Cushion assembly

Abstract

To provide a cushion assembly.SOLUTION: A assembly having a unitary mesh of expanded thermoplastic resin strands with an aperture formed are bundled is provided. The assembly is further provided with a trim cord inserted within the aperture of the unitary mesh. The trim cord is installed in the aperture by one or more of the following: being inserted into the aperture; welding the trim cord to the unitary mesh of expanded thermoplastic resin strands; and a first segment of the expanded thermoplastic resin strands being welded to a second segment of the expanded thermoplastic resin strands at least partially over the aperture.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023, claims priority to Danish Patent Application No. PA202470202, filed on July 30, 2024, and claims priority to U.S. Patent Application No. 18 / 980,826, filed on December 13, 2024. The disclosure content of those applications is hereby incorporated by reference in their entirety into this specification.

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023, and claims priority to Danish Patent Application No. PA202470202, filed on July 30, 2024. The disclosure content of those applications is hereby incorporated by reference in their entirety into this specification.

[0003] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023. The disclosure content of that application is hereby incorporated by reference in its entirety into this specification.

[0004] Various embodiments relate to a cushion formed from an integral mesh of foamed thermoplastic resin strands.

Summary of the Invention

[0005] According to one aspect of the present invention, a gathered mesh of foamed thermoplastic resin strands having apertures formed therein, a trim cord inserted into the apertures of the gathered mesh, and The trim code is installed in the aperture by one or more of the following: the trim code is inserted into the aperture, the trim code is welded to a mesh of foamed thermoplastic resin strands gathered together, or a first segment of the foamed thermoplastic resin strand is welded to a second segment of the foamed thermoplastic resin strand, covering at least partially the aperture, and an assembly is provided.

[0006] According to another aspect of the present invention, a gathered mesh of foamed thermoplastic resin strands in which an aperture is formed, a trim code inserted into the aperture of the gathered mesh, wherein a first segment of the foamed thermoplastic resin strand is welded to a second segment of the foamed thermoplastic resin strand, covering at least partially the aperture, and an assembly is provided. An assembly comprising is provided.

Brief Description of the Drawings

[0007]

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Mode for Carrying Out the Invention

[0008] Next, refer to the embodiments in detail. Examples thereof 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 have not been described in detail so as not to obscure aspects of the embodiments.

[0009] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily drawn to an exact scale ratio, and some features may be exaggerated or minimized in order to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather should be interpreted as a representative basis for teaching those skilled in the art how to variously employ the embodiments according to the present disclosure.

[0010] "One or more" includes that a function is performed by one element, that a function is performed by two or more elements in a distributed manner, for example, that multiple functions are performed by one element, that multiple functions are performed by multiple elements, or any combination of the above.

[0011] Also, although the terms first, second, etc. are used herein in some instances to describe various elements, it will be understood that these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first segment may be referred to as the second segment, and similarly, the second segment may be referred to as the first segment. The first segment and the second segment are both segments, but they are not the same segment.

[0012] The terms used in the description of the various described embodiments herein are for the purpose of describing particular embodiments only and are not intended to be limiting. When used in the description of the various described 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 dictates otherwise. Also, the term "and / or" as used herein, when referring to the relevant listed items, is understood to mean any and all possible combinations of one or more of the associated listed items and is used to encompass the same. Further, the terms "comprising" or "including" as used herein, when referring to a specified feature, integer, step, operation, element, and / or component, are understood to specify the presence of the stated feature, integer, step, operation, element, component, and / or group thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0013] As used herein, the term "when ~" is optionally construed, depending on the context, to mean "when ~", or "as soon as ~", or "depending on the determination", or "depending on the detection". Similarly, the phrases "when determined" or "when [specified condition or event] is detected" are optionally construed, depending on the context, to mean "as soon as the determination is made", or "depending on the determination", or "as soon as [specified condition or event] is detected", or "depending on the detection of [specified condition or event]".

[0014] FIG. 1 shows a seat assembly 20 as a vehicle seat assembly 20 according to an embodiment. Although the vehicle seat assembly 20 is illustrated and described, any seat assembly 20 can be employed. The seat assembly 20 can be used in land vehicles, aircraft, ships, etc. The seat assembly 20 can also be used as an office chair, a comfort chair, etc.

[0015] The illustrated seat assembly 20 includes a seat bottom 22, a seat back 24, and a headrest 26. The seat bottom 22 is provided with a seat bottom cushion 28 that supports the pelvis and thighs of the seated occupant. The seat back 24 includes a seat back cushion 30 that supports the back and shoulders of the seated occupant. To conceal the cushions 28, 30 and provide a uniform and smooth contact surface to the occupant, a trim cover 32 is provided to cover the seat cushions 28, 30.

[0016] Generally referring to FIG. 2, a cushion assembly 34 removed from the seat assembly 20 is shown. In the illustrated embodiment, the cushion assembly 34 includes a cushion body 35 formed from an integral mesh of foamed thermoplastic resin strands 36. The cushion body 35 can be manufactured according to the teachings of U.S. Patent Application Publication No. 2023 / 0191678 to Blair et al., published on June 22, 2023, to Lear Corporation. The cushion body 35 may be formed from a foam material according to another embodiment. The cushion assembly 34 provides support to a seated person on the seat assembly 20. The cushion assembly 34 is elastically deformable and provides comfort to the seated person while supporting the seated person.

[0017] The cushion assembly 34 is a non-foam component or includes at least one non-foam component. Non-foam components are mainly referred to as mesh members, but may also be referred to as strand members, looped members, intertwined members, filament mesh structures, mesh structures, strand meshes, looped meshes, intertwined meshes, or mesh cushions. In FIG. 2, the cushion assembly 34 is shown as a non-foam component that does not include a foam component or foam material such as urethane or polyurethane foam, but it is contemplated that the cushion assembly 34 may include a foam component or foam material in addition to the non-foam component to provide additional cushioning or local cushioning to the seated person on the seat. For example, a foam material may be provided between the cushion assembly 34 and the trim cover 32 disposed on the cushion assembly 34, within the cushion assembly 34, or a combination thereof. By reducing the amount of foam material provided in the cushion assembly 34 or eliminating the foam material from the cushion assembly 34, the weight can be reduced and the support and comfort of the seated person on the seat can be improved. In addition, by eliminating the foam material, the recycling of the cushion assembly 34 can be facilitated.

[0018] The following describes the cushion assembly 34 in a situation where the cushion assembly 34 does not include a foam material. In this context, the cushion assembly 34 is made of filaments 36 of a polymeric material that are randomly looped, bent, kinked, or intertwined and integrally joined, as will be discussed in detail later. The filaments 36 are joined directly to another filament 36 rather than being joined indirectly with a resin or other intermediate material.

[0019] The filaments 36, which can also be referred to as strands or threads, are made of any suitable single or plural materials. In some configurations, the filaments 36 are made of a polymeric material or a thermoplastic material such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or a combination thereof. As one example, the polyethylene-based filaments may be made of linear low-density polyethylene (LLPDE). The filament material can be recyclable, unlike the foam material, or can be recycled more easily than the foam material. It is also contemplated that the filaments 36 may include reinforcing fibers and that the reinforcing fibers may not be made of a thermoplastic material.

[0020] In some configurations, the filaments 36 can be monofilaments made of a single material. In some configurations, the filaments 36 are made of a plurality of materials. As an example, the filaments 36 made of a plurality of 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. It is contemplated that the cushion assembly 34 may include a combination of monofilaments and filaments made of a plurality of materials and not monofilaments.

[0021] The randomly looped, bent, looped, twisted, or intertwined filaments 36 are joined together where one filament 36 contacts another filament 36, thereby resulting in a lightweight breathable cushion assembly 34 or mesh structure having openings or voids between the filaments 36.

[0022] The cushion assembly 34 is installed within a trim cover (FIG. 1). To attach the cushion assembly 34 to other seat components, the cushion assembly includes a trim cord 40. The trim cord 40 can be attached to other seat components such as a seat frame, seat suspension, etc. The trim cord 40 can also be used to attach other components such as the trim cover 32 to the cushion assembly 34. The trim cord 40 can be formed of a structural and flexible material, such as a polyethylene material or any suitable material. Alternatively, the trim cord 40 may be formed from a steel wire.

[0023] An aperture or opening 38 is formed in the cushion assembly 34. In the illustrated embodiment, the aperture 38 is a slot or groove 38 formed along the length of the body 35. When another cushion body 35 is stacked on top of the cushion body 35, the groove 38 can be hidden along its length with an aperture opening at the end of the groove 38. The trim cord 40 is inserted into the groove 38. According to the illustrated embodiment, to maintain the trim cord 40 within the cushion body 35, the trim cord 40 is welded to the body 35 at a weld 39 within the groove 38. The trim cord 40 can be welded by friction welding, ultrasonic welding, heat caulking, etc. such that the trim cord 40 is joined to and integrated with the body 35. Alternatively, to join the trim cord 40 to the body 35 by cooling, the material of an additional weld 39 may be melted and deposited. According to another embodiment, the trim cord 40 is welded to the cushion body 35 without an additional adhesive.

[0024] Referring to FIG. 3, another cushion assembly 56 removed from the seat assembly 20 is shown. The cushion assembly 56 includes a cushion body 60 formed of an integral mesh of foamed thermoplastic strands 36. The cushion body 60 can also be formed from a general foam material according to another embodiment. The cushion assembly 56 may be the same as the cushion assembly 34 of FIG. 2, or may be another cushion assembly 56 as shown.

[0025] The cushion assembly 56 includes a trim cord 58 joined to the cushion body 60 at a connection portion 62. According to one embodiment, the connection portion 62 is a heat staking portion that partially melts the trim cord 58 and the cushion body 60 to join the trim cord 58 to the cushion body 60. According to another embodiment, the connection portion 62 is a welded portion 62.

[0026] An aperture 64 is formed in the cushion assembly 56, and a trim cord 66 is inserted into the aperture 64. The trim cord 66 can be formed of a polyethylene material. The aperture 64 is shown as a groove 64. FIG. 3 shows another method of installing the trim cord 66 within the aperture 64 according to one embodiment. A segment 42 of the foamed thermoplastic strand is welded to the integral mesh of the foamed thermoplastic strands 36 so as to at least partially cover the aperture 64. In the illustrated embodiment, a first segment 52 of the foamed thermoplastic strand is welded to a second segment 54 of the foamed thermoplastic strand so as to at least partially cover the aperture 64.

[0027] Figures 4 - 6 illustrate a method and system for inserting trim code 68 into aperture 70 of cushion body 72. Cushion body 72 can be formed from foam, an integrally molded mesh of extruded thermoplastic resin, or any suitable material. A linear actuator assembly 74 is provided for attaching trim code 68 to cushion body 72. Linear actuator assembly 74 can be utilized without welding trim code 68 to cushion body 72. Linear actuator assembly 74 includes a pair of bases 76 that provide a pair of guides. A pair of sliders 78 are installed on bases 76 so as to translate relative to bases 76. A pair of linear actuators, such as pneumatic cylinders 80, are installed on bases 76 and are connected to the end portions of sliders 78 so as to extend and retract sliders 78 relative to bases 76. A elongate end effector 82 is attached to each slider 78. Although a pair of bases 76, sliders 78, linear actuators 80 and end effectors 82 are illustrated and described, any number can be employed to install any number of trim codes 68.

[0028] Figures 4 and 5 show linear actuator assembly 74 in an idle position, whereby cushion body 72 is presented so as to be proximate to the end portions of end effectors 82. In Figure 6, linear actuator 80 extends slider 78 from base 76 so that end effector 82 is inserted into cushion body 72. At the extended position of Figure 6, end effector 82 releases trim code 68 into cushion body 72. Linear actuator 80 then retracts to the idle position of Figures 4 and 5.

[0029] Figures 7 and 8 show the cushion body 72 with the trim code 68 installed. The aperture 70 of the gathered mesh 36 has an inner dimension, and the trim code 68 has an outer dimension such as a cross-section that is smaller than the inner dimension of the aperture 70. In some embodiments, the cross-section of the trim code 68 is greater than 3 millimeters and less than 5 millimeters. In some embodiments, the inner dimension 44 of the aperture 70 is at least 5 millimeters greater than the cross-section of the trim code 68. Further, in some embodiments, the inner dimension of the aperture 70 is less than 10 millimeters. In some embodiments, the inner dimension of the aperture 70 is 100 percent to 166 percent greater than the cross-section of the trim code 68.

[0030] Figure 9 shows the trim cover 32 of the seat assembly 20 according to various embodiments. Figure 10 shows the cushion body 72 together with the trim cover 32 of the seat assembly 20. The trim cover 32 is attachable to the trim code 68. In some embodiments, the trim cover 32 is provided with a plurality of clips 48 sewn to the trim cover 32. The clips 48 are sized to receive the trim code 68 and hold the trim code 68 in the integrated or gathered mesh 36. The trim cover 32 can also be provided with a fastener assembly 50 attached to the trim cover 32. The fastener assembly 50 is sized to receive the trim code 68 and hold the trim code 68 in the gathered mesh 36.

[0031] The fastener assembly 50 includes a strip or wire 44 that is sewn to the trim cover 32. According to some embodiments, the wire 44 may be a metal wire 44. The fastener assembly 50 also includes a plurality of hog rings 46 that have a discontinuous loop and are rings that are deformed by a tool to close the loop to provide a fastener - type connection. The hog rings 46 connect the wire 44 to the trim cord 68. The hog rings 46 are installed around the wire 44 and the trim cord 68 and are closed. According to another embodiment, the hog rings 46 may be installed around the wire 44 and closed, and then the trim cord 68 may be installed within the closed hog rings 46.

[0032] According to claim 1, an assembly is provided that may or may not be combined with any of the subsequent claims and includes an integrated or bundled mesh of foamed thermoplastic resin strands in which an aperture is formed. The trim cord is inserted into the aperture of the bundled mesh. The trim cord is installed within the aperture by one or more of: the trim cord being inserted into the aperture, the trim cord being welded to the bundled mesh of foamed thermoplastic resin strands, or a first segment of the foamed thermoplastic resin strands being welded to a second segment of the foamed thermoplastic resin strands at least partially covering the aperture.

[0033] According to claim 2, an assembly as described in any of the preceding or subsequent claims is provided, wherein the trim cord is welded to an area of the bundled mesh of foamed thermoplastic resin strands within a groove formed in the integral mesh.

[0034] According to claim 3, an assembly as described in any of the preceding or subsequent claims is provided, wherein the trim cord is welded to the bundled mesh of foamed thermoplastic resin strands.

[0035] According to claim 4, there is provided an assembly as described in any of the preceding or subsequent items, wherein the trim code is welded without an adhesive.

[0036] According to claim 5, there is provided an assembly as described in any of the preceding or subsequent items, wherein segments of the foamed thermoplastic resin strands are welded to the gathered mesh of the foamed thermoplastic resin strands so as to at least partially cover the apertures.

[0037] According to claim 6, there is provided an assembly as described in any of the preceding or subsequent items, wherein the apertures of the gathered mesh have an inner dimension, and the trim code has a cross-section smaller than the inner dimension of the apertures.

[0038] According to claim 7, there is provided an assembly as described in any of the preceding or subsequent items, wherein the cross-section of the trim code is larger than 3 millimeters.

[0039] According to claim 8, there is provided an assembly as described in any of the preceding or subsequent items, wherein the cross-section of the trim code is smaller than 5 millimeters.

[0040] According to claim 9, there is provided an assembly as described in any of the preceding or subsequent items, wherein the inner dimension of the apertures of the gathered mesh is at least 5 millimeters larger than the cross-section of the trim code.

[0041] According to claim 10, there is provided an assembly as described in any of the preceding or subsequent items, wherein the inner dimension of the apertures of the gathered mesh is smaller than 10 millimeters.

[0042] According to claim 11, there is provided an assembly as described in any of the preceding or subsequent items, wherein the inner dimension of the apertures of the gathered mesh is 100% to 166% larger than the cross-section of the trim code.

[0043] According to claim 12, there is provided an assembly as described in any of the preceding or subsequent claims, comprising a trim cover and at least one clip stitched to the trim cover, the clip being sized to receive a trim cord and hold the trim cover in a gathered mesh.

[0044] According to claim 13, there is provided an assembly as described in any of the preceding or subsequent claims, comprising a trim cover, a wire stitched to the trim cover, and at least one ring for attaching a trim cord to the wire.

[0045] According to claim 14, there is provided an assembly as described in any of the preceding or subsequent claims, comprising a trim cover and at least one fastener stitched to the trim cover, the fastener being sized to receive a trim cord and hold the trim cover in a gathered mesh.

[0046] According to claim 15, there is provided an assembly which may or may not be combined with any of the preceding or subsequent claims, comprising a gathered mesh of foamed thermoplastic resin strands in which an aperture is formed. The trim cord is inserted into the aperture of the gathered mesh, and a first segment of the foamed thermoplastic resin strand is welded to a second segment of the foamed thermoplastic resin strand at least partially covering the aperture.

[0047] According to claim 16, there is provided an assembly as described in any of the preceding or subsequent claims, in which the trim cord is welded to a gathered mesh of foamed thermoplastic resin strands.

[0048] According to claim 17, there is provided an assembly as described in any of the preceding or subsequent claims, in which the trim cord is welded without an adhesive.

[0049] According to claim 18, an assembly is provided that may or may not be combined with any of the preceding or following claims and includes a bundled mesh of foamed thermoplastic resin strands. A trim code is attached to the bundled mesh and welded to the bundled mesh of foamed thermoplastic resin strands.

[0050] According to claim 19, an assembly as described in any of the preceding or following claims is provided, wherein the trim code is welded without an adhesive.

[0051] According to claim 20, an assembly as described in any of the preceding or following claims is provided, comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive the trim code and hold the trim cover to the bundled mesh.

[0052] According to claim 21, an assembly as described in any of the preceding or following claims is provided, comprising a trim cover and at least one fastener sewn to the trim cover, the fastener being sized to receive the trim code and hold the trim cover to the bundled mesh.

[0053] According to claim 22, an assembly as described in any of the preceding or following claims is provided, comprising a trim cover, a wire sewn to the trim cover, and at least one ring for attaching the trim code to the wire.

[0054] According to claim 23, any combination of any of the preceding claims is provided.

[0055] While the exemplary embodiments have been described above, these embodiments are not intended to represent all possible forms according to the present disclosure. In that regard, it is understood that the language used herein is for description rather than limitation, and various modifications can be made without departing from the spirit and scope of the present disclosure. Additionally, features of various embodiments can be combined to form further embodiments according to the present disclosure.

Claims

1. An assembly comprising a bundled mesh of foamed thermoplastic resin strands in which an aperture is formed, a trim cord inserted into the aperture of the bundled mesh, wherein the trim cord is installed in the aperture by one or more of: the trim cord being inserted into the aperture, the trim cord being welded to the bundled mesh of foamed thermoplastic resin strands, or a first segment of the foamed thermoplastic resin strands being welded to a second segment of the foamed thermoplastic resin strands at least partially covering the aperture.

2. The assembly according to claim 1, wherein the trim cord is welded to a region of the bundled mesh of foamed thermoplastic resin strands within a groove formed in the bundled mesh.

3. The assembly according to claim 1 or 2, wherein the trim cord is welded to the bundled mesh of foamed thermoplastic resin strands.

4. The assembly according to any one of claims 1 to 3, wherein the trim cord is welded without an adhesive.

5. The assembly according to any one of claims 1 to 4, wherein a segment of the foamed thermoplastic resin strands is welded to an integral mesh of the foamed thermoplastic resin strands at least partially covering the aperture.

6. The assembly according to any one of claims 1 to 5, wherein the aperture of the bundled mesh has an inner dimension, and the trim cord has a cross-section smaller than the inner dimension of the aperture.

7. The assembly according to claim 6, wherein the cross-section of the trim cord is greater than 3 millimeters.

8. The assembly according to claim 6 or 7, wherein the cross-section of the trim cord is smaller than 5 millimeters.

9. The assembly according to any one of claims 6 to 8, wherein the inner dimension of the aperture of the bundled mesh is at least 5 millimeters greater than the cross-section of the trim cord.

10. The assembly according to any one of claims 6 to 9, wherein the inner dimension of the aperture of the bundled mesh is smaller than 10 millimeters.

11. The inner dimension of the aperture of the bundled mesh is 100 percent to 166 percent larger than the cross-section of the trim code, the assembly according to any one of claims 6 to 10.

12. Further comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive the trim code and hold the trim cover to the bundled mesh, the assembly according to any one of claims 1 to 11.

13. Further comprising a trim cover, a wire sewn to the trim cover, and at least one ring for attaching the trim code to the wire, the assembly according to any one of claims 1 to 12.

14. Further comprising a trim cover and at least one fastener sewn to the trim cover, the fastener being sized to receive the trim code and hold the trim cover to the bundled mesh, the assembly according to any one of claims 1 to 13.

15. A bundled mesh of foamed thermoplastic resin strands in which an aperture is formed, A trim code inserted into the aperture of the bundled mesh, wherein a first segment of the foamed thermoplastic resin strand is welded to a second segment of the foamed thermoplastic resin strand at least partially covering the aperture, the trim code, An assembly comprising.

16. The trim code is welded to the bundled mesh of the foamed thermoplastic resin strands, the assembly according to claim 15.

17. The trim code is welded without an adhesive, the assembly according to claim 15 or 16.

18. A bundled mesh of foamed thermoplastic resin strands, A trim code attached to the bundled mesh, the trim code being welded to the bundled mesh of the foamed thermoplastic resin strands, An assembly comprising.

19. The trim code is welded without an adhesive, the assembly according to claim 18.

20. The assembly according to claim 18 or 19, further comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive the trim cord and hold the trim cover to the bundled mesh.

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