body 120 into opening 134 without protruding above second side 132. In other configurations, free end 160 may move upward but may not enter opening 134.

[0063] First segment 150 and second segment 152 may act like a wedge to press one or more filaments 52 around hook 122. As a result, filament 52 may move away from gap 170 located between first segment 150 and second segment 152, which may be located above bend 154, thereby having no filament 52 or fewer filaments 52 disposed in gap 170 as compared to adjacent regions of filament mesh structure 90.

[0064] Referring to FIG. 8, the hook 122 operates (e.g., pushed, pulled, moved, bent, flexed, positioned) within the cushion 50 with respect to the body 120. The operation of the hook 122 may occur while the body 120 is held against the outer side 110 of the cushion 50. When the hook 122 is actuated, the hook deflects away from the body 120 and towards the filament mesh structure 90. For example, actuating the hook 122 may include pushing a portion of the hook 122 into the filament mesh structure 90, pulling the hook into the filament mesh structure 90, or a combination thereof. The operation of the hook 122 is described below mainly in the context of pushing the hook 122 into the filament mesh structure 90.

[0065] In some configurations, a force is applied to the hook 122 by a tool 180 such as a shaft, rod, lever, bar, wedge, etc. As an example, the tool 180 can be aligned with a portion of the hook 122 such as the second segment 152. Thereafter, the tool 180 can engage the second segment 152. For example, the tool 180 can engage or contact the second segment 152 between the free end 160 and the bend 154. Depending on the position of the tool 180, the tool can enter or pass through the opening 134 before or after the tool 180 engages the second segment 152. A force can be applied with the tool 180 to push the second segment 152 downward and into the filament mesh structure 90. A force can be applied with the tool 180 to the second segment 152 to move the hook 122 away from the first segment 150. The hook 122 can bend or flex at the bend 154. Some or all of the force applied with the tool 180 can be directed towards the filament mesh structure 90.

[0066] Sufficient force applied by tool 180 presses the second segment 152 deeper into the filament mesh structure 90. As a result, bending or flexure can occur along the first segment 150, the second segment 152, the bend 154, or combinations thereof. The second segment 152 can move away from the body 120 and the second side 132 by bending, flexing, or otherwise moving such that the free end 160 moves into the filament mesh structure 90 or deeper away from the outer side 110 within the filament mesh structure 90. In some configurations, a force can be applied such that the angle α3 between the first segment 150 and the second segment 152 increases and becomes greater than the angle α1 shown in FIG. 6. For example, the angle α3 can be made greater than 90°, such as between 90° and 180°. As a result, the second segment 152 extends away from the body 120, thereby allowing one or more filaments 52 to enter the gap 170 between the first segment 150 and the second segment 152. In some configurations, when the free end 160 is pushed into the filament mesh structure 90, it is positioned under the first segment 150, the bend 154, or both, or away from the first side 130 relative to the first segment 150, the bend 154, or both.

[0067] Referring to FIG. 9, the hook 122 is shown after being released. By releasing the hook 122, the hook 122 can flex towards or back to its initial position shown in FIG. 6. The hook 122 can be released by retracting the tool 180 and / or removing the tool 180 from the hook 122. By releasing the hook 122, the hook 122 can capture, snag, grip, or otherwise capture one or more members of the set of filaments 52, thereby coupling the attachment pad 102 to the filament mesh structure 90. In the illustrated configuration, by releasing the hook 122, one or more filaments 52 are disposed within the gap 170 and are captured between the first segment 150 and the second segment 152 of the hook 122 such that the second segment 152 can move upwardly towards the body 120 and the opening 134. Thus, at least one member of the set of filaments 52 can engage the hook 122 and be received between the first segment 150 and the second segment 152. After being released, the second segment 152 may extend towards the opening 134 or into the opening and towards the trim cover 100 when the trim cover 100 is attached.

[0068] Members of the set of filaments 52 can engage the first side 130 of the body 120 and the hook 122. For example, filament 52’ is shown engaging at least one of the first side 130 and the first segment 150 and the second segment 152 of the hook 122. An example of an assembly resulting in an attachment pad 102 coupled to the cushion 50 is shown in FIG. 5.

[0069] The trim cover 100 may be attached to the main body 120 before or after the attachment pad 102 is fixed or coupled to the filament mesh structure 90. In some configurations, after the hook 122 is released and the attachment pad 102 is coupled to the cushion 50, the trim cover 100 is attached to the attachment pad 102. The trim cover 100 may be attached to the attachment pad 102 before the hook 122 is inserted into the filament mesh structure 90, which may be implemented in a configuration where the attachment pad 102 is pulled against the filament mesh structure 90.

[0070] Referring to FIG. 3, the trim cover 100 may be attached to the second side 132 of the main body 120. The trim cover 100 may be attached to the main body 120 in any suitable manner. For example, the trim cover 100 may be attached to the attachment pad 102 by adhering or bonding the trim cover 100 to the main body 120 using an adhesive 190 or the like disposed between the lower surface of the trim cover 100 and the second side 132. Also, the trim cover 100 may be attached to the attachment pad 102 using a fastener such as a hook and loop fastener.

[0071] The present invention enables a cushion on which a trim clip is disposed to be provided with an attachment pad useful for better fixing a trim cover at a position near the center of the cushion without providing a recess or groove in the cushion. The present invention can fix a trim cover using an attachment pad that can provide a larger surface area for attaching the trim cover compared to using individual trim clips. This can provide a larger surface area on which the trim cover and the attachment pad can be attached, thereby enabling the trim cover to be fixed at more positions compared to trim clips. The present invention enables an attachment pad to be securely fixed to a filament mesh structure having a plurality of hooks that may be arranged in different directions, such that the plurality of hooks can prevent removal of the attachment pad against a load. Further, the attachment pad and the filament mesh structure can be recycled together, thereby avoiding disassembly during the recycling process.

[0072] Section 1 A cushion comprising a filament mesh structure having a set of filaments of a thermoplastic material, each member of the set of filaments being looped and joined 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 joined to the filament mesh structure, the body being disposed outside the contoured outer side of the filament mesh structure, A seat assembly comprising the trim cover attached to the attachment pad. Section 2 The seat assembly according to Section 1, wherein each member of the set of hooks extends from the body at different positions. Section 3 The set of hook members extends into the filament mesh structure and captures at least one filament of the filament mesh structure, according to any of the sections of the sheet assembly described above. Section 4 Each member of the set of hooks further comprises a first segment and a second segment, the first segment extending from the body away from the trim cover, and the second segment extending from an end of the first segment towards the trim cover, according to the sheet assembly of section 1 described above. Section 5 The second segment further includes a free end disposed on the opposite side of the first segment, the free end being disposed within the filament mesh structure, according to the sheet assembly of section 4 described above. Section 6 The body further comprises a first side and a second side disposed opposite the first side, the first side engaging the contoured outer side of the cushion, and the second side engaging the trim cover, according to any of the sections described above. Section 7 The body defines an opening extending from the first side of the body to the second side, and the second segment extends from an end of the first segment towards the opening, according to the sheet assembly of section 6 dependent on section 4. Section 8 The set of filament members engages the set of hook members and is received between the first segment and the second segment, according to the sheet assembly of section 4, section 5, section 6 dependent on section 4, or section 7 described above. Section 9 The set of filament members engages the first side of the body and at least one of the first segment and the second segment of the set of hook members, according to the sheet assembly of sections 6 to 8 described above. Section 10 The set of hooks includes a first hook and a second hook, and the body further has a first opening and a second opening extending from a first side of the body to a second side thereof. The first hook is disposed adjacent to the first opening, and the second hook is disposed adjacent to the second opening. The seat assembly according to any one of the preceding paragraphs. Section 11 The seat assembly according to paragraph 10, wherein the first hook and the second hook extend in opposite directions. Section 12 The first opening is a through hole surrounded by the body, and the second opening is disposed along the periphery of the body and is not surrounded by the body. The seat assembly according to paragraph 10 or 11. Section 13 An engaging step of engaging an attachment pad and a cushion including a body and a hook extending from the body, wherein the cushion includes a filament mesh structure including a set of filaments of a thermoplastic material, and each member of the set of filaments is in a loop shape and is coupled to at least one other member of the set of filaments. A step of actuating the hook with respect to the body. A method comprising releasing the hook, thereby causing the hook to capture at least one member of the set of filaments and coupling the attachment pad to the filament mesh structure. Section 14 The method according to paragraph 13, wherein when the hook is actuated, at least a part of the hook deflects away from the body, and when the hook is released, at least a part of the hook deflects towards the body. Section 15 The engagement between the attachment pad and the cushion further includes engaging a first side of the body with the filament mesh structure and actuating the hook when the first side of the body engages with the filament mesh structure. The method according to paragraph 13 or 14. Section 16 Actuating the hook further comprises pushing the hook into the filament mesh structure, as described in Sections 13 to 15 of the method. Section 17 Actuating the hook further comprises applying a force to the hook with a tool, as described in Sections 13 to 16 of the method. Section 18 Releasing the hook further comprises releasing the tool from the hook with a tool, as described in Section 17 of the method. Section 19 The method described in Sections 13 to 18 further comprises the step of attaching a trim cover to the attachment pad after releasing the hook. Section 20 The step of attaching the trim cover to the attachment pad further comprises the step of adhering the trim cover to the body with an adhesive, as described in Section 19 of the method.

[0073] Exemplary embodiments have been described above, but these embodiments are not intended to describe all possible forms of the invention. Rather, the terms used herein are terms of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, the features of the various embodiments can be combined to form further embodiments of the invention.

Claims

1. a cushion comprising a filament mesh structure having a set of filaments of a 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 adapted to couple to the filament mesh structure, the body being disposed on a contoured outer portion of the filament mesh structure; a trim cover attached to the mounting pad.

2. 2. The seat assembly of claim 1, wherein each member of said set of hooks extends from said body at a different location.

3. 2. The seat assembly of claim 1, wherein said set of hook members extends into said filament mesh structure and captures at least one filament of said filament mesh structure.

4. 2. 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 away from the trim cover and the second segment extending from an end of the first segment toward the trim cover.

5. The seat assembly of claim 4 , wherein the second segment further includes a free end disposed opposite the first segment, the free end being disposed within the filament mesh structure.

6. 5. 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 a contoured outer portion of the cushion and the second side engaging the trim cover.

7. 7. The seat assembly of claim 6, wherein the body defines an opening 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 opening.

8. 8. The seat assembly of claim 7, wherein said set of filament members engage said set of hook members and are received between said first segment and said second segment.

9. 8. The seat assembly of claim 7, wherein said set of filament members engage said first side of said body and at least one of said first segment and said second segment of said set of hook members.

10. 2. The seat assembly of claim 1, wherein the set of hooks comprises a first hook and a second hook, the body further having a first opening and a second opening extending from a first side to a second side of the body, the first hook being disposed adjacent to the first opening and the second hook being disposed adjacent to the second opening.

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

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

13. engaging the cushion with an attachment pad having a body and hooks extending from the body, the cushion comprising a filament mesh structure comprising a set of filaments of a thermoplastic material, each member of the set of filaments being looped and coupled to at least one other member of the set of filaments; actuating the hook relative to the body; and releasing the hook, whereby the hook captures at least one member of the set of filaments and couples the attachment pad to the filament mesh structure.

14. 14. The method of claim 13, wherein actuating the hook causes at least a portion of the hook to deflect away from the body and releasing the hook causes at least a portion of the hook to deflect towards the body.

15. 14. The method of claim 13, wherein engaging the mounting pad with the cushion further comprises: engaging a first side of the body with the filament mesh structure; and activating the hook when the first side of the body engages the filament mesh structure, wherein the hook is activated when the mounting pad is flush against the cushion to secure the mounting pad in place.

16. 14. The method of claim 13, wherein actuating the hook further comprises forcing the hook into the filament mesh structure.

17. The method of claim 13 , wherein actuating the hook further comprises applying a force to the hook with a tool.

18. The method of claim 17 , wherein releasing the hook further comprises releasing the tool from the hook with a tool.

19. The method of claim 13 further comprising the step of attaching a trim cover to the mounting pad after releasing the hooks.

20. 20. The method of claim 19, wherein attaching the trim cover to the mounting pad further comprises adhesively adhering the trim cover to the body.

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