Seat assembly and method of assembly

Abstract

To provide a seat assembly and a method for assembling the seat assembly.SOLUTION: In a seat assembly and method of assembly, the seat assembly comprises a frame, a cushion, and a fastening arrangement. The cushion is disposed on the frame and comprises a mesh member including a set of filaments of polymeric material. The fastening arrangement extends through the aperture in the frame and secures the cushion to the frame.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a seat assembly and a method for assembling the seat assembly. Summary of the Invention [Problem to be solved by the invention]

[0002] To provide a seat assembly and a method for assembling the seat assembly. [Means for solving the problem]

[0003] The problem is solved by a seat assembly comprising a frame having an opening, a cushion having a mesh member having a set of filaments of a polymer material, at least two members of the set of filaments being connected to each other in a loop shape, the cushion being placed on the frame, and a fastening device for fixing the cushion to the frame, the fastening device extending through the opening in the frame.

[0004] The problem is solved by an assembly method for assembling a seat assembly, which includes: a positioning step of positioning a cushion on a frame, wherein the cushion comprises a mesh member having a set of filaments of a polymer material, at least two members of the set of filaments being connected to each other in a loop shape, and the frame having an opening; and a fixing step of fixing the cushion to the frame with a fastening device, wherein the fastening device extends through the opening in the frame. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a perspective view of an example of a sheet assembly including a filament mesh structure. [Figure 2] FIG. 1 is a perspective view of an example of a sheet assembly including a filament mesh structure. [Figure 3] FIG. 1 is an enlarged view of an example of a filament mesh structure. [Figure 4] FIG. 1 is a side view of a portion of a seat assembly with the trim cover omitted for clarity. [Figure 5] 5 is a cross-sectional view of a seat assembly along section line 5-5, including a first example of a trim cover and fastening device. [Figure 6] 1 is a cross-sectional view of a seat assembly and a second example of a fastening device. [Figure 7] 10 is a cross-sectional view of a seat assembly and a third example of a fastening device. [Figure 8] 10 is a cross-sectional view of a seat assembly and a fourth example of a fastening device. [Figure 9] 10 is a cross-sectional view of a seat assembly and a fifth example of a fastening device. [Figure 10] 10 is a cross-sectional view of a seat assembly and a sixth example of a fastening device. [Figure 11] 10 is a cross-sectional view of a seat assembly and a sixth example of a fastening device. [Figure 12] 10 is a cross-sectional view of a seat assembly and a sixth example of a fastening device. [Figure 13] 10 is a cross-sectional view of a seat assembly and a sixth example of a fastening device. DETAILED DESCRIPTION OF THE INVENTION

[0006] Reference will now be made in detail to the 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 embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail as not to unnecessarily obscure aspects of the embodiments.

[0007] It should be understood that the disclosed embodiments are merely exemplary and that various 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 should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the embodiments in accordance with the disclosure.

[0008] "One or more" includes functions performed by one element, functions performed by multiple elements, e.g., some functions performed by one element, some functions performed by multiple elements in a distributed manner, or any combination of the above.

[0009] Terms such as "first," "second," and the like are used herein to describe various elements in some instances, but it should 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, a first contact can be referred to as a second contact, and similarly, a second contact can be referred to as a first contact, without departing from the scope of the various embodiments described. Although a first contact and a second contact are both contacts, they are not the same contact.

[0010] The terminology used in describing the various embodiments described herein is intended to describe particular embodiments only and is not intended to be limiting. As used in describing the various embodiments described herein and the appended claims, the indefinite and definite articles "a," "an," and "an" as singular are intended to include the plural, unless the context clearly indicates otherwise. It will also be understood that the term "and / or," as used herein, refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that, as used herein, the terms "comprise," "include," "comprises," and / or "comprises" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0011] As used herein, the term "if" is interpreted to mean, depending on the context, optionally, "when" or "in the condition," "subject to a decision," or "subject to recognition" or "in determining," depending on the context. Similarly, the phrase "if determined" or "recognizing that [the stated condition or event]" is interpreted to mean, depending on the context, optionally, "subject to a decision," or "subject to a decision," "in determining," or "subject to recognition of [the stated condition or event]."

[0012] 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, or bus, or a non-land vehicle, such as an aircraft or watercraft. For example, the seat assembly 10 for a land vehicle can be shaped and sized as a front driver or passenger seat, a second-row seat, a third-row seat, or other rear-row seat, and can include a bucket-style seat, a bench-style seat, or other seat styles. Furthermore, the seat assembly 10 can be a non-stowable seat or a stowable seat that can be folded and stowed into a cavity within the vehicle floor. Furthermore, the seat assembly 10 can be configured for non-vehicle applications, such as furniture.

[0013] 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or a stool, the seat back 22 may be omitted.

[0014] The seat 20 is configured to receive a seated occupant and support the pelvis and thighs of the occupant. The seat 20 includes a seat frame 30, a cushion 32, and a trim cover .

[0015] The seat frame 30 is a structure that supports the cushion 32. The seat frame 30 includes 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 frame 30 includes a panel, seat pan, suspension mat, or suspension wire on which the cushion 32 is positioned.

[0016] A cushion 32 is disposed on the seat frame 30. The cushion 32 is made of a flexible material that supports the seat occupant and distributes load from the seat occupant to the seat frame 30. The cushion 32 and associated manufacturing methods are described in more detail below.

[0017] The trim cover 34 covers at least a portion of the cushion 32. Additionally, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. A seat occupant may place themselves on the trim cover 34 when seated in the seat assembly 10. The trim cover 34 may be made of any suitable material or materials, such as cloth, natural leather, synthetic leather, vinyl, or a combination thereof. The trim cover 34 may include multiple trim panels assembled by any suitable method, such as by fusing or stitching. The trim cover 34 may be attached to the seat frame 30, the cushion 32, or both. For example, the trim cover 34 may include a trim attachment portion attached to the seat frame 30, the cushion 32, or both, to prevent removal of the trim cover 34 and to help the trim cover 34 conform to the contours of the seat frame 30, the cushion 32, or both.

[0018] The seat back 22 is configured to support the back of a seated occupant. The seat back 22 is disposed adjacent to the seat 20. For example, the seat back 22 may be disposed above the seat 20 and near the rear of the seat 20. The seat back 22 extends generally upwardly away from the seat 20. In some configurations, the seat back 22 may be attached to the seat 20 and rotatable relative to the seat 20. In other configurations, the seat back 22 is not attached to the seat 20. For example, the seat back of a vehicle 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.

[0019] 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 wires on which the cushion 42 is positioned. Also, in some configurations, the seat back frame 40 may be integrally formed with the seat frame 30.

[0020] 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 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 20 or may be separate from the cushion 32 of the seat 20. The cushion 42 and related manufacturing methods are described in more detail below.

[0021] The trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible exterior surfaces of the seat back 22. A seat occupant may place themselves on the trim cover 44 when seated in the seat assembly 10. The trim cover 44 may be made of any suitable material, such as cloth, leather, leatherette, vinyl, or a combination thereof. The trim cover 44 may include a trim panel or multiple trim panels assembled by any suitable method, such as fusion or stitching. The trim cover 44 may be attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include a trim attachment portion attached to the seat back frame 40, the cushion 42, or both, to prevent removal of the trim cover 44 and to help the trim cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both.

[0022] If provided, the headrest 46 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 the end of the seat back 22 opposite the seat cushion 20. The headrest 46 may be movable in one or more directions relative to the seat back 22, or may be formed integrally with the seat back 22.

[0023] 3, an enlarged view of an example cushion 50 is shown. The cushions are generally referred to by the reference numeral 50 for ease of reference. It should be understood that the structure and description of cushion 50 may be applicable to cushion 32 of seat 20, cushion 42 of seat back 22, or both.

[0024] The cushion 50 is non-foamed or includes at least one non-foamed component. Non-foamed components are commonly referred to as mesh components, but may also be referred to as twisted, looped, tangled, filament mesh, mesh, twisted mesh, loop mesh, tangled mesh, or mesh cushion. In FIG. 3, the cushion 50 is depicted as non-foamed, without a foamed component or foam material, such as urethane foam or polyurethane foam. However, it is contemplated that the cushion 50 may include a foamed component or foam material in addition to the non-foamed component to provide additional or localized cushioning for the seat occupant. For example, foam material may be provided between the cushion 50 and a trim cover disposed on the cushion 50 (e.g., trim covers 34, 44), within the cushion 50, or a combination thereof. Reducing the amount of foam material provided in the cushion 50 or removing foam material from the cushion 50 can reduce weight and improve support and comfort for the seat occupant. Additionally, removing the foam material can facilitate recycling of the cushion 50.

[0025] The cushion 50 is described below in connection with a cushion 50 that does not include a foam material. In this regard, the cushion 50 is made of filaments 52 of polymeric material that are randomly looped, bent, curled, or entangled and bonded to one another as described in detail below. The filaments 52 are directly bonded to other filaments 52 rather than indirectly bonded with a resin or other intermediate material. For clarity, only a few filaments 52 are shown in FIG. 3 .

[0026] The filaments 52, also referred to as strands or threads, may be made of any suitable material or materials. In some configurations, the filaments 52 are made of a polymeric or 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 an example, a polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike or more easily recycled than a foamed material. It is also contemplated that the filaments 52 may include reinforcing fibers, but the reinforcing fibers may not be made of a thermoplastic material.

[0027] In some configurations, the filament 52 may be a monofilament made from a single material. In some configurations, the filament 52 is made from multiple materials. As an example, a multi-material filament 52 may include a core made from a first thermoplastic material and a sheath surrounding the core made from a second thermoplastic material different from the first thermoplastic material. It is contemplated that the cushion 50 may include a combination of monofilaments and multi-material, non-monofilament filaments.

[0028] The randomly looped, bent, looped, curled, or tangled filaments 52 are bonded together where one filament 52 contacts another filament 52, thereby producing a lightweight, air-permeable cushion (e.g., cushion 32 and / or 42) or mesh structure having openings or voids between the filaments 52. An example of a manufacturing system 60 for making a cushion or filament mesh structure is also shown in FIG. 2. In this example, the manufacturing system 60 includes a material feed 70, an extruder 72, and a funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0029] 2, 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, material supply 70 is configured as a container or hopper. Material supply 70 supplies the material stock to extruder 72.

[0030] The extruder 72 melts the material stock and extrudes it 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. Rotation of the screw moves the material through the barrel and helps heat the material due to friction generated as the screw rotates. The material exits the barrel in a molten state under pressure and is transported under pressure to a die 80 of the extruder 72.

[0031] The die 80, also known as a die plate or extrusion die, has a plurality of through-holes or filament-forming openings through which molten material passes. A single filament 52 is extruded from each through-hole. The filament 52 falls downward from the die 80 under gravity into the funnel 74.

[0032] The funnel 74 consolidates or groups the filaments 52 into a more compact arrangement, causing the filaments to bend, curl, or loop, and for each filament 52 to contact and bond with at least one other filament 52. The funnel 74 has an entrance opening or funnel inlet and an exit opening or funnel outlet that is smaller than the funnel inlet. Individual, separated filaments 52 enter the funnel inlet. The filaments 52 bend, curl, or loop, and as they accumulate, they move toward contact. The filaments 52 move through the funnel 74 toward the funnel outlet. As the filaments move toward the funnel outlet, some 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 exist at other locations where one filament 52 does not contact or bond with another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter a cooling tank 76. For ease of reference, the joined filaments 52 are referred to as a mesh member or filament mesh structure 90 .

[0033] The cooling tank 76 holds a liquid, such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 supports the entangled and bonded filaments 52, limiting further compression or interlocking of the filaments 52 and maintaining the desired porosity and density of the filament mesh structure 90. In this manner, the liquid provides some buoyancy or resistance that can further bend, curl, or loop the filaments 52 adjacent the surface of the liquid or within the funnel 74 to further build the filament mesh structure 90. The liquid also cools the filaments 52 while they are in the liquid. For example, the liquid cools the filaments 52 from the outside, solidifying the filaments 52 and preventing them from bonding in additional locations. At this point, the filaments 52 are relatively rigid and no longer in a plastic state; therefore, they generally retain their shape and cannot be molded or reshaped without reheating.

[0034] 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 help move 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 filaments 52.

[0035] 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 toward a conveyor belt 96 and shaker table 98 located outside the cooling tank 76. The shaker table 98 shakes the filament mesh structure 90 while 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 toward the filament mesh structure 90 to help remove the liquid from the filament mesh structure 90, or both. The filament mesh structure 90 can also be drip-dried or dried in ambient air.

[0036] The manufacturing system 60 described above is a continuous flow process, in which the filament mesh structure 90 is formed as a continuous structure when the extrusion of the filaments is uninterrupted. Further processing of the filament mesh structure 90 occurs after it exits the cooling tank 76, cutting the filament mesh structure 90 into individual pieces or blanks for individual cushions. Such processing is performed by a cutting system of the manufacturing system 60. The cutting system may be of any suitable type. For example, the cutting system may use a blade, knife, hot knife, saw, fluid jet, or the like to cut the filaments 52 of the filament mesh structure 90 into blanks. The cutting system may also be used to shape or contour the blank. The blank may be further shaped or contoured by other manufacturing processes, such as molding the entire blank or a portion thereof.

[0037] By the above process, cushion 50 may be formed from a set of filaments 52, at least two members of the set of filaments 52 being looped and bonded to one another. In one or more embodiments, each member of the set of filaments 52 is looped and bonded to at least one other member of the set of filaments.

[0038] 4 through 13, examples of portions of a seat assembly 10 are shown. The portion of the seat assembly 10 may be a portion of the seat bottom 20 or the seat back 22. Because the portion of the seat assembly 10 may be the seat bottom 20 or the seat back 22, the cushion, frame, and trim cover have been given general reference numerals for clarity and ease of reference.

[0039] The cushion is generally designated by the reference numeral 50 as previously mentioned.

[0040] The frames are generally designated by the reference numeral 100. The frame 100 may be the seat frame 30 or the seat back frame 40. The cushion 50 is disposed on the frame 100.

[0041] The trim covers are generally designated by the reference numeral 110 in Figures 5-13. The trim cover 110 may be the trim cover 34 of the seat cushion 20 or the trim cover 44 of the seat back 22. The trim cover 110 is not shown in Figure 4 for clarity.

[0042] In summary, the cushion 50, including the mesh member or filament mesh structure 90, may move or slide relative to the frame 100 when the cushion 50 is not secured to the frame 100, for example, when another component is attached to or attached to the cushion 50. For example, the cushion 50 may move or slide relative to the frame 100 when the trim cover 110 is pulled over or attached to the cushion 50 and the frame 100. Similarly, an intervening component, such as a heating pad disposed between the cushion 50 and the trim cover 110, may also move from a desired position on the cushion 50. As a result, the trim cover 110, heating pad, or other component may be difficult to install or require additional time to install when the cushion 50 is not secured to the frame 100. Furthermore, in configurations in which the cushion 50 is folded or wrapped around multiple sides of the frame 100, the flaps or segments of the cushion 50 that are folded or wrapped around the frame 100 tend to straighten out rather than following the contours of the frame 100 or the surface of the frame 100 on which the cushion 50 is positioned. As a result, the flaps of the cushion 50 may interfere with the installation of other components, such as trim covers, when the flaps are not secured to the frame 100. Furthermore, a cushion 50 that is generally vertically oriented, such as positioned along the height of a seatback frame, may sag, droop, slide, or move due to gravity when the cushion 50 is not secured to the frame 100, which may also cause the cushion 50 to move from its desired position and result in additional assembly time or effort.

[0043] To address these issues, the present invention secures (e.g., attaches, fastens, mates) the cushion 50 to the frame 100 using fasteners 120, some examples of which are shown in FIGS. 5-13. The fasteners 120 serve to hold the cushion 50 in a predetermined or desired position relative to the frame 100. One or more fasteners 120 can secure the cushion 50 to the frame 100. For example, as shown in FIG. 4, multiple fasteners 120 can be provided to secure the cushion 50 to the frame 100 at different locations. In some configurations, the fasteners 120 extend through apertures 136 (e.g., holes, openings, slits, slots, through-holes) in the frame 100. Examples of apertures 136 are shown in FIGS. 5-13. The fasteners 120 are generally designated by reference numeral 120, which may be followed by a letter (e.g., A, B, C, etc.) when referring to the fasteners shown in a particular figure, such as FIGS. 5-13.

[0044] The fasteners 120 are detached (e.g., disconnected, detached, unattached, uncoupled, unsecured) from the trim cover 110. As such, the fasteners 120 secure the cushion 50 to the frame 100, but do not secure, attach, join, or fasten the trim cover 110 to the cushion 50, the frame 100, or both. Thus, the fasteners 120 are distinct from the components that secure the trim cover 110 to the frame 100.

[0045] In some configurations, the fasteners 120 support the trim cover 110. For example, the fasteners 120 may directly support the trim cover 110 or may indirectly support the trim cover 110. The fasteners 120 may directly support the trim cover 110, for example, by contacting or engaging the side of the trim cover 110 that faces the cushion 50. The fasteners 120 may indirectly support the trim cover 110, for example, when an intermediate component or layer is disposed between the fasteners 120 and the cushion 50 and the side of the trim cover 110 that faces the fasteners 120.

[0046] 4 and 5, an example of a portion of a frame 100 is shown. In some configurations, the frame 100 includes multiple frame members, such as a first frame member 130, a second frame member 132, and a third frame member 134. One or more of the frame members (e.g., the first frame member 130, the second frame member 132, the third frame member 134) include an opening 136 (e.g., an opening, a hole, a through-hole, a slit, a slot). In some configurations, the opening 136 is surrounded or enclosed by the frame members. In some configurations, the opening 136 may be open-ended or may be partially surrounded or enclosed by the frame members. The opening 136 can facilitate attachment or mounting of a fastening device 120 to the frame 100, as described in more detail below.

[0047] The first frame member 130, the second frame member 132, and the third frame member 134 may be integrally formed or may be separate components that are assembled to one another, such as by welding or one or more fasteners. The first frame member 130 and the second frame member 132 may be disposed along opposite sides of the seat assembly 10. For example, the first frame member 130 and the second frame member 132 may be disposed along opposite left and right sides of the seat 20 or opposite left and right sides of the seat back 22. The third frame member 134 may interconnect the first frame members 130 within the second frame member 132. For example, the third frame member 134 may extend from the first frame member 130 to the second frame member 132. As one example, the third frame member 134 may be a front cross member or a rear cross member of the seat frame 30. As another example, the third frame member 134 may be an upper cross member or a lower cross member of the seat back frame 40.

[0048] The cushion 50 may engage or contact one or more frame members, such as the first frame member 130, the second frame member 132, the third frame member 134, or a combination thereof. In some configurations, the cushion 50 may contact or engage one or more sides of the frame 100 or frame members. For example, in some configurations, the cushion 50 may include one or more flaps 140 (best shown in FIG. 4) folded or wrapped around the frame 100 or frame members such that the flaps 140 engage or contact multiple sides of the frame 100 or frame members. Three flaps 140 are shown in FIG. 4. Each flap 140 is separated from another flap 140 by a cut or slit through the cushion 50. The two cuts or slits are represented in FIG. 4 by angled lines extending from two upper corners of the cushion 50 between adjacent flaps 140. The flaps 140 may be an integral part of the cushion 50. For example, the flap 140 may be integrally formed with the main body or central body 142 of the cushion 50 that can support a seat occupant, and the flap 140 may extend from or be provided along the periphery of the main body or central body 142.

[0049] Referring primarily to FIG. 5 , the cushion 50 may have a first side 144 and a second side 146. The first side 144 may face the frame 100. For example, the first side 144, or a portion thereof, may engage or contact the frame 100. The first side 144 may include a main body or central body 142 and a flap 140. In some configurations, such as when a flap 140 is included, the first side 144 of the cushion 50 engages or contacts multiple sides of the frame 100 or frame member. In the example shown in FIGS. 5 through 12 , the cushion 50 is folded or wrapped around the frame 100 such that the main body or central body 142 engages a first frame side 150 of the frame 100 or frame member and the flap 140 engages or contacts one or more additional sides of the frame 100 or frame member, e.g., a second frame side 152 and a third frame side 154. In some configurations, the second frame side 152 may extend from the first frame side 150, and the third frame side 154 may extend from the second frame side 152. For example, the second frame side 152 may extend from the first frame side 150 to the third frame side 154. Thus, in this example, the first side 144 of the cushion 50 engages the first frame side 150, the second frame side 152, and the third frame side 154. The cushion 50 may also wrap around or extend onto fewer sides of the frame 100 or frame member. For example, the cushion 50 may engage the first frame side 150 and the second frame side 152 without extending to the third frame side 154.

[0050] The second side 146 of the cushion 50 is disposed opposite the first side 144. As such, the second side 146 may face away from the frame 100 or may face toward the trim cover 110 and engage or contact the trim cover.

[0051] The cushion 50 includes a hole 160 (e.g., an opening, a slit, a slot). In some configurations, the hole 160 is a through hole extending from the first side 144 of the cushion 50 to the second side 146 of the cushion 50. Examples of holes 160 configured as through holes are shown in FIGS. 5-9 and 11-13. In some configurations, the hole 160 is a blind hole as shown in FIG. 10. For example, a hole 160 configured as a blind hole may extend from the first side 144 of the cushion 50 toward the second side 146 of the cushion 50, but may not extend to the second side of the cushion. The fastener 120 is received within the hole 160 of the cushion 50. The fastener 120 is configured to extend through the hole 160 of the cushion 50.

[0052] Referring primarily to FIG. 5, in some configurations, the hole 160 in the cushion 50 includes a recess 162 and a linkage 164 .

[0053] The recess 162 (e.g., a recess, cavity, open slot) can extend from the second side 146 of the cushion 50 toward the first side 144 of the cushion 50. The recess 162 can receive an anchor of the fastening device 120, as discussed in more detail below. For example, the recess 162 can extend from the second side 146 toward the coupling portion 164. In some configurations, the recess 162 can include, or at least partially define, a recess perimeter 166 and a recess bottom 168.

[0054] The recess perimeter 166 may extend from the second side 146 of the cushion 50 to the recess bottom 168. The recess perimeter 166 may include one or more sides that surround, enclose, or form a peripheral boundary of the recess 162. In some configurations, the recess perimeter 166 may have a circular or arcuate configuration. However, it is contemplated that the recess perimeter 166 may have a non-circular configuration, such as a polygonal configuration, an elliptical configuration, or a combination of straight and curved sides. In some configurations, the recess perimeter 166 may be disposed substantially perpendicular to the second side 146. However, it is contemplated that the recess perimeter 166 may not be perpendicular, but instead may be tapered, curved, or angled such that the recess perimeter 166 extends away from the second side 146 of the cushion 50 toward the recess bottom 168.

[0055] The recess bottom 168, also referred to as the recess bottom side, extends from the recess perimeter 166 to the connector 164. The recess bottom 168 is offset from the first side 144 and the second side 146 of the cushion 50. For example, the recess bottom 168 can be recessed or positioned deep within the cushion 50 such that the recess bottom 168 is positioned between the first side 144 and the second side 146. The recess bottom 168 can extend or protrude outward in one or more directions from the connector 164.

[0056] The interlocking portion 164 (e.g., a slit, incision, slot, or opening) extends from the recess 162 to the first side 144 of the cushion 50. For example, the interlocking portion 164 can extend from the recess bottom 168 to the first side 144 of the cushion 50. The interlocking portion 164 is smaller or narrower than the recess 162. As such, the interlocking portion 164 can be sized to prevent or inhibit an anchor of the fastening device 120 received in the recess 162 from passing through or being pulled through the interlocking portion 164, as described in more detail below.

[0057] 5-13, various configurations of the fastening device 120 will now be described in more detail. In some configurations, the fastening device 120 includes an anchor 170, a connecting member 172, and an attachment portion 174.

[0058] The anchor 170 helps secure the fastening device 120A to the cushion 50. For example, the anchor 170 (e.g., a base, clamp, foundation, reinforcement, etc.) may be received in the cushion 50 and may distribute a load force across a portion of the cushion 50. In some configurations, the anchor 170 is disposed in the recess 162. For example, the anchor 170 may engage or contact the recess bottom 168 or extend between the recess bottom 168 and the trim cover 110. In some configurations, the anchor 170 may be aligned with or flush with the second side 146 of the cushion 50 to help support the trim cover 110 and mask the location of the anchor 170. For example, aligning the side of the anchor 170 facing the trim cover 110 with the second side 146 of the cushion 50 may provide a visible bulge or recess in the trim cover 110, providing a desired aesthetic appearance. Anchor 170 may be sized such that anchor 170 does not fit through connector 164 of hole 160, or such that anchor 170 cannot be pulled out of recess 162 and into or through connector 164 in such a way that fastening device 120 no longer secures cushion 50 to frame 100. For example, anchor 170 may extend outward from connecting member 172 and connector 164 of hole 160.

[0059] The connecting member 172 may extend from the anchor 170 to the attachment portion 174. The connecting member 172 may extend from the anchor 170 into the connection portion 164 of the hole 160 in the cushion 50. The connecting member 172 may have any suitable configuration. For example, the connecting member 172 may be configured as a strap, strip, cord, ribbon, rod, shaft, wire, tube, etc. The connecting member 172 may be sufficiently resistant to stretch so that the fastening device 120, when attached, helps the fastening device 120 to maintain the cushion 50 taut relative to the frame 100, thereby maintaining the position of the cushion 50 relative to the frame 100.

[0060] The attachment portion 174 secures the fastening device 120 to the frame 100. In some configurations, the attachment portion 174 is located on the end of the connecting member 172 opposite the anchor 170. The attachment portion 174 engages or contacts the frame 100. The attachment portion 174 may be provided in a variety of configurations. For example, the attachment portion 174 may be configured as a fastener (e.g., a threaded fastener, a pin, etc.), a ring, a clip, a hook, a barbed or "Christmas tree" fastener, a bead, an expanding bead, a hook and loop fastener, etc. In some configurations, the attachment portion 174 and the connecting member 172 are located on opposite sides of the frame 100 or on opposite sides of the frame member in which the opening 136 is provided. 5 and 7-13, the mounting portion 174 is disposed on a first side (left side from the perspective of the illustration) of a frame member, such as third frame side 154, while the connecting member 172 is disposed on or extends from an opposite second side (right side or third frame side 154) from the perspective of the illustration. Locating the mounting portion 174 and the connecting member 172 on opposite sides of the frame 100, frame member, or wall of the frame member can help the mounting portion 174 resist disengagement from the frame 100.

[0061] The openings 136 in the frame 100, the holes 160 in the cushion 50, and the fasteners 120 may be located in a variety of positions. For example, these features may be provided such that the fasteners 120 are located along the side of the seat assembly 10 that faces or is located below the seat occupant, or along the side of the seat assembly 10 that does not face or is not located below the seat occupant. For example, while the fasteners 120 in FIGS. 5-13 are illustrated as extending through the flaps 140 of the cushion 50, it is contemplated that the fasteners 120 may extend through holes 160 in the main or central body 142 of the cushion 50, and that the holes 136 in the frame 100 may be located adjacent to or aligned with the holes 160 in the main or central body 142. In such a configuration, the fasteners 120 may be recessed further into the cushion 50 such that a seat occupant is less likely to notice the presence of the fasteners 120. It is also contemplated that the fastening device 120 may extend through the flap 140 in a different position or orientation, such as vertically or in a more vertical direction than that shown in Figures 5 through 13. As an example, the fastening device 120 may extend through a hole 160 in the flap 140 to a hole 136 provided in the second frame side 152.

[0062] Various fastening arrangements will now be described in more detail with reference to Figures 5 to 13.

[0063] Referring to FIG. 5 , fastener 120A is shown in which attachment portion 174 has an enlarged head, such as a bead, barbed wire, or "Christmas tree" fastener. Attachment portion 174 is insertable through opening 136 in at least one direction, such as extending left from the perspective shown. For example, attachment portion 174 may be compressible such that attachment portion 174 is tightened or compressed to allow attachment portion 174 to pass through opening 136 and then expands toward or to its previous configuration upon exiting opening 136. Connecting member 172 extends through connecting portion 164 of hole 160 in cushion 50. Anchor 170 is received in recess 162 in cushion 50.

[0064] 6, fastener 120B is shown in which attachment portion 174 mates with corresponding threads in hole 160 of cushion 50 or is self-tapping and forms threads in hole 160 when rotated and driven into frame 100. In some configurations, fastener 120B may be configured as a screw in which connecting member 172 is the rigid or rigid shank of the screw and anchor 170 is the head of the screw.

[0065] 7, a fastening device configuration is shown in which the attachment portion 174 of the fastening device 120C is a hook. The hook may be configured so that the hook is insertable and removable through the opening 136 and frame 100 at a particular angle but not through the opening 136 in other directions. For example, in the configuration shown, the hook extends along the side of the frame 100 or frame member in a direction away from the opening 136 to secure the cushion 50 to the frame 100 and prevent removal through the hole 160. In such a configuration, the fastening device 120C may be integrally formed with the connecting member 172.

[0066] 8, an illustrative fastener configuration is shown in which fastener 120D includes attachment portion 174 configured as a hook that is not integrally formed with connecting member 172. Attachment portion 174 may be secured to connecting member 172 in any suitable manner, such as by stitching, adhesive, welding, fasteners extending through attachment portion 174 and coupling portion 164, or a combination thereof. In this configuration, the hook is shown with a more rounded or "J" shape that facilitates insertion of the hook through opening 136.

[0067] 9, a fastener arrangement 120E is shown in which a mounting portion 174 of the fastener arrangement 120E extends through at least one opening 136 in the frame 100 and extends at least partially around the connecting member 172. For example, the mounting portion 174 can be configured as a ring that extends around or encircles the connecting member 172 and at least a portion of the frame 100. For example, the mounting portion 174 can be a ring that engages and extends around an enlarged end of the connecting member 172, which is shown in a circular configuration in FIG. 9. In some configurations, the mounting portion 174 can extend through a pair of openings 136 and the frame 100. The ring may have a U-shape in which the free ends of the ring are first inserted through the different openings 136, 136 and then bent or crimped to at least partially extend around or surround the intervening region of the frame 100 that is located between the pair of openings 136, 136 to form a loop or ring that at least partially surrounds the intervening region, thereby securing the mounting portion 174 to the frame 100 and the connecting member 172.

[0068] Referring to FIG. 10 , the fastening device 120F is shown with an anchor 170 disposed in a hole 160 in the cushion 50 configured as a blind hole. The blind hole extends from the first side 144 of the cushion 50 toward the second side 146 of the cushion 50, but does not necessarily extend to the second side 146 of the cushion 50. The attachment portion 174 may have any of the configurations described above and secures the fastening device to the frame 100. The connecting member 172 extends from the attachment portion 174 into the hole 160. The anchor 170 is disposed on the interior side of the cushion 50. The anchor 170 may be disposed between the first side 144 of the cushion 50 and the second side 146 of the cushion 50. In some configurations, the anchor 170 may be positioned away from the second side 146 of the cushion 50 such that the filament mesh structure 90 extends between the anchor 170 and the second side 146 to prevent a person or seat occupant from feeling the presence of the fastening device 120F when the second side 146 of the filament mesh structure 90 is compressed toward the anchor 170.

[0069] In some configurations, the anchor 170 is configured as a clip that engages the connecting member 172 and hooks (e.g., latches, interlocks, intermeshes, grasps, clenches, etc.) to at least one member of the set of filaments 52. For example, the anchor 170 can include one or more arms 180 and one or more protrusions 182. In the illustrated configuration, two arms 180 are shown having hooks 184 at their spaced-apart distal ends. The arms 180 are flexible to allow a portion of the connecting member 172 or the enlarged end of the connecting member 172 to be inserted through the gap between the hooks 184 and into a cavity disposed between the arms 180. The hooks 184 are configured to grip and retain the connecting member 172 or the enlarged end within the cavity. In this manner, the anchor 170 engages or grips the connecting member 172. One or more protrusions 182 may extend from arms 180 and may be configured to engage and hook with filaments 52 of filament mesh structure 90 to prevent removal of anchor 170 from cushion 50. In some configurations, protrusions 182 may be angled to extend toward frame 100 or positioned substantially parallel to the side of frame 100 to help prevent removal of anchor 170 from holes 160.

[0070] 11-13, fastening configurations using a hook and loop fastener 190 are shown. In these configurations, as in the configurations previously described, including those shown in FIGS. 5-9, the attachment portion 174 engages with the frame 100 to secure the fastening configuration to the frame 100, and the connecting member 172 extends from the attachment portion 174 into the hole 160 in the cushion 50. The anchor 170 is positioned in the recess 162 in the cushion 50 and includes the hook and loop fastener 190. In some configurations, the hook and loop fastener 190 includes two components or straps. The first component 192 or strip of the hook and loop fastener 190 can include a hook or a loop. The second component 194 or strip of the hook and loop fastener 190 can include a loop or a hook. For example, if the first component 192 includes a hook, the second component 194 can include a loop, and vice versa. When the hook and loop engage with each other, the first component 192 is secured to the second component 194. The hook and loop fastener 190 can be placed in the recess 162 of the cushion 50. In Figures 11-13, the anchor 170 and its hook and loop fastener 190 are shown as being placed in the recess 162 of the cushion 50.

[0071] Referring to FIG. 11 , fastening system configurations are shown in which a first component 192 of a hook and loop fastener 190 engages and optionally secures to the cushion 50, and a second component 194 of the hook and loop fastener 190 is secured to a connecting member 172 of the fastening system 120G. In some configurations, the first component 192 is attached to or is attached to the anchor 170 or a reinforcing panel of the anchor 170. In some configurations, the anchor 170 or its reinforcing panel engages the recess bottom 168. In other configurations, the anchor 170 or the first component 192 of the hook and loop fastener 190 is secured to the cushion 50 with adhesive, welding, fasteners, etc. The second component 194 is secured (e.g., secured, attached, coupled, secured, joined) to the connecting member 172 in any suitable manner, such as with fasteners, adhesive, welding, stitching, or a combination thereof. As shown, the hook and loop fastener 190 is positioned between the recess bottom 168 and the connecting member 172, and the second component 194 is positioned closer to the trim cover 110 than the first component 192 is positioned on the trim cover 110.

[0072] Referring to FIG. 12 , the fastener elements are shown with the connecting member 172 of the fastener 120H engaging the recess bottom 168, and the hook and loop fastener 190 positioned between the anchor 170 or a reinforcing panel of the anchor 170 and the connecting member 172. The anchor 170 may include or be configured with a panel or reinforcing feature to which the first component 192 is attached. The anchor 170 or a reinforcing panel of the anchor 170 may be positioned adjacent to, engage with, or contact the trim cover 110. The second component 194 is secured to the connecting member 172, as previously described. The connecting member 172 engages the recess bottom 168 and is removably attached to the cushion 50. In this manner, the hook and loop fastener 190 is positioned between the anchor 170 or a reinforcing panel of the anchor 170 and the connecting member 172, and the first component 192 is positioned closer to the trim cover 110 than the second component 194 is positioned to the trim cover 110.

[0073] Referring to FIG. 13 , a fastening system 120I is shown having multiple connecting members and attachment portions. For example, the fastening system can include a first connecting member 172 and a second connecting member 172′. The first connecting member 172 and the second connecting member 172′ are secured to the frame 100 by corresponding attachment portions 174, which can have any of the configurations described above. Each attachment portion can be associated with or adjacent to a different opening 136, 136′ in the frame 100. The first connecting member 172 can extend through a first connecting portion 164 in the cushion 50. The second connecting member 172′ can extend through a second connecting portion 164′ in the cushion 50. In some configurations, the first connecting portion 164 and the second connecting portion 164′ abut or extend from a recess 162 in the cushion 50. A hook and loop fastener 190 can be secured to the first connecting member 172 and the second connecting member 172′. For example, a first component 192 of the hook and loop fastener 190 can be secured to the first connecting member 172, and a second component 194 of the hook and loop fastener 190 can be secured to the second connecting member 172'. The first component 192 engages with the second component 194 to secure the first connecting member 172 to the second connecting member 172'. In this manner, the first connecting member 172 and the second connecting member 172' are secured to the frame 100 and are secured or fastened to each other by the hook and loop fastener 190, securing the cushion 50 to the frame 100 therebetween.

[0074] The seat assembly can be assembled using a variety of processes. In some configurations, the fasteners 120 are attached after the cushion 50 is placed on the frame 100 and before one or more other components, such as the trim cover 110, are attached to or on the cushion 50. For example, the seat assembly can be assembled by placing the cushion 50 on the frame 100 and then securing the cushion 50 to the frame 100 with the fasteners 120 extending through the openings 136 in the frame 100.

[0075] In some configurations, placing the cushion 50 on the frame 100 further includes folding or bending the cushion 50, such as one or more flaps 140 of the cushion 50, around the frame 100 before securing the cushion 50 to the frame 100 with the fastening device 120. Folding or bending the cushion 50 around the frame 100 can position the first side 144 of the cushion 50 to engage multiple sides of the frame, as previously described.

[0076] In some configurations, securing the cushion 50 to the frame 100 with the fasteners further includes inserting the fasteners 120 into holes in the cushion 50 or through the holes 160. The fasteners 120 can be inserted into the holes 160 before or after positioning the cushion 50 on the frame 100. For example, in some configurations, the fasteners 120 are inserted into the holes 160 in the cushion 50 and the openings 136 in the frame 100 after the cushion 50 is positioned on the frame 100. In other configurations, the fasteners 120 are positioned into the holes in the cushion 50 before the cushion 50 is positioned on the frame 100, and then the fasteners 120 are inserted into the openings 136 when the cushion 50 is placed on the frame 100. 10 , anchors 170 are inserted into holes 160 in cushion 50, connecting members 172 are secured to frame 100 using attachment portions 174, and then connecting members 172 are secured to anchors 170 after cushion 50 is positioned on frame 100. Trim cover 110 can be installed on or over cushion 50 after fastening cushion 50 to frame 100 using fasteners 120.

[0077] Clause 1. A seat assembly comprising: a frame having an opening; a cushion comprising a mesh member having a set of filaments of a polymeric material, at least two members of the set of filaments being looped and connected to one another, the cushion being positioned on the frame; and a fastener securing the cushion to the frame, the fastener extending through the opening in the frame.

[0078] Clause 2. The seat assembly of clause 1, further comprising a trim cover disposed over the cushion, the fastening device supporting the trim cover and being separate from the trim cover.

[0079] Clause 3. The seat assembly of clause 1 or clause 2, wherein the fastening device extends through a hole in the cushion.

[0080] Clause 4. The seat assembly of clause 3, wherein the hole in the cushion is a through hole extending from a first side of the cushion facing the frame to a second side of the cushion disposed opposite the first side.

[0081] Clause 5. The seat assembly of clause 3 or clause 4, wherein the hole in the cushion further comprises a recess extending from the second side of the cushion and a connecting portion extending from the recess to the first side of the cushion, the recess being at least partially defined by a recess bottom extending from the connecting portion and a recess perimeter extending from the recess bottom toward the second side.

[0082] Clause 6. The seat assembly of clause 5, wherein the fastening device comprises an anchor disposed in the recess.

[0083] Clause 7. The seat assembly of clause 6, wherein the fastening system comprises a connecting member extending from the anchor to the connecting portion of the hole in the cushion.

[0084] Clause 8. The seat assembly of clause 7, wherein the fastening device comprises a mounting portion that engages the frame to secure the fastening device to the frame.

[0085] Clause 9. The seat assembly of clause 8, wherein the mounting portion and the connecting member are disposed on opposite sides of the frame.

[0086] Clause 10. The seat assembly of clause 8 or clause 9, wherein the mounting portion extends through the opening in the frame and at least partially around the connecting member.

[0087] Clause 11. The seat assembly of clause 3, wherein the fastening device comprises: a mounting portion that engages with the frame to secure the fastening device to the frame; a connecting member that extends from the mounting portion to the hole in the cushion; and an anchor that is disposed inside the cushion and is disposed between a first side of the cushion facing the frame and a second side of the cushion that is disposed opposite the first side.

[0088] Clause 12. The sheet assembly of any of clauses 7 to 11, wherein the anchor engages the connecting member and hooks onto at least one member of the set of filaments.

[0089] Clause 13. The seat assembly of any of Clauses 3 to 5, wherein the fastening device comprises a mounting portion that engages with the frame and secures the fastening device to the frame, a connecting member that extends from the mounting portion into the hole in the cushion, and an anchor that is disposed in the recess, the anchor comprising a hook and loop fastener.

[0090] Clause 14. The seat assembly of clause 13, wherein the hook and loop fastener has a first component secured to the cushion and a second component secured to the connecting member, the first component secured to the second component.

[0091] Clause 15. The seat assembly of clause 13, wherein the connecting member engages the recess bottom, and the hook and loop fastener is disposed between the anchor and the connecting member.

[0092] Clause 16. The seat assembly of clause 13, subject to clause 5, wherein the fastening system further comprises a second connecting member secured to the frame and extending through a second hole in the cushion, the hook and loop fastener having a first component secured to the connecting member and a second component secured to the second connecting member, the first component secured to the second component.

[0093] Clause 17. A method of assembling a seat assembly, comprising: positioning a cushion on a frame, the cushion comprising a mesh member having a set of filaments of a polymeric material, at least two members of the set of filaments being looped and connected to one another, the frame comprising an opening; and securing the cushion to the frame with a fastener, the fastener extending through the opening in the frame.

[0094] Clause 18. The assembly method of clause 17, wherein the positioning step of positioning the cushion on the frame further comprises the step of folding the cushion around the frame before securing the cushion to the frame such that a first side of the cushion engages a first frame side of the frame and a second frame side of the frame.

[0095] Clause 19. The assembly method of clause 17 or clause 18, wherein the step of fastening the cushion to the frame with the fastening device further comprises inserting the fastening device through a hole in the cushion, the hole extending from a first side of the cushion facing the frame to a second side of the cushion positioned opposite the first side.

[0096] Clause 20: The assembly method of any one of clauses 17 to 19, further comprising attaching a trim cover over the cushion after securing the cushion to the frame.

[0097] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the present disclosure. In this regard, it is understood that the terms used herein are terms of description rather than limitation, and that various changes can be made without departing from the spirit and scope of the present disclosure. Furthermore, features of various embodiments can be combined to form further embodiments of the present disclosure.

Claims

1. a frame having an opening; a cushion comprising a mesh member having a set of filaments of a polymeric material, at least two members of the set of filaments being connected to each other in a looped configuration, the cushion being positioned on the frame; a fastener for securing the cushion to the frame, the fastener extending through the opening in the frame.

2. 2. The seat assembly of claim 1, further comprising a trim cover disposed over the cushion, the fasteners supporting the trim cover and being separate from the trim cover.

3. 2. The seat assembly of claim 1, wherein the fasteners extend through holes in the cushion.

4. 4. The seat assembly of claim 3, wherein the hole in the cushion is a through hole extending from a first side of the cushion facing the frame to a second side of the cushion disposed opposite the first side.

5. the hole in the cushion further comprises a recess extending from the second side of the cushion and a connecting portion extending from the recess to the first side of the cushion; 5. The seat assembly of claim 4, wherein the recess is at least partially defined by a recess bottom extending from the connecting portion and a recess perimeter extending from the recess bottom toward the second side.

6. 6. The seat assembly of claim 5, wherein the fastening device comprises an anchor disposed in the recess.

7. 7. The seat assembly of claim 6, wherein the fastening system comprises a connecting member extending from the anchor to the connecting portion of the hole in the cushion.

8. 8. The seat assembly of claim 7, wherein the fastener comprises a mount that engages the frame to secure the fastener to the frame.

9. 9. The seat assembly of claim 8, wherein the mounting portion and the connecting member are located on opposite sides of the frame.

10. 9. The seat assembly of claim 8, wherein the mounting portion extends through the opening in the frame and at least partially around the connecting member.

11. 4. The seat assembly of claim 3, wherein the fastening device comprises: a mounting portion that engages with the frame to secure the fastening device to the frame; a connecting member that extends from the mounting portion to the hole in the cushion; and an anchor that is disposed inside the cushion and is disposed between a first side of the cushion facing the frame and a second side of the cushion that is disposed opposite the first side.

12. 12. The sheet assembly of claim 11, wherein the anchor engages the connecting member and hooks onto at least one member of the set of filaments.

13. 6. The seat assembly of claim 5, wherein the fastening device comprises a mounting portion that engages the frame and secures the fastening device to the frame, a connecting member that extends from the mounting portion to the hole in the cushion, and an anchor that is disposed in the recess, the anchor comprising a hook and loop fastener.

14. 14. The seat assembly of claim 13, wherein the hook and loop fastener has a first component secured to the cushion and a second component secured to the connecting member, the first component secured to the second component.

15. 14. The seat assembly of claim 13, wherein the connecting member engages the recess bottom and the hook and loop fastener is disposed between the anchor and the connecting member.

16. 14. The seat assembly of claim 13, wherein the fastening system further comprises a second connecting member secured to the frame and extending through a second hole in the cushion, the hook and loop fastener having a first component secured to the connecting member and a second component secured to the second connecting member, the first component secured to the second component.

17. positioning a cushion on a frame, the cushion comprising a mesh member having a set of filaments of a polymeric material, at least two members of the set of filaments being looped and connected to one another, and the frame comprising an opening; and fastening the cushion to the frame with a fastener, the fastener extending through the opening in the frame.

18. 18. The assembly method of claim 17, wherein the positioning step of positioning the cushion on the frame further comprises the step of folding the cushion around the frame before securing the cushion to the frame so that a first side of the cushion engages a first frame side of the frame and a second frame side of the frame.

19. 18. The assembly method of claim 17, wherein the step of securing the cushion to the frame with the fastening device further comprises inserting the fastening device through a hole in the cushion, the hole extending from a first side of the cushion facing the frame to a second side of the cushion disposed opposite the first side.

20. 18. The method of claim 17, further comprising attaching a trim cover over the cushion after securing the cushion to the frame.

Images