Retaining clip for seat assembly and assembly method - Patents.com

Abstract

A retaining clip, a seat assembly having the retaining clip, and a method of assembly. The retaining clip has a helical anchor and at least one retaining feature. The helical anchor is configured to be threaded into the cushion. The retaining feature extends away from the helical anchor and is configured to secure a seat component to the retaining clip.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 17 / 724,866, filed April 20, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to a retaining clip, a seat assembly having a retaining clip, and an assembly method. [Background technology]

[0003] A seat assembly including a cushion and a retaining clip is disclosed in US Pat. No. 5,399,633. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Pat. No. 8,191,971 Summary of the Invention

[0005] In at least one embodiment, a retaining clip is provided for attaching a seat component to a cushion of a seat assembly, the retaining clip including a helical anchor helically disposed about an anchor axis and at least one retaining feature for securing the seat component, the retaining feature extending away from the helical anchor.

[0006] In at least one embodiment, a seat assembly is provided that includes a cushion, a seat component, and a retention clip having a helical anchor that screws into the cushion to secure the retention clip to the cushion and at least one retention feature that engages the seat component to secure the seat component to the retention clip.

[0007] In at least one embodiment, a method of assembling a seat assembly is provided that includes providing a cushion that is a three-dimensional mesh structure formed from a plurality of filaments bonded in random loops, providing a retention clip having a helical anchor and at least one retention feature adapted to engage a seat component, and threading the helical anchor into the three-dimensional mesh structure of the cushion to secure the retention clip to the cushion. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of an example of a seat assembly. [Diagram 2] FIG. 2 is a perspective view of an example of a retaining clip. [Diagram 3] FIG. 2 is a fragmentary side view of a portion of a seat assembly showing an example of a retaining clip mounted to a cushion and a seat component mounted to the retaining clip. [Figure 4] 4 is a side view of the retaining clip taken from the opposite side to the side view shown in FIG. 3. [Diagram 5] 5 is a cross-sectional view of the retaining clip shown in FIG. 4 taken along the anchor axis of the retaining clip. [Figure 6] FIG. 6 is an enlarged view of a portion of FIG. 5 showing the retaining clip mounted on the cushion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Where necessary, detailed embodiments of the present invention are disclosed herein, but it should be understood that the disclosed embodiments are merely exemplary of the present invention, which may be embodied in various alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show the details of certain 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 use the present invention in various ways.

[0010] 1, there is shown an example of a seat assembly 10. The seat assembly 10 may be configured for use in a motor vehicle, such as an automobile or truck. The seat assembly 10 may include a seat back 12 and a seat bottom 14.

[0011] The seat back 12 may be configured to support the back of a seat occupant. The seat back 12 may pivot about an axis 16 relative to a seat bottom 14. For example, the seat back 12 may be pivotally connected to the seat bottom 14 by one or more recline mechanisms, pivot pins, or the like. Alternatively, the seat back 12 or a portion thereof may not be pivotally connected to the seat bottom 14. For example, the seat back 12 may be pivotally mounted to the vehicle body structure, as is the case in some bench seat configurations.

[0012] The seat back 12 may include a head restraint 20 that may be configured to support the head of a seat occupant. The head restraint 20 may be disposed at the top of the seat back 12. The head restraint 20 may be integral with the seat back 12 or may be a separate component that may be adjustably positioned relative to the top of the seat back 12.

[0013] The seat bottom 14 may be configured to support a seat occupant. In a vehicle application, the seat bottom 14 may be mounted to a support surface, such as a vehicle floor.

[0014] The seat back 12 and the seat bottom 14 may each include at least one seat component 30 and a cushion 32. The seat component 30 may be secured to the cushion 32 by one or more retaining clips 34, as described in more detail below.

[0015] The seat component 30 may be disposed over or on the cushion 32. The seat component 30 may have any suitable configuration and may be of any suitable type. For example, the seat component 30 may be a trim cover assembly that provides at least a portion of the visible exterior surface of the seat assembly 10. The trim cover assembly 30 may include multiple trim panels assembled in any suitable manner, such as by stitching. The trim panels may be made of any suitable material or materials, such as cloth, leather, vinyl, or combinations thereof. The seat component 30 may also be a component that is hidden by or disposed under the trim cover assembly 30 and disposed on the cushion 32, such as, for example, a temperature regulating device, such as a heating pad or heating mat, an inflatable device for increasing the comfort of the seat occupant, such as a lumbar support, or a device providing a massage function, an air permeable material to promote air flow for a ventilated seat, etc.

[0016] Referring to FIG. 3 , the seat component 30 may also include at least one engagement feature 40. The engagement feature 40 may help secure the seat component 30 to the retaining clip 34 to hold the trim cover assembly 30 in a desired position. Additionally, the engagement feature 40 may help secure the seat component 30 to inhibit unaesthetic folding, puckering, or wrinkling of the seat component 30. The engagement feature 40 may have any suitable configuration, such as a male configuration, a female configuration, or a combination thereof. As some examples, the engagement feature 40 may be configured or provided as hooks, holes, barbs, linkages, loops, and the like, or may be provided as part of a hook-and-loop fastener such as Velcro®. The engagement feature 40 may be provided in any suitable location. For example, the engagement feature 40 may be provided proximate an end or edge of one or more trim cover panels. Alternatively or additionally, the engagement feature 40 may include a panel, web, or other intermediate component that interconnects the engagement feature to one or more trim cover panels. The engagement feature 40 may be coupled to the sheet component 30 in any suitable manner, such as by stitching, mechanical fasteners, molding, bonding, adhesives, etc. Additionally, the engagement feature 40 may be made from any suitable material, such as a polymeric material.

[0017] The cushion 32 may be at least partially hidden by the seating components 30 and may be directly or indirectly supported by a support structure of the seating assembly 10, such as a frame, a panel, a support wire, or the like. The cushion 32 includes a three-dimensional mesh structure formed from a plurality of filaments 50 joined together in a random loop, an example of which is best shown in FIG. 6. (In FIG. 3, the filaments are pictorially represented by randomly drawn lines for simplicity.) For example, the filaments 50 may be extruded filaments made from a polymeric material such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based, polypropylene-based, polystyrene-based, or combinations thereof. As an example, the filaments 50 may be made of linear low density polyethylene (LLDPE). The extruded filaments 50 may be randomly looped, curled, or entangled and may be joined together where one filament 50 contacts another filament 50, thus providing a lightweight and breathable cushion with openings or voids between the filaments 50. Methods for making the extruded filament mesh cushion are disclosed in U.S. Patent Application Serial No. 17 / 555,875, which is incorporated herein by reference in its entirety. As such, the cushion 32 need not be made of a foam, such as urethane foam, and may replace some or all of a conventional urethane foam cushion. In at least one configuration, the cushion 32 may include one or more cushion recesses 60, as shown in FIG. 3.

[0018] The cushion recess 60 may be a recess such as an elongated channel, hole, dimple, or groove in the cushion 32. The cushion recess 60 may be located in any suitable location. For example, the cushion recess 60 may be located on a side of the cushion 32 that faces the seat occupant. As some further examples, the cushion recess 60 may be located where the side bolster 62 meets the central seating portion 64 of the cushion 32, and the cushion recess 60 may cross the central seating portion 64 front to back, left to right, or combinations thereof. Multiple cushion recesses 60 may be spaced apart from one another or may intersect. In at least one configuration, the cushion recess 60 may be at least partially defined by one or more surfaces. For example, the cushion recess 60 may be at least partially defined by at least one side surface, such as first and second side surfaces 72, and a bottom surface 74. In the configuration shown in FIG. 3, the bottom surface 74 may extend between the first and second side surfaces 70, 72.

[0019] 2-4, one or more retention clips 34 may be provided to secure the seat component 30 to the cushion 32. Specifically, the retention clips 34 may be configured to engage one or more engagement features 40 of the seat component 30 to provide localized retention of the seat component 30. The retention clips 34 may be disposed partially within the cushion 32. Additionally, the retention clips 34 may be disposed at least partially within the cushion recess 60, as described in more detail below. In at least one configuration, the retention clips 34 may include a base 80, a helical anchor 82, and at least one retention feature 84.

[0020] The base 80 may be disposed between the helical anchor 82 and the retaining feature 84. In at least one configuration, the base 80 may be configured as a panel, plate, or disk that may be received in the cushion recess 60. The base 80 may rest on the bottom surface 74 of the cushion recess 60.

[0021] The helical anchor 82 may facilitate mounting of the retention clip 34 to the cushion 32. The helical anchor 82 may extend from the base 80 in a direction extending away from the retention feature 84. Additionally, the helical anchor 82 may be integrally formed with the base 80 or may be provided as a separate piece attached to the base 80. The helical anchor 82 may spiral about and be spaced apart from the anchor axis 90. The base 80 may extend further away from the anchor axis 90 than the helical anchor 82. For example, the base 80 may extend outwardly or radially away from the anchor axis 90 further than the helical anchor 82 extends outwardly or radially away from the anchor axis 90.

[0022] In at least one configuration, the helical anchor 82 may have a non-circular cross-section, an example of which is shown in FIG. 5. A non-circular cross-section, or a cross-section that differs from the cross-section of the filaments 50 of the cushion 32, allows the helical anchor 82 to better grip the cushion 32 during deployment. In the configuration shown in FIG. 5, the helical anchor 82 has a quadrilateral or rectangular cross-section, but it is contemplated that other cross-sectional configurations may be provided that may have more or fewer sides. In the four-sided configuration, the helical anchor 82 may include an inner surface 100, an outer surface 102, an upper surface 104, and a lower surface 106. These sides extend away from the base 80 in a spiral fashion about the anchor axis 90, and thus progressively away from the base 80 as the sides extend toward the distal end of the helical anchor 82. The helical anchor 82 may also include an end surface 108, best shown in FIGS. 2 and 4.

[0023] 4 and 5, the inner surface 100 faces toward the anchor axis 90. Additionally, the inner surface may be spaced apart from the anchor axis 90 and may be positioned closer to the anchor axis 90 than the outer surface 102.

[0024] The outer surface 102 may be disposed opposite the inner surface 100. As such, the outer surface 102 may face away from the anchor axis 90.

[0025] The upper surface 104 may face toward the base 80. Additionally, the upper surface 104 may extend between the inner surface 100 and the outer surface 102, such as from the inner surface 100 to the outer surface 102. The upper surface 104 may be interrupted by one or more notches 110, making it discontinuous, as described in more detail below.

[0026] The lower surface 106 may be disposed opposite the upper surface 104. As such, the lower surface 106 may face away from the base 80. The lower surface 106 may extend between the inner surface 100 and the outer surface 102, for example, from the inner surface 100 to the outer surface 102. The lower surface 106 may be interrupted by one or more notches 110′ and may be discontinuous, as described in more detail below.

[0027] With reference to FIG. 4, an end surface 108 may extend between the inner surface 100 and the outer surface 102, and between the upper surface 104 and the lower surface 106. In at least one configuration, the end surface 108 may be disposed substantially parallel to the base 80, substantially perpendicular to the anchor axis 90, or both. As used herein, the term "substantially parallel" means the same as or very close to parallel, including features or axes that are within ±2.5° of being parallel to each other. As used herein, the term "substantially perpendicular" is used to designate features or axes that are the same as or very close to being perpendicular, including features that are within ±2° of being perpendicular to each other. The end surface 108 may be disposed inside the three-dimensional mesh structure of the cushion 32 when the retaining clip 34 is attached as shown in FIG. 3.

[0028] 5, the cross-sectional area of ​​the helical anchor 82 may change as the helical anchor 82 extends away from the base 80. For example, the cross-sectional area of ​​the helical anchor 82 may be greater at a first end of the helical anchor 82 as compared to a second end of the helical anchor 82. The first end of the helical anchor 82 may be disposed adjacent to the base 80. The second end of the helical anchor 82 may be disposed opposite the first end and may be the distal or free end of the helical anchor 82. In the configuration shown in FIG. 5, the cross-sectional area of ​​the helical anchor 82 gradually decreases as the helical anchor 82 extends away from the base 80 or as the helical anchor 82 extends from the first end to the second end, regardless of any notches 110, 110' that may be provided with the helical anchor 82.

[0029] 2 and 4-6, the helical anchor 82 can include one or more notches 110, 110'. The notches 110, 110' can be configured to receive the filament 50 of the cushion 32 to help secure the retaining clip 34 to the cushion 32 and resist loosening of the retaining clip 34 after installation. For example, the filament 50 can be received in the notches 110, 110' to resist or inhibit rotation of the retaining clip 34 about the anchor axis 90. The notches 110, 110' can reduce the cross-sectional area of ​​the helical anchor 82. In at least one configuration, the helical anchor 82 can include a first set of notches 110, a second set of notches 110', or both.

[0030] 2, 4, and 5, the first set of notches 110 may be formed in the upper surface 104 of the helical anchor 82. As such, a member of the first set of notches 110 may extend in a direction extending away from the base 80 and the retaining feature 84. A plurality of members of the first set of notches 110 may extend between the inner surface 100 and the outer surface 102. For example, a member of the first set of notches 110 may extend from the inner surface 100 toward the outer surface 102, from the outer surface 102 toward the inner surface 100, or from the inner surface 100 toward the outer surface 102. A plurality of members of the first set of notches 110 may be spaced apart from one another. A member of the first set of notches 110 may have any suitable shape. In the illustrated configuration, each notch 110 has a generally two-sided configuration including a ramp surface 120 and a stepped surface 122.

[0031] The angled surface 120 of the notch 110 extends from the upper surface 104 in a direction extending away from the base 80 or in a direction extending parallel to the base 80. For example, a first end 130 of the angled surface 120 intersects the upper surface 104, while a second end 132 of the angled surface 120, disposed opposite the first end 130, may be disposed farther from the base 80 than the first end 130. The angled surface 120 may extend laterally from the inner surface 100, the outer surface 102, or both.

[0032] The step surface 122 may extend from the second end 132 of the angled surface 120 in a direction extending toward the base 80. As such, the step surface 122 may extend from the second end 132 of the angled surface 120 to the upper surface 104. The step surface 122 may extend laterally from the inner surface 100, the outer surface 102, or both. In at least one configuration, the step surface 122 may have a generally vertical orientation that may extend substantially parallel to the anchor axis 90.

[0033] A second set of notches 110' may be formed in the underside 106 of the helical anchor 82. As such, a member of the second set of notches 110' may extend in a direction extending toward the base 80 and the retaining feature 84. A plurality of members of the first set of notches 110' may extend between the inner surface 100 and the outer surface 102. For example, a member of the second set of notches 110' may extend from the inner surface 100 toward the outer surface 102, from the outer surface 102 toward the inner surface 100, or from the inner surface 100 toward the outer surface 102. A plurality of members of the second set of notches 110' may be spaced apart from one another. A member of the second set of notches 110' may have any suitable shape. In the illustrated configuration, each notch 110' has a generally two-sided configuration including a sloped surface 120' and a stepped surface 122'.

[0034] The angled surface 120' of the notch 110' may extend from the lower surface 106 in a direction extending toward the base 80 or in a direction extending parallel to the base 80. For example, a first end 130 of the angled surface 120 may intersect the upper surface 106, while a second end 132 of the angled surface 120, disposed opposite the first end 130, may be disposed closer to the base 80 than the first end 130. The angled surface 120' may extend laterally from the inner surface 100, the outer surface 102, or both.

[0035] The step surface 122' can extend from the second end 132' of the angled surface 120' in a direction extending away from the base 80. As such, the step surface 122' can extend from the second end 132' of the angled surface 120' to the lower surface 106. The step surface 122' can extend laterally from the inner surface 100, the outer surface 102, or both. In at least one configuration, the step surface 122 can have a generally vertical orientation that can extend substantially parallel to the anchor axis 90.

[0036] 4, a member of the first set of notches 110 may or may not be aligned with a member of the second set of notches 110'. In the configuration shown in FIG. 4, a member of the first set of notches 110 is aligned with a member of the second set of notches 110' and disposed directly opposite a member of the second set of notches 110' such that a gap 140 is provided therebetween. Such a configuration may increase the effective size of the gap 140 available to receive the filament 50 since the pair of notches 110, 110' may extend away from one another. Additionally, the notches 110, 110' may be arranged such that the notches 110 extend from the upper surface 104 toward the opposing notch 110' extending from the lower surface 106 by not disposing the notches 110, 110' directly opposite one another. This avoids a reduction in the cross-sectional area of ​​the helical anchor 82 from both the upper surface 104 and the lower surface 106 which could weaken the helical anchor 82 .

[0037] 2 and 3, one or more retention features 84 may be provided to engage and secure the sheet component 30. The retention feature 84 may extend in a direction extending away from the base 80 and away from the helical anchor 82. As such, the retention feature 84 and the helical anchor 82 may be disposed on opposite sides of the base 80. The retention feature 84 may have any suitable configuration. For example, the retention feature 84 may have a male configuration, a female configuration, or a combination thereof. As some examples, the retention feature 84 may be configured or provided as a hook, hole, barb, linkage, loop, or the like, or may be provided as a portion of a hook-and-loop fastener such as Velcro. In the illustrated embodiment, the retention feature 84 is configured as a pair of spaced apart barbs 150 extending from the base 80. The barbs 150 may be configured to flex away from one another to receive the sheet component 30 and / or the engagement feature 40 in a snap-fit ​​arrangement. As best shown in FIG. 3, the retention feature 84 may extend into the cushion recess 60 .

[0038] The cushion 32 and the retaining clip 34 may be manufactured as separate pieces and then assembled. The retaining clip 34 may be installed as described below.

[0039] First, the retaining clip 34 may be aligned to a desired mounting location on the cushion 32. The desired mounting location may be the cushion recess 60. The retaining clip 34 may be oriented so that the helical anchor 82 extends toward the cushion 32.

[0040] The retaining clip 34 may then be engaged to the cushion 32. For example, the distal end or end face 108 of the helical anchor 82 may engage a portion of the cushion 32, such as the bottom surface 74 of the cushion recess 60.

[0041] Next, the retention clip 34 may then be rotated about the anchor axis 90 while being advanced into the cushion 32. This threads the helical anchor 82 into the three-dimensional mesh structure of the cushion 32 and secures the retention clip 34 to the cushion 32 without the retention clip 34 bonding to the cushion 32. The filament 50 of the cushion 32 may be captured in the gap 140 formed by the helical anchor 82, captured in one or more notches 110, 110', or both. Additionally, the helical anchor 82 may compress or bend the filament 50 as it is rotated, which may help retain the helical anchor 82 within the cushion 32. The rotation may continue until the base 80 contacts the bottom surface 74, until the retention feature 84 is positioned in the desired orientation, or both.

[0042] The sheet component 30 may then be mounted to the retention feature 84, thereby securing the sheet component 30 to the retention clip 34. For example, the engagement feature 40 of the sheet component 30 may engage or couple with the retention feature 84 of the retention clip 34 to secure the sheet component 30. The sheet component 30 may be mounted to the retention feature 84 after the helical anchor 82 is screwed into the three-dimensional mesh structure of the cushion to avoid twisting of the sheet component 30.

[0043] The above-mentioned retaining clip may secure the sheet component to the extruded filament mesh cushion by threading the retaining clip into the cushion, so that the helical anchor may capture or engage the filament in a manner that anchors the retaining clip. In this way, the helical anchor may engage and pass between the filaments when threaded into the cushion without tearing or cutting the filaments. The helical anchor may be provided with a cross-sectional shape and notches that may engage the filaments in a manner that makes it difficult to remove or rotate the retaining clip once installed. Additionally, the retaining clip may be provided with any suitable retaining features that match the engagement features in the sheet component. This facilitates multiple retaining clip designs.

[0044] Although exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms of the present invention. Rather, the words used herein are words of description rather than of limitation, and it is understood that various changes may be made without departing from the spirit and scope of the present invention. In addition, features of the various implementation embodiments may be combined to form further embodiments of the present invention.

Claims

1. 1. A retaining clip for attaching a seat component to a cushion of a seat assembly, comprising: a helical anchor that forms a spiral around an anchor axis; at least one retention feature extending away from the helical anchor for securing the seat component; Including, the retention clip includes a base, the helical anchor and the retention feature extending from opposite sides of the base; A retaining clip, wherein the helical anchor includes a first set of notches formed on an upper side of the helical anchor facing the retaining feature, the notches extending away from the retaining feature.

2. The retaining clip of claim 1 , wherein the helical anchor is spaced apart from the anchor axis so as not to intersect with the anchor axis.

3. The retaining clip of claim 2 , wherein the base extends further away from the anchor shaft than the helical anchor.

4. The retaining clip of claim 1 , wherein the helical anchor is spaced from the anchor shaft.

5. The retaining clip of claim 1 , wherein the helical anchor further comprises a non-circular cross-section.

6. The retaining clip of claim 1 , wherein the helical anchor further comprises a rectangular cross section.

7. The retaining clip of claim 1 , wherein the cross-sectional area of ​​the helical anchor varies from the first end to the second end of the helical anchor.

8. The retaining clip of claim 1 , wherein the members of the first set of notches reduce a cross-sectional area of ​​the helical anchor.

9. 2. The retaining clip of claim 1, wherein the helical anchor further includes an inner surface facing the anchor axis and an outer surface disposed opposite the inner surface, and wherein a plurality of members of the first set of notches extend from the inner surface to the outer surface.

10. A retaining clip for attaching a seat component to a cushion of a seat assembly, comprising: a helical anchor that forms a spiral around an anchor axis; at least one retention feature extending away from the helical anchor for securing the seat component; Including, the retention clip includes a base, the helical anchor and the retention feature extending from opposite sides of the base; A retention clip, wherein the helical anchor includes a second set of notches formed on a lower surface of the helical anchor facing away from the retention feature, the notches extending toward the retention feature.

11. 11. The retaining clip of claim 10, wherein the helical anchor further includes an inner surface facing the anchor axis and an outer surface disposed opposite the inner surface, and wherein a plurality of members of the second set of notches extend from the inner surface to the outer surface.

12. 2. The retaining clip of claim 1, wherein the helical anchor further includes a first set of notches and a second set of notches, the first set of notches being positioned such that one member of the first set of notches is directly opposite one member of the second set of notches.

13. 1. A seat assembly comprising: Cushion and Seat parts; Retaining clip and Including, the retention clip includes a helical anchor that screws into the cushion to secure the retention clip to the cushion, and at least one retention feature that engages the seat component to secure the seat component to the retention clip; The helical anchor further includes a notch located remotely from a free end of the helical anchor and not extending beyond the free end.

14. 14. The seat assembly of claim 13, wherein the cushion is a three-dimensional mesh structure formed from a plurality of filaments bonded together in random loops.

15. The seat assembly of claim 14 , wherein the one notch is configured to receive a one filament of the cushion.

16. 15. The seat assembly of claim 14, wherein the retaining clip includes a base, the helical anchor and the retaining feature are disposed on opposite sides of the base, and the helical anchor further includes an end surface disposed substantially parallel to the base and disposed inside the three-dimensional mesh structure.

17. 1. A method of assembling a seat assembly, comprising: The method includes threading a helical anchor of a retention clip into a cushion that is a three-dimensional mesh structure formed from a plurality of filaments joined in a random loop pattern; the retaining clip further includes at least one retaining feature adapted to engage a sheet component; the helical anchor further includes a first notch and a second notch positioned remotely from a free end of the helical anchor and not extending from the free end, the first notch and the second notch receiving different filaments of the three-dimensional mesh structure of the cushion to secure the retaining clip to the different filaments.

18. The method of claim 17 further comprising mounting the retaining feature to the sheet component to secure the sheet component to the retaining clip.

19. 20. The method of claim 18, wherein the sheet component is mounted to the retaining feature after threading the helical anchor into the three-dimensional mesh structure.

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