Seat Assembly

Abstract

The seat assembly has a seat cushion defining a first surface for supporting an occupant and a second surface opposite the first surface, the first surface further defining a groove. The fastener has a longitudinal body having a central region located between the first end region and the second end region and a base extending outwardly from the second end region and transversely to the body. The first end region tapers away from the second end region, and the central region of the body defines a recess that meets the sidewall of the body to form a hook and slopes inwardly toward the first end region. The fastener penetrates the seat cushion with the base abutting the second surface and the first end region of the body extending into the groove.

Description

[Technical field]

[0001] Various embodiments relate to fasteners for use with a seat assembly, a seat assembly, and a method of assembling a seat assembly.

[0002] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application is a continuation of U.S. Patent Application No. 17 / 714,511, filed April 6, 2022, the disclosure of which is incorporated by reference in its entirety herein. [Background technology]

[0003] Vehicle seat assemblies may include fasteners used, for example, to hold a trim cover to an underlying cushion. Examples of vehicle seat assemblies and fasteners can be found in U.S. Pat. No. 6,899,399, U.S. Pat. No. 10,676,000, U.S. Patent Publication No. 2019 / 0344691, and International Publication No. WO01 / 24665. Summary of the Invention

[0004] In one embodiment, a seat assembly includes a seat cushion defining a first surface for supporting an occupant and a second surface opposite the first surface, the first surface further defining a groove. A fastener includes a longitudinal body having a central region disposed between a first end region and a second end region, and a base extending outwardly from the second end region and transversely relative to the body. The first end region tapers away from the second end region, and the central region of the body defines a recess that meets a sidewall of the body to form a hook and slopes inwardly toward the first end region. The fastener penetrates the seat cushion such that the base abuts the second surface and the first end region of the body extends into the groove.

[0005] In a further embodiment, the seat cushion is formed from interwoven mesh material members.

[0006] In a further embodiment, the braided mesh material member comprises a polymer mesh having a plurality of integrated polymer strands.

[0007] In another further embodiment, a trim cover is provided forming a seating surface, and tie-downs are connected to the trim cover, and the fasteners engage the tie-downs to connect the trim cover to the seating cushion.

[0008] In a further embodiment, a cushioning layer is disposed between the first surface of the seating cushion and the trim cover.

[0009] In a further embodiment, the tie-down defines an opening adjacent a bead of the tie-down, and the body of the fastener passes through the opening to connect the trim cover to the seating cushion.

[0010] In a further embodiment, the opening is at least partially defined by the bead of the tie-down.

[0011] In a further embodiment, a frame is provided to support the seat cushion.

[0012] In another further embodiment, the body defines a first finger extending from the first end region toward the base to a first distal end, the first finger cooperating with the central region to define the recess and form the hook.

[0013] In a further embodiment, the body defines a second finger extending from the second end region toward the first end region to a second distal end, the second finger cooperating with the central region to define the recess.

[0014] In a further embodiment, the second finger is angled inwardly relative to the body toward the second distal end.

[0015] In a further embodiment, the first distal end and the second distal end do not laterally overlap.

[0016] In a further embodiment, the fastener defines a central opening extending longitudinally through the second end region and intersecting the base.

[0017] In a further embodiment, the central opening intersects with the recess.

[0018] In another further embodiment, the base has a first surface facing the first end region of the body and a second surface opposite the first surface, the base defining at least one post extending longitudinally outward from the first surface of the base, the at least one post being spaced apart from the body.

[0019] In a further embodiment, the base defines an index that indicates an orientation of the hook.

[0020] In still further embodiments, the central region defines at least one projection extending outwardly from the central region and angled away from the first end region.

[0021] In another embodiment, the fastener comprises a member forming a longitudinal body having a central region disposed between the first end region and the second end region, the first end region tapering away from the second end region. The member forms a base extending outwardly from the second end region and laterally relative to the body. The central region of the body defines a recess extending laterally within the central region of the body and toward the first end region to meet a sidewall of the member and form a hook.

[0022] In yet another embodiment, a method of assembling a seat assembly is provided in which the tapered distal end of the fastener is inserted through the cushion until the base of the fastener abuts a first outer surface of the cushion and the distal end extends into a groove formed in a second outer surface of the cushion opposite the first outer surface. A trim cover having a tie-down is positioned on the second surface of the cushion. A hook defined by the fastener is inserted through an opening defined by the tie-down to connect the trim cover to the cushion.

[0023] In another embodiment, the cushion is formed from a woven mesh material that does not have pre-formed holes for the fasteners. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 illustrates a perspective view of a seat assembly according to one embodiment.

[0025] [Diagram 2] FIG. 2 is a partial perspective view of the vehicle seat assembly of FIG. 1 with fasteners according to one embodiment.

[0026] [Diagram 3] 2 is a partial cross-sectional view of the vehicle seat assembly of FIG. 1 with a fastener according to another embodiment.

[0027] [Figure 4] FIG. 4 is a front view of the fastener of FIG.

[0028] [Diagram 5] FIG. 4 is a top perspective view of the fastener of FIG.

[0029] [Figure 6] FIG. 4 is a bottom perspective view of the fastener of FIG.

[0030] [Figure 7] FIG. 13 is a top perspective view of a fastener according to yet another embodiment.

[0031] [Figure 8] FIG. 8 is a bottom perspective view of the fastener of FIG. 7.

[0032] [Figure 9] FIG. 8 is a side view of the fastener of FIG.

[0033] [Figure 10] FIG. 13 is a top perspective view of a fastener according to another embodiment.

[0034] [Figure 11] FIG. 11 is a bottom perspective view of the fastener of FIG.

[0035] [Figure 12] FIG. 11 shows a side view of the fastener of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] Where necessary, detailed embodiments of the present invention are disclosed herein. However, it should be understood that the disclosed embodiments are merely examples and can be implemented in various alternative forms. The drawings are not necessarily to scale. Some features may be exaggerated or minimized to show details of specific components. Therefore, specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art how to variously utilize the present disclosure.

[0037] Referring to FIG. 1, a seat assembly 20 is shown, such as a vehicle seat assembly 20. In other examples, the seat assembly 20 may be shaped and sized as a front row driver or passenger seat, a second row, a third row, or other rear row seat, and may include a bench seat as shown, a bucket seat, or other seating styles. Additionally, the seat assembly may be a non-stowable seat, or a stowable seat that may be foldable and stowable into a cavity in the vehicle floor. Additionally, the seat assembly 20 may be configured for use in other non-vehicle applications.

[0038] The seat assembly 20 includes a frame 22 or other support structure. The seat assembly includes seat components including at least a seat bottom 24 and a seat back 26. The seat bottom 24 may be sized to receive a seated occupant and support the occupant's pelvis and thighs. The seat back 26 may be sized to extend upright from the seat bottom 24 and support the occupant's back. The seat assembly may further include a head rest 27, which is shown only for the adjacent seat assembly. The seat bottom 24 includes a seat bottom cushion 28. The seat back 26 includes a back cushion 30. The frame 22 may include a wire suspension mat or other structure that supports the cushions 28, 30.

[0039] The frame 22 provides rigid structural support for the seat components, e.g., the seat bottom 24 and backrest 26, and may be provided as a plurality of frame members that are movable relative to one another to provide adjustment of the seat assembly. The frame may be formed from stamped steel alloy, fiber reinforced polymer, or any suitable structural material.

[0040] The trim cover 32 is used to cover the seat bottom cushion 28 and the seat back cushion 30 and provide a seating surface for the seat assembly 20. The vehicle seat assembly 20 is shown without the trim cover, while the adjacent seat assembly shows the trim cover 32. In one example, the trim cover 32 covers both the cushions 28, 30. In other examples, multiple trim covers are provided to cover the seat bottom and seat back cushions. The trim cover 32 may be formed from one or more panels of fabric, leather, synthetic leather, vinyl, or other materials.

[0041] The seat cushion 40 is described in further detail below, which description may apply equally to the seat bottom cushion 28 or the back cushion 30.

[0042] In the illustrated example, the seating cushion 40 includes at least one non-foamed component or member 42. In one example, as illustrated, the seating cushion 40 is formed solely from the non-foamed component 42 such that the non-foamed component 42 provides all of the cushioning for the seating components between the frame 22 and the trim cover 32. In other examples, the seating cushion 40 may be formed from the non-foamed component 42 and one or more foamed components, such as a component formed from molded polyurethane foam. The seating cushion 40 may have non-foamed and foamed components arranged to provide different regions of the cushion 40 for the seating components, for example, a central region and side bolster regions. Alternatively or additionally, the seating cushion 40 may have a thin foamed component or other layer of material arranged between the non-foamed component 42 and the trim cover 32 to provide additional cushioning for one or more regions of the seating components. Additionally, the seating assembly 20 may have a heating pad or heating mat arranged between the cushion 40 and the trim cover 32. By eliminating some or all of the traditional foam components from the seat cushion 40, the seat assembly 20 may provide improved support and comfort as well as reduced weight. In another example, the seat cushion 40 may be formed from a foam material, such as molded polyurethane foam.

[0043] In one non-limiting example, the non-foamed component or member 42 of the seat cushion 40 is formed by a twisted mesh material, also known as an intertwined three-dimensional filament structure. The twisted mesh material is formed from a polymer mesh having a plurality of integrated polymer strands. The twisted mesh material may be formed, for example, from a linear low density polyethylene (LLPDE) material, although other polymers and materials are contemplated that are effective in providing the desired properties and functionality. The twisted mesh material may be formed using extruded filaments of linear low density polyethylene (LLDPE), which are randomly twisted, bent, looped, or otherwise arranged and oriented, and directly bonded to each other to provide a porous mesh structure, an example of which is shown in detail in FIG. 3. The present disclosure is generally described below by way of example with respect to the twisted mesh material member 42. However, another non-foamed or molded component may be used in place of the twisted mesh material member 42 according to various embodiments of the present disclosure.

[0044] 1-3, the braided mesh material member 42 includes a first surface 44 and a second surface 46 disposed opposite the first surface 44. The first surface 44 is disposed on the seat assembly 20 to support an occupant of the seat assembly. The first surface 44 defines at least one groove 48. As used herein, the groove 48 may refer to an open channel or groove formed in the braided mesh material member 42 and intersecting the first surface 44. The groove 48 may further refer to a recess or blind hole formed in the braided mesh material member 42 and intersecting the first surface 44. The groove 48 has a floor 50 located between the first surface 44 and the second surface 46 of the braided mesh material member 42. Thus, the seat cushion 40 and interwoven mesh material member 42 have a first thickness between the first surface 44 and the second surface 46 adjacent the groove portion and a second thickness between the floor 50 and the second surface 46, the second thickness being less than the first thickness.

[0045] One or more fasteners 60 are provided and used to connect or attach the trim cover 32 to the seat cushion 40, which may include the intertwined mesh material member 42 described above or may be formed from another material. FIG. 2 illustrates an example fastener 60, and FIG. 3 illustrates another example fastener 100. The fastener 100 has a longitudinal body 102 extending from a first end region 104 to a second end region 106. The fastener 100 has a base 108 extending outwardly from the second end region 106 and transversely relative to the body 102. The first end region 104 tapers away from the second end region 106. A central region 110 of the body 102 is located between the first end regions 104, 106 and the second end region and forms a recess 112 that intersects with a sidewall 114 of the body 102. The recess 112 tapers inwardly toward the first end region 104 to form a hook. The fastener 60 has similar features as described above for the fastener 100, including the body 102, the base 108, and the hooked recess 112.

[0046] The fastener 100 is positioned to penetrate the twisted mesh material member 42 with the base 108 abutting the second surface 46. In another example, the fastener 100 is positioned to penetrate the seating cushion 40 or a component thereof. The first end region 104 of the body extends into the groove 48. The fastener 60 is inserted through the twisted mesh material member 42 from the second surface 46. The fastener 60 may be inserted by pushing or applying force to the base 108 of the fastener, for example, via a pin or other member on the fixture during the assembly process. The first end region 104 of the fastener 60 is forced through the twist of the member 42 as it is inserted, forming its own hole or passage through the twisted mesh material member 42 during insertion. In one example, there is no pilot hole or other hole for the fastener 100 formed or otherwise provided in the twisted mesh material member 42 before the fastener 100 is inserted. In another example, the cushion member 40 may be provided with preformed openings for the fasteners 100. As such, the assembly fixture may require guides or other alignment features for the cushion member 40 or interwoven mesh material member 42 to insert the fasteners 100 into the grooves 48. In a foam cushion, the fasteners may be overmolded or otherwise surrounded by the foam to position and locate the fasteners relative to the foam. However, these methods of attaching fasteners are not available for non-foam cushions 40 or interwoven mesh material members 42 as disclosed herein.

[0047] 1-3, the trim cover 32 includes a tie-down 80. The fastener 60 engages the tie-down 80 to connect the trim cover 32 to the seat cushion and the interwoven mesh material member 42. In one example, the tie-down 80 is formed from a nonwoven material and has a first edge region 82 and a second edge region 84. The first edge region 82 is sewn, glued, welded, or otherwise attached to the underside of the trim cover 32 or to a seam joining adjacent panels of the trim cover 32. The second edge 84 is connected to a bead 86. The bead 86 may be formed from plastic or other rigid material. The tie-down 80 defines an opening 88 between the two edge regions 82, 84. The body of the fastener passes through the opening 88 to connect the trim cover 32 to the seat cushion 40, and the hook holds the tie-down 80 to the fastener 60. In one example, the opening 88 is directly adjacent the bead 86 such that the hooks of the fastener 60 engage the bead 86 itself, e.g., the opening 88 is at least partially defined by the bead 86. In other examples, the opening 88 may be located away from the bead 86 and defined only through the nonwoven portion of the tie-down 80.

[0048] An optional cushioning layer 90 is shown in dashed lines in FIG. 3 , which covers the first surface 44 of the interwoven mesh material member 42 so as to be disposed between the first surface 44 of the interwoven mesh material member and the trim cover.

[0049] Figure 3 illustrates a partial cross-sectional view of the seat cushion 40 of Figure 1 described above and a fastener 100 according to one embodiment. Figures 4-6 show additional views of the fastener 100 of Figure 3.

[0050] The longitudinal body 102 extends from a first end region 104 to a second end region 106. The longitudinal body 102 has sidewalls 114 that circumscribe a longitudinal axis. A central region 110 is located between the first end region 104 and the second end region 106. As shown in Figures 3-6, the body 102 has a generally circular cross-sectional shape. As used herein, "generally" means a perimeter that includes any recessed regions and omits any ribs or other features that project outwardly from the body 102. As used herein, "generally" also means a perimeter that has a circular or other curved non-circular shape, such as an ellipse, oval, or oval, and whose distance from the center (or the longitudinal axis of the fastener) varies by 20% or less in cross section.

[0051] The first end region 104 of the body tapers away from the second end region 106 and tapers to a rounded or blunt end or nose. In one example, the first end region 104 may be ogive shaped with a parabolic or other rounded end or nose. The tapered shape of the first end region 104 allows for easy insertion of the fasteners 100 into the braided mesh material member 42 and also provides a rounded or blunt nose for occupant comfort when the cushion 40 is compressed sufficiently during use such that the fasteners 100 can be felt by the occupant.

[0052] A central region 110 of the body is located between the first end region 104 and the second end region 106 and defines a recess 112 that intersects with a sidewall 114 of the body. The recess 112 slopes inwardly toward the first end region 104 to form a hook for a fastener. The recess 112 and the hook are shaped and sized to receive a tie-down, such as a bead of a tie-down.

[0053] The body 102 defines a first finger 120 that extends from the first end region 104 toward the base 108 to a first distal end 122. The first finger 120 defines a recess 112 to cooperate with the central region 110 to form a hook. The first distal end 122 of the first finger 120 may have a convex profile as shown in FIG. 4 to help retain the tie-down 80. An inner surface 124 of the first finger 120 may be shaped such that the tie-down 80 is guided toward the first end region 104 once inserted into the recess 112.

[0054] In some examples, as shown, the body 102 also defines a second finger 130 that extends from the second end region 106 toward the first end region 104 to a second distal end 132. The second finger 130 may be angled inwardly relative to the body 102 to its second distal end 132, as shown. The second finger 130 also cooperates with the central region 110 to define a recess 112. The recess 112 may be collectively defined by the first and second fingers 120, 130 and the neck 140.

[0055] The second finger 130 may prevent or limit twisting of the intertwined mesh material member 42, or other cushion member 40 material, from entering the recess as the fastener 100 is inserted through the recess 112. The second finger 130 may also assist in retaining the tie-down 80 within the recess 112. The second finger 130 may have an average lateral thickness that is less than the average lateral thickness of the first finger 120, such that the second finger 130 can flex or move relative to the body 102. This allows the second finger 130 to flex as the tie-down 80 is inserted into the recess 112. The second finger 130 also has an outer guide surface 134, which may be planar as shown. The outer guide surface 134 similarly assists in inserting the tie-down into the recess 112.

[0056] In one example, as shown, the first distal end 122 of the first finger and the second distal end 132 of the second finger do not laterally overlap. In other examples, the first distal end 122 of the first finger and the second distal end 132 of the second finger may laterally overlap one another, which may further assist in retaining the bead of the tie-down 80.

[0057] The body 102 forms a neck 140 adjacent the recess 112 in the central region 110. Ribs 142 or fins extend longitudinally and outwardly from the fastener sidewall 114 from the base 108 and second end region 106 toward the first end region 104. As shown, the ribs 142 may taper toward the first end region 104 to aid in fastener insertion. The ribs 142 or fins overlap the fastener neck 140 to reinforce the neck.

[0058] The base 108 extends outwardly and laterally from the second end region 106. The base 108 has a first surface 150 facing the first end region 104 of the body and a second surface 152 opposite the first surface. When the tie-down 80 engages an attached fastener 60,100, as shown in Figures 2-3, the tie-down 80 may exert a tension force on the fastener 60,100. The first surface 150 of the base 108 engages and cooperates with the second surface 46 of the cushion member 40 or braided mesh material member 42 to limit movement of the fastener 100 and hold the fastener 100 in its position within the cushion member 40 or braided mesh material member 42.

[0059] The base 108 may define one or more indicators 154 that indicate the orientation of the fastener recesses 112 and hooks. In the illustrated example, the base 108 has radial projections 156 or fins extending from the base second surface 152 from a central region of the base 108 toward the edge of the base, the projections 156 being radially aligned with the recesses 112 and hooks. In other examples, the indicators 154 may be provided as grooves in the base second surface 152. In yet another example, the cross-sectional shape of the base 108 may be non-circular, such as a D-shape, or include a notch or other flat edge to provide the orientation indicators 154 with respect to the recesses 112 and hooks. A fastener used to insert the fastener 100 may include features that mate or engage with the orientation indicators 154 to align the fastener and the cushion member 40 or the braided mesh material member 42. Alternatively, the orientation indicator 154 may be used as a visual cue for manually inserting a fastener into the cushion member 40 or the interwoven mesh material member 42 .

[0060] The fastener may also define a central opening 160 extending longitudinally through the second end region 106 and intersecting with the base 108 as shown. In the illustrated example, the central opening 160 may also intersect with the recess 112 to provide a through hole. The central opening 160 may be used with a pin or other member of a fastener used in attaching the fastener 100 to the cushion member 40 or the twisted mesh material member 42. The pin is inserted into the central opening 160. A shoulder may be provided on the pin to apply a force against the second surface 152 of the base. Alternatively or additionally, the pin may extend into the recess 112 during attachment to apply a force to an inner surface of the recess 112 adjacent the first end region 104. In other examples, the fastener 100 may be provided without a central opening such that the insertion force is applied to the second surface 152 of the base 108.

[0061] Alternatively, instead of indicators 154 formed on base 108 as shown, openings 160 may be formed with a cross-sectional shape to provide an orientation indicator, such as a D-shape, or a notch or other flat edge. A pin or other member on the fixture that inserts the fastener through cushion member 40 or interwoven mesh material member 42 may then be formed to have a shape that corresponds to opening 160 for orienting the fastener.

[0062] Figures 7 to 9 show a fastener 200 according to yet another embodiment. The fastener 200 may be used with a vehicle seat assembly 20 as described above with respect to Figures 1 to 3. Elements that are the same or similar to those described above with respect to Figures 1 to 6 bear the same reference numbers for simplicity. Furthermore, only those features that differ from those described above will be described in detail below.

[0063] Similar to the fastener 100 of FIGS. 3-6, the fastener has a rib 142 extending outwardly from the body sidewall 114 from the second end region 106 toward the first end region 104. The rib 142 also tapers toward the first end region 104. The rib 142 defines at least one projection 202 that is angled away from the first end region 104. The projection 202 acts to retain the fastener 200 within the cushion member 40 or interwoven mesh material member 42 and to limit or prevent the fastener from dislodging from the cushion member 40 or interwoven mesh material, for example, by moving away from the groove 48 and the tie-down. After engaging the strands of the interwoven mesh material member 42, the projection 202 may further limit rotational movement of the fastener 200 within the cushion member 40 or interwoven mesh material member 42, for example, about the longitudinal axis of the fastener. As shown, the shape and size of the spaces between the protrusions 202 may be configured to receive one or more strands of interwoven mesh material.

[0064] Also, as shown, the first distal end 122 of the first finger 120 and the second distal end 132 of the second finger 130 overlap each other laterally, which may further aid in retaining the bead of the tie-down.

[0065] Figures 10-12 show a fastener 250 according to yet another embodiment. The fastener 250 may be used with the vehicle seat assembly 20 as described above with respect to Figures 1-3. Elements that are the same or similar to those described above with respect to Figures 1-6 bear the same reference numbers for simplicity. Furthermore, only those features that differ from those described above will be described in detail below.

[0066] Fastener 250 has only first finger 120 and no second finger. First finger 120 is long enough to hold tie-down 80 in recess 112 with the tension on the tie-down and fastener.

[0067] The first surface 150 of the base 108 defines at least one post 252 extending longitudinally outward therefrom. Although two posts 252 are shown, a single post or more than one post are contemplated. The post 252 is spaced apart from the body 102 of the fastener. Upon engagement with the cushion member 40 or the braided mesh material member 42, the post 252 limits rotational movement of the fastener 250 within the cushion member or braided mesh material member, e.g., rotational movement about the longitudinal axis of the fastener. The post 252 has a length that is less than the length of the body 102 and a diameter that is less than the diameter of the second end region 106 of the body. Although the post 252 is shown as having a generally smooth outer surface, it is also contemplated that the outer surface of the post 252 may include a sloped protrusion away from the first end region 104 to further limit longitudinal movement of the fastener 250 relative to the cushion member 40 or the braided mesh material 42.

[0068] The second surface 152 of the base 108 defines a plurality of indicia that cooperate to provide an orientation indication of the hooks and recesses 112 .

[0069] The fastener 250 defines a central opening 254 that extends longitudinally through the second end region 106 and intersects with the base 108. As shown in Figures 10-11, the central opening 160 is formed as a blind hole that does not intersect with the recess 112.

[0070] It is further contemplated that various features of the fasteners 60, 100, 200, 250 described above with respect to Figures 2-12 may be interchanged to form additional fasteners of the present disclosure.

[0071] Methods of assembling the seat assembly are also provided. The cushioning members may be formed or otherwise provided and may be provided as foamed or non-foamed components. According to one example, with respect to the braided mesh material member, the member 42 may be formed by extruding thin filaments of linear low density polyethylene or other suitable material from a hopper or other material source through a die plate. The thin filaments may be heated as they are extruded to exit the die plate in a molten state. The filaments are then solidified or grouped through a funnel or similar structure such that the filaments bend or loop and contact and bond with other filament(s). The grouped filaments may then enter a water bath or other cooling system to cool and solidify the filaments to provide additional resistance for further bending or looping of the filaments, prevent further solidification of the filaments, maintain the porosity of the structure, and prevent further bonding between the filaments. The water or cooling system may include various rollers or other conveying members that act to move the solidified filament structure and may additionally form one or more grooves or other features within the filament structure. The assembled filament structure is then dried and cut into the appropriate shape for the cushion member 42. If grooves are not formed in the structure during the forming process, e.g., in the cooling system, grooves may be machined or otherwise provided in the interwoven mesh material member after it is dried and before or after it is cut into the selected shape. According to one example, the non-foamed material cushion is formed without preformed holes for the fasteners 60, 100, 200, 250. According to another example, preformed holes for the fasteners 60, 100, 200, 250 are formed when the member 40 is formed or are machined or otherwise formed thereafter.

[0072] The braided mesh material member 42 with the grooves 48 is then placed into a tool having a fixture for inserting the fastener(s) 60, 100, 200, 250. The fastener(s) 60, 100, 200, 250 are provided on a fixture, which positions and orients the fastener(s) 60, 100, 200, 250 relative to the member 42 and the grooves, as described above. A fixture may be required to position and orient the fastener(s) 60, 100, 200, 250 since the grooves 48 are not visible from the surface 46. The tapered distal end 104 of the fastener 60, 100, 200, 250 is inserted through the cushion member 40 or braided mesh material member 42 until the base 108 of the fastener abuts the outer surface 46 of the cushion and the distal end 104 extends into the groove 48 formed in the opposing outer surface 44 of the cushion 40.

[0073] The trim cover 32 is then placed over the outer surface 44 of the cushion member 40. The trim cover 32 includes a tie-down 80. The tie-down 80 is connected to the fastener 60, 100, 200, 250 by inserting a hook defined by the fastener into an opening through the tie-down to connect the trim cover to the cushion. The tie-down 80 is received within the recess 112 of the fastener 60, 100, 200, 250.

[0074] The cushion member 40 or the stranded material member 42 may need to be compressed from its relaxed state in order for the tie-downs 80 to connect to the fasteners 60, 100, 200, 250. As such, the stranded material member 42 of the cushion member 40 may apply a force to the trim cover 32 that places the tie-downs 80 and fasteners 60, 100, 200, 250 in tension. Furthermore, as the trim cover 32 is wrapped or otherwise connected to the various connection points of the seat assembly, the trim cover 32 may be stretched or placed in tension, which may further increase the tension on the tie-downs 80 and fasteners 60, 100, 200, 250. Longitudinal movement of the fasteners 60, 100, 200, 250 is limited by the engagement of the base 108 with the surface 46 of the member 40. As such, the fasteners 60, 100, 200, 250 are retained within the member 42 when the seat assembly 20 is assembled. Features such as ribs 142 or posts may limit rotational movement of the fasteners within the member 40. Additionally, features such as protrusions 202 may limit longitudinal movement of the fasteners, for example, preventing the fasteners 60, 100, 200, 250 from backing out of the member 40.

[0075] Although exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms of the present disclosure. Rather, the terms used herein are terms of description rather than limitation, and it is understood that various modifications can be made without departing from the spirit and scope of the present invention. Moreover, features of various embodiments may be combined to form further embodiments of the present disclosure.

Claims

1. a seating cushion defining a first surface for supporting an occupant and a second surface opposite the first surface, the first surface further defining a groove; A fastener having a longitudinal body having a central region disposed between first and second end regions, and a base extending outwardly from said second end region and transversely relative to said body, said first end region tapering away from said second end region, said central region of said body defining a recess that meets a sidewall of said body to form a hook and slopes inwardly toward said first end region. Equipped with the fastener defines a central opening extending longitudinally through the second end region and intersecting the base; The fastener extends through the seat cushion such that the base abuts the second surface and the first end region of the body extends into the groove.

2. 10. The seat assembly of claim 1, wherein the seat cushion is formed from a member of intertwined mesh material.

3. The seat assembly of claim 2 , wherein the interwoven mesh material member comprises a polymer mesh having a plurality of integrated polymer strands.

4. a trim cover that forms a seating surface; a tie-down connected to said trim cover; Furthermore, The seat assembly of claim 1 , wherein the fastener engages the tie-down to connect the trim cover to the seat cushion.

5. the tie-down defines an opening adjacent a bead of the tie-down; 5. The seat assembly of claim 4, wherein the body of the fastener extends through the opening to connect the trim cover to the seat cushion.

6. The seat assembly of claim 5 , wherein the opening is at least partially defined by the bead of the tie-down.

7. The seat assembly of claim 1 further comprising a frame supporting the seat cushion.

8. 2. The seat assembly of claim 1, wherein the body defines a first finger extending from the first end region toward the base to a first distal end, the first finger cooperating with the central region to define the recess and form the hook.

9. 9. The seat assembly of claim 8, wherein the body defines a second finger extending from the second end region toward the first end region to a second distal end, the second finger cooperating with the central region to define the recess.

10. 10. The seat assembly of claim 9, wherein the second finger is angled inwardly relative to the body toward the second distal end.

11. 10. The seat assembly of claim 9, wherein the first distal end and the second distal end do not laterally overlap.

12. The seat assembly of claim 1 , wherein the central opening intersects with the recess.

13. the base has a first surface facing the first end region of the body and a second surface opposite the first surface; 2. The seat assembly of claim 1, wherein the base defines at least one post extending longitudinally outward from the first surface of the base, the at least one post being spaced apart from the body.

14. The seat assembly of claim 1 , wherein the base defines an index that indicates the orientation of the hook.

15. 2. The seat assembly of claim 1, wherein the central region defines at least one protrusion extending outwardly from the central region and angled away from the first end region.

16. a member forming a longitudinal body having a central region disposed between first and second end regions, the body having a generally circular cross-sectional shape and having sidewalls circumscribing a longitudinal axis, the first end region tapering away from the second end region to a rounded nose; the member forms a base extending outwardly from the second end region and laterally relative to the body, the central region of the body intersecting the sidewalls of the member to form a hook and defining a recess in the central region of the body extending laterally toward the first end region.

17. The body defines a first finger extending from the first end region toward the base to a first distal end, the first finger cooperating with the central region to define the recess and form the hook; and 17. The fastener of claim 16, wherein the body defines a second finger extending from the second end region toward the first end region to a second distal end, the second finger cooperating with the central region to define the recess, the second finger sloping inwardly relative to the body from the second end region toward the second distal end.

18. A fastener as described in claim 16, wherein the member defines a central opening extending longitudinally therethrough and intersecting the base.

19. A method of assembling a seat assembly, comprising: inserting a fastener through the cushion until a base of the fastener abuts a first outer surface of the cushion and a tapered distal end of the fastener extends into a groove formed in a second outer surface of the cushion opposite the first outer surface, the fastener being inserted from the first outer surface toward the second outer surface, the second outer surface being positioned to support an occupant of the seat assembly; positioning a trim cover having tie-downs on the second surface of the cushion; inserting a hook defined by the fastener through an opening defined by the tie-down to connect the trim cover to the cushion; A method comprising:

20. forming the cushion from a twisted mesh material without pre-formed holes for the fasteners; 20. The method of claim 19, further comprising:

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