Fasteners for non-foam cushions

Abstract

A fastener and method for attaching a non-cushioned cushion of intertwined or tangled polymer filaments to a non-cushioned component. In a first embodiment, the fastener comprises a retaining portion for fixing the fastener within a mesh member cushion composed of a plurality of bundled or joined polymer filaments, and a projection extending through the polymer filaments of the cushion to another fastener. The retaining portion may be larger in size, area, or cross-sectional area than the projection so as to prevent the retaining portion from penetrating through the polymer filaments.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Patent Application No. 18 / 750,517, filed on June 21, 2024, the disclosure of which is hereby incorporated by reference in its entirety as part of this specification.

[0002] This disclosure relates to a cushion assembly, a fastener for securing the cushion, and a method of fastening the cushion. More specifically, it relates to a fastener for fastening a non - foam filament non - woven mesh structure.

Brief Description of the Drawings

[0003] [Figure 1] It is a perspective view of an example of a seat assembly. [Figure 2] It is a partial cross - sectional view of a first embodiment of a fastener for fastening a non - foam filament non - woven mesh structure to a surface. [Figure 3] It is a schematic partial cross - sectional view of an example of a manufacturing system for producing a filament mesh structure. [Figure 4] It is a front perspective view of a second embodiment of the fastener. [Figure 5] It is a front perspective view of a cushion and a fastener disposed therein. [Figure 6] It is a front perspective view of the fastener of FIG. 5 disposed within the cushion of FIG. 5. [Figure 7] It is a front perspective view of the surface to which the cushions of FIGS. 5 and 6 are fastened. [Figure 8] It is a front perspective view of the surface of FIG. 7 fastened to the cushions of FIGS. 5 - 7. [Figure 9] It is a top perspective view of a first embodiment of a non - cushion sheet component (e.g., an armrest) to which two fasteners are fastened. [Figure 10] It is a schematic cross - sectional side view of a first embodiment of the non - cushion sheet component of FIG. 9 to which a cushion is fastened. [Figure 11]This is a side view of a second embodiment of a non-cushioned sheet component to which a cushion has been fastened. [Figure 12] This is a flowchart showing how to manufacture a seat assembly. [Modes for carrying out the invention]

[0004] Embodiments of the present disclosure are described herein. However, it should be understood that the embodiments disclosed are merely examples, and other embodiments may take various alternative forms. The drawings are not necessarily to a constant scale. Some features may be exaggerated or minimized to illustrate details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds for teaching those skilled in the art to employ various embodiments of the present invention. As those skilled in the art will understand, various features illustrated and described with reference to any one of the drawings can be combined with features shown in one or more other drawings to generate embodiments not expressly illustrated or described. Combinations of illustrated features provide representative embodiments for typical uses. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desirable for particular applications or embodiments.

[0005] Except as provided in examples or otherwise expressly indicated, all quantities in this specification indicating the amount of material or the conditions of reaction and / or use should be understood to be modified by the word “about” when describing the broadest scope of the invention. It is generally preferred to carry out the work within the limits of the numerical values ​​stated. Also, unless otherwise specified, percentage, part, and ratio values ​​are by weight. The term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” etc. Any description of a group or class of materials as suitable or preferred for a given purpose relating to the invention implies that any two or more mixtures of members of that group or class are equally suitable or preferred. The molecular weight provided for any polymer refers to the number-average molecular weight. The description of components in chemical terms refers to the components when added to any combination specified in the description, and does not necessarily exclude chemical interactions between components of a mixture once it has been mixed. The initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation herein, and is applied mutatis mutandis to the usual grammatical variations of the initially defined abbreviation. Unless otherwise noted, the measurement of a property is determined by the same technique as previously or later referenced for the same property.

[0006] Since certain components and / or conditions can change, the present invention is not limited to the specific embodiments and methods described below. Furthermore, the terms used herein are used solely for the purpose of describing specific embodiments of the present invention and are not intended to limit them in any way.

[0007] As used herein and in the appended claims, singular forms ("a," "an," and "the") refer to multiple subjects unless explicitly indicated in the context. For example, a reference to a singular component is intended to refer to multiple components.

[0008] The terms “substantially,” “generally,” or “about” may be used herein to describe embodiments disclosed or claimed. The terms “substantially,” “generally,” or “about” may modify values ​​or relative characteristics disclosed or claimed herein to indicate that they are within manufacturing tolerances and / or within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of such values ​​or relative characteristics.

[0009] With respect to the terms “equipped with,” “consisting of,” and “essentially consisting of,” if any of these three terms is used herein, the subject matter of this disclosure and the claims may include the use of any of the other two terms.

[0010] Furthermore, it should be understood that a range of integers explicitly includes all intervening integers. For example, the integer range 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, ... 97, 98, 99, and 100. Likewise, if any range is specified, an intervening number that is the increment obtained by dividing the difference between the upper and lower bounds by 10 can be adopted as an alternative upper or lower bound. For example, if the range is 1.1 to 2.1, the following numbers can be selected as the lower or upper bound: 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0.

[0011] Referring to Figure 1, an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for land vehicles such as automobiles, trucks, and buses, or for non-land vehicles such as aircraft or ships. For example, a seat assembly 10 for a land vehicle can be molded and sized as a front-row driver's or passenger seat, a second row, a third row, or other rear-row seats, and may include bucket-style seats, bench-style seats, or other seat styles. Furthermore, the seat assembly 10 may be a non-storable seat, or a storable seat that is foldable and can be stored in a cavity in the vehicle floor. In addition, the seat assembly 10 may be configured for non-vehicle applications such as furniture.

[0012] In the configuration shown in Figure 1, the seat assembly 10 comprises a seat bottom 20 and a seat back 22. The seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or stool. In one or more embodiments, the seat bottom 20 is configured to receive a seated person and support the seated person's pelvis and thighs. In various embodiments, the seat bottom 20 comprises a seat bottom frame 30, a cushion 32, and a trim cover 34. In many embodiments, the seat bottom frame 30 is a structure that supports the cushion 32. In one modification, the seat bottom frame 30 comprises one or more structural members and can be made from any suitable material such as a metal alloy, a polymer material, a fiber-reinforced polymer material, or a combination thereof. In some configurations, the seat bottom frame 30 comprises a panel, seat pan, suspension mat, or suspension wire on which the cushion 32 is placed. In one or more embodiments, the cushion 32 is placed on the seat bottom frame 30. In various embodiments, the cushion 32 is made from a suitable material that supports the seat occupant and distributes the load force from the seat occupant to the seat bottom frame 30.

[0013] In various embodiments, the trim cover 34 covers at least a portion of the cushion 32. In addition, the trim cover 34 provides one or more visible outer surfaces of the seat back 22. The seat occupant can be positioned on the trim cover 34 when seated on the seat assembly 10. In one or more embodiments, the trim cover 34 is made from any suitable one or more materials such as cloth, leather, synthetic leather, vinyl, or a combination thereof. In one modification, the trim cover 34 may comprise a plurality of trim panels assembled in any suitable way, such as by fusion or sewing. In one improved embodiment, the trim cover 34 is attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may be provided with a trim mounting mechanism attached to the seat bottom frame 30, the cushion 32, or both to prevent the trim cover 34 from being removed and to help conform the trim cover 34 to the contours of the seat bottom frame 30, the cushion 32, or both. Alternatively, the trim cover 34 may be attached to a mounting pad.

[0014] In one or more embodiments, the seat back 22 is configured to support the back of a seated person. In various embodiments, the seat back 22 is positioned adjacent to the seat bottom 20. For example, the seat back 22 may be positioned above the seat bottom 20 and near the rear of the seat bottom 20. In one variation, the seat back 22 extends away from the seat bottom 20 and generally upward. In some configurations, the seat back 22 can be attached to the seat bottom 20 and pivotable relative to the seat bottom 20. In other embodiments, the seat back 22 is not attached to the seat bottom 20. For example, a vehicle seat back can be attached to a vehicle body structure, such as in some second-row seat assemblies. In one or more embodiments, the seat back 22 comprises a seat back frame 40, a cushion 42, a trim cover 44, and optionally a headrest 46.

[0015] In various embodiments, the seat back frame 40 is a structure that supports the cushion 42. In one or more embodiments, the seat back frame 40 includes one or more structural members and can be made from 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 comprises a panel, pan, suspension mat, or suspension wire on which the cushion 42 is placed. It is also conceivable that, in some configurations, the seat back frame 40 may be formed integrally with the seat bottom frame 30.

[0016] In one or more embodiments, the cushion 42 is positioned on the seat back frame 40. In various embodiments, the cushion 42 is made of a suitable material that supports the seat occupant and distributes the load force from the seat occupant to the seat back frame 40. The cushion 42 may be formed integrally with the cushion 32 of the seat bottom 20, or it may be separate from the cushion 32 of the seat bottom 20.

[0017] In one or more embodiments, the trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible outer surfaces of the seatback 22. A seat occupant can be positioned on the trim cover 44 when seated on the seat assembly 10. In various embodiments, the trim cover 44 is made from any suitable single or plural materials such as cloth, leather, synthetic leather, vinyl, or combinations thereof. In one variant, the trim cover 44 may comprise one trim panel or may comprise plural trim panels assembled in any suitable manner such as by fusing or sewing. In one refinement, the trim cover 44 is attached to the seatback frame 40, the cushion 42, or both. For example, the trim cover 44 can comprise trim attachment features attached to the seatback frame 40, the cushion 42, or both to prevent removal of the trim cover 44 and to assist in conforming the trim cover 44 to the contours of the seatback frame 40, the cushion 42, or both. The trim cover 44 may be attached to an attachment pad, as discussed in more detail below.

[0018] In one refinement, the frame 30 and / or 40 supports other components such as a massage assembly, a ventilation assembly, a temperature control assembly, a sensor assembly, and / or an electronic assembly. In various embodiments, the seat frame(s) 30 and / or 40 is made from a rigid material (e.g., metal, plastic, wood, or combinations thereof) sufficient to support a seated occupant, one or more components / subassemblies. For example, seat frames 30, 40 made of steel and / or aluminum are used.

[0019] In various embodiments, the headrest 46, when provided, is configured to support the head of a seat occupant. In one or more embodiments, the headrest 46 is disposed at the upper portion of the seat back 22 or at an end of the seat back 22 disposed opposite the seat bottom 20. The headrest 46 may be movable in one or more directions relative to the seat back 22 or may be integrally formed with the seat back 22.

[0020] Referring to FIG. 2, an example of a cushion 100 is shown. It should be understood that the structure and description of the cushion 100 may be applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, and / or any other cushion described herein. In various embodiments, unlike conventional cushions that are entirely molded foam, one or more of the cushions are without foam or are composed of non-foam materials such as a plurality of intertwined and / or braided polymer filaments 52 that define one or more cushion bodies as shown in FIGS. 2 and 11. In other words, portions of the various polymer filaments are intertwined or otherwise bound to portions of other polymer filaments such that the plurality of polymer filaments serve as a unit, fragment, cushion, pillow, pad, or mat.

[0021] In one or more embodiments, the cushion 100 is a non-foam component or includes at least one non-foam component. Non-foam components are mainly called mesh members, but may also be called strand members, loop members, entangled members, filament mesh structures, mesh structures, strand meshes, loop meshes, entangled meshes, or mesh cushions. In one modification, the cushion 100 is shown as a non-foam component that does not include foam components or foam materials such as urethane foam or polyurethane foam. However, it is conceivable that the cushion 100 may include foam components or foam materials in addition to non-foam components to provide additional or localized cushioning for the seat occupant. For example, foam material can be provided between the cushion 100 and trim covers (e.g., trim covers 34, 44) placed on the cushion 100, within the cushion 100, or a combination thereof. By reducing the amount of foam material provided with the cushion 100 or by eliminating foam material from the cushion 100, the weight can be reduced and the support and comfort of the seat occupant can be improved. In addition, by eliminating foam material, the recycling of the cushion 100 can be facilitated.

[0022] The cushion 100 is described below in the context of a cushion that does not contain foam material. In one or more embodiments, the cushion 100 is made from filaments 52 of a polymer material that are randomly looped, bent, twisted, or intertwined and joined together, as shown, for example, in Figures 2 and 3. In one modification, one or more filaments 52 are directly joined to one or more other filaments 52, rather than being joined indirectly using a resin or other intermediate material.

[0023] In various embodiments, the filament 52 may also be called a strand or twisted yarn and is made from any suitable one or more materials. In some configurations, the filament 52 is made from a polymer material such as a thermoplastic material, polymer, and / or resin (or a molten polymer material if appropriate for the particular use / invention). For example, the polymer material may be polyamide, polyester, polyimide, polyolefin (e.g., polypropylene, polyethylene, etc.), polystyrene, acrylic, polyurethane, their derivatives, combinations thereof, or any other suitable polymer material. As one example, a polyethylene filament may be made from linear low-density polyethylene (LLPDE). In one or more embodiments, the polymer filament material, such as a thermoplastic polymer material, may be recyclable unlike the foam material, or may be more easily recyclable than the foam material. In some embodiments, the filament 52 may include reinforcing fibers, and the reinforcing fibers may not be made from a thermoplastic material.

[0024] 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. For example, a filament 52 made from multiple materials 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. In one or more embodiments, it is envisioned that the cushion 100 may include a combination of monofilaments and non-monofilamentary filaments made from multiple materials. In various embodiments, randomly looped, bent, twisted, or entangled filaments 52 are joined together at the points where one filament 52 contacts, entangles, and / or connects with another filament 52, thereby obtaining a lightweight, breathable cushion (e.g., cushion 100) or mesh structure with openings or gaps between the filaments 52.

[0025] Referring to Figure 3, an example of a manufacturing system 60 for producing a cushion or filament mesh structure is shown. In this example, the manufacturing system 60 comprises a material supply unit 70, an extruder 72, and a funnel 74. In one or more embodiments, the manufacturing system 60 also comprises a cooling tank 76 and a material handling subsystem 78. In various embodiments, the material supply unit 70 holds a stock of extruded material, such as solid beads, flakes, granules, pellets, or powder, which are produced from the material. In some configurations, the material supply unit 70 is configured as a container or hopper. In one or more embodiments, the material supply unit 70 provides the stock of material to the extruder 72.

[0026] In many embodiments, the extruder 72 melts a material stock and extrudes the material stock as a set of filaments 52. The extruder 72 can have any preferred configuration. In some configurations, the extruder 72 comprises a rotatable screw and a barrel that receives a heating element. In one or more embodiments, the rotation of the screw moves the material through the barrel, and the friction generated as the screw rotates helps to heat the material. In various embodiments, the material exits the barrel in a molten state under pressure and is transported under pressure to the die 80 of the extruder 72.

[0027] In one or more embodiments, the die 80, which may also be called a die plate or extrusion die, has a plurality of through holes or filament-forming openings through which the molten material passes. In various embodiments, a single filament 52 is extruded from each through hole. In one improved embodiment, the filament 52 is extruded through the die 80 so that the filament 52 falls downward from the die 80 into the funnel 74 under gravity.

[0028] In various embodiments, the funnel 74 integrates or bundles the filaments 52 into a more compact arrangement such that the filaments bend, twist, or loop, and / or one or more filaments 52 contact and join with at least one other filament 52. In one improved embodiment, the funnel 74 has an inlet opening or funnel inlet and an outlet opening or funnel outlet smaller than the funnel inlet, and individual, separate filaments 52 enter the funnel inlet and, as they accumulate while the filaments 52 move through the funnel 74 toward the funnel outlet, they bend, twist, loop, and / or come into contact. In one modified example, as the filaments move toward the funnel outlet, some filaments may slide along the funnel 74 or an intervening sheet placed on the funnel 74. In various embodiments, joints are formed between the filaments 52 at the contact points, while openings or gaps between the filaments 52 exist elsewhere where a filament 52 or part thereof does not contact or join with another filament 52. In one or more embodiments, the intertwined and joined filaments 52 pass through the funnel outlet of the funnel 74 and enter the cooling tank 76. For convenience of reference, the joined filaments 52 are referred to as a mesh member or filament mesh structure 90.

[0029] The cooling tank 76 holds a liquid, such as water or a mixture of water and other fluids. The liquid in the cooling tank 76 supports the intertwined and joined filaments 52, helping to limit the formation of a configuration with fewer openings or lower porosity by further compacting or integrating the filaments 52, thereby maintaining the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides some buoyancy or resistance that can cause further bending, twisting, or looping of the filaments 52 adjacent to the liquid surface or within the funnel 74, in order to further construct 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, causing them to solidify and preventing them from joining further. At this point, the filaments 52 are relatively hard and no longer in a plastic state, thus largely maintaining their shape and being unmoldtable or unmodifiable unless reheated.

[0030] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 is equipped with various rollers and conveyors that help move the filament mesh structure 90 through the liquid to the outside of the liquid. In some configurations, a tractor conveyor 92 is provided inside 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.

[0031] One or more other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide it through the cooling tank 76. For example, roller 94 may 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 it is on the conveyor belt 96 to remove the liquid. Alternatively or in addition, the liquid may be removed by squeezing the filament mesh structure 90, or by blowing air toward the filament mesh structure 90 to help remove the liquid from it, or both. It is also conceivable that the filament mesh structure 90 may be drip-dried, i.e., dried in ambient air.

[0032] 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 filament extrusion is not interrupted. Further processing of the filament mesh structure 90 is performed after it leaves the cooling tank 76, in which the filament mesh structure 90 is cut into individual pieces or blanks for individual cushions. Such processing is performed by the cutting subsystem of the manufacturing system 60. The cutting system can be any suitable type. For example, the cutting system can employ blades, knives, hot knives, saws, fluid jets, etc., to cut the filaments 52 of the filament mesh structure 90 into blanks. The cutting system can be used to shape or contour the blanks. It is also conceivable that the blanks may be further shaped or contoured by other manufacturing processes such as molding of the entire blank or a part thereof.

[0033] Through the above process, a cushion 100 can be formed from a set of filaments 52, wherein at least two members of the set of filaments 52 are made into loops and / or joined to each other. In one or more embodiments, each member of the set of filaments 52 is made into a loop and / or joined to at least one other member of the set of filaments.

[0034] Non-foam or foam-free cushion structures may be difficult to fasten with conventional fasteners designed for fastening foam, for example. Therefore, in one or more embodiments, the cushion assembly 200 comprises one or more fasteners 202, as shown in Figures 2 and 4-11. In one improved embodiment, the one or more fasteners 202 fasten one or more cushions 100 in place and / or bond the cushions 100 to a surface 204 of another component 206 (e.g., an armrest). For example, the cushion assembly 200 comprises fasteners 202 positioned within the cushions 100. In various embodiments, the fasteners 202 can cooperate with non-cushion components 206. In one improved embodiment, the non-cushion component 206 is a rigid body such as a structural support or carrier board of the seat assembly 10 (e.g., an armrest support shown in Figure 9). For example, the non-cushion component 206 is a plastic such as polyethylene having a thickness (X as shown in Figure 10) of at least 1 mm, more preferably at least 3 mm, even more preferably at least 5 mm, or still even more preferably at least 7 mm.

[0035] In one or more embodiments, the cushion 100 and the non-cushioned component 206 are positioned such that the cushion 100 is closer to the seated person than the trim cover. In various embodiments, the cushion 100 and the non-cushioned component 206 are configured to be positioned such that the cushion 100 is positioned between the seated person / trim cover and the rigid, hard non-cushioned component 206. In one modification, the non-cushioned component 206 defines a shape or silhouette facing the seated person, and the cushion 100 is defined as having the same contour shape or silhouette.

[0036] In one or more embodiments, the fastener 202 and the non-cushion component 206 cooperate via corresponding male and female components. In one improved embodiment, the male and female components may or may not be coupled together and locked. For example, the fastener 202 may have a male portion and the non-cushion component 206 may have a female portion, or vice versa. In other words, the fastener 202 may have a protruding portion 207 and the non-cushion component 206 may have a hole / orifice 205 sized to receive the protruding portion 207, or vice versa.

[0037] In various embodiments, as shown in Figure 4, the fastener 202 has a retaining or anchoring portion 302 that serves to hold or fix the fastener 202 within a mesh member cushion (e.g., a plurality of polymer filaments). In one improved embodiment, the fastener 202 also includes a protruding portion 207 extending from the retaining or anchoring portion 302. In various embodiments, the protruding portion 207 is configured to be received by a non-cushioning component 206, such as those shown in Figures 2, 7 to 11. In one modified example, the fastener 202 and the non-cushioning component 206 are fixed, locked, and / or fastened to each other via a interference fit or the like. In addition or alternatively, the protruding portion 207 includes a fastening mechanism 306 such as a screw (i.e., a helical protrusion), a clip (e.g., a Christmas tree clip), a clasp, a hook, a rivet, a snap, or any other known fastening mechanism (e.g., friction base, keying, micro-brazing, fusion, screw action, rivet, adhesive, etc.), as shown in Figure 2. For example, the protruding part 207 is a long, slender clip.

[0038] In various embodiments, as shown in Figures 5 to 8, the cushion 100 has a side defining a surface or surface portion 208 and a slot 210 located below the surface or surface portion 208. For example, the cushion 100 has a first side (e.g., top surface) where the slot 210 defines a first surface 208 (e.g., top surface) located below it. In one or more embodiments, the slot 210 is defined into the cushion 100 from a second side / surface 212, such as the right or rear side / surface of the cushion 100. For example, the slot 210 is cut into the cushion 100 from a different surface after extrusion molding, and the fastener 202 is inserted into the cushion 100 through the slot 210. Alternatively, the slot 210 may be defined by the die during extrusion molding. In one improved embodiment, the slot defines an inlet port along the surface. The surfaces or surface portions described herein refer to the cushion body formed by polymer filaments, and not to individual polymer filaments. For example, as shown in Figure 5, cushion 100 includes a first surface 208 corresponding to a first surface plane defined by axes X and Y, and a second surface 212 corresponding to a second surface plane defined by axes Y and Z. Although cushions are illustrated as rectangles or cubes in this specification, the shape and size of cushions are not particularly limited in terms of their shape or size, and the surfaces are not limited to planes.

[0039] In various embodiments, the fastener 202 is positioned in the slot 210 such that a retaining or anchoring portion 302 is held within the slot 210, as shown in Figures 6 to 8, while a protruding portion 207 extends through the filaments of the mesh member cushion 100 to cooperate with the non-cushioning component 206. For example, the protruding portion 207 is received by a hole / orifice 205 in the non-cushioning component 206, as shown in Figure 8. In one improved embodiment, the protruding portion 207 engages with the hole / orifice via an interference fit to bond the cushion 100 to the non-cushioning component 206. In one or more embodiments, the fastener 202 and the non-cushioning component 206 are bonded such that the first surface 208 and the surface of the non-cushioning component 206 are adjacent to each other.

[0040] As shown in Figures 2, 8, 10, and 11, the non-cushion component 206 is configured to receive the fastener 202. In various embodiments, the non-cushion component 206 includes a hole / orifice 205 or projection for cooperating with the fastener 202. In one modification, the non-cushion component 206 includes a fastening mechanism corresponding to the fastening mechanism of the fastener 202. For example, the non-cushion component 206 defines a cavity, hollow bin, or hole / orifice configured to receive a projection 207 of the fastener 202. For example, in some embodiments, the projection 207 of the fastener 202 includes a screw (i.e., a helical protrusion), and the non-cushion component 206 is configured to receive the screw. For example, the cavity / orifice of the non-cushion component 206 includes a groove corresponding to a screw for coupling the fastener 202 to the non-cushion component 206. In yet another example, the fastening mechanism is a clip 306 (e.g., a Christmas tree clip), and the cavity of the non-cushion component 206 is provided with one or more holes (e.g., multiple holes, or at least two holes) for receiving the clip 306.

[0041] In one improved embodiment, the retaining or anchoring portion 302 of the fastener 202 is provided with a plurality of return portions. In other words, any embodiment described herein may be provided with a retaining or anchoring portion 302 with return portions to more securely hold or anchor the fastener 202 within the cushion 100. For example, the retaining or anchoring portion 302 is configured to receive a portion of the non-cushioning component 206 through a hole / orifice and is provided with a plurality of return portions.

[0042] Referring again to Figure 4, the fastener 202 comprises a holding portion or anchor portion 302 and a protruding shaft portion 207 extending therefrom. In one modified example, the fastener 202 also comprises a head portion 606 positioned on the shaft portion 207 opposite to the holding portion or anchor portion 302. In one improved form, the head portion 606 is tapered, rounded, or pointed. In one improved form, the head portion 606 is the dimension W of the shaft portion. s It is essentially the same, the same, or W s Smaller dimensions than W h (For example, width) is included. Alternatively, the head portion 606 has dimensions W of the shaft portion. s Dimensions W that are larger or longer than W h (For example, width) is provided. In one or more embodiments, the head portion 606 is configured to prevent the non-cushioning component 206 from sliding or falling off the shaft portion 207.

[0043] In one or more embodiments, the non-cushion component 206 is configured to cooperate with the shaft portion 207 by coupling to the shaft portion 207 (e.g., friction fit, snap fastening, and / or clip fastening). For example, the fastener 202 is positioned within the cushion 100 such that the head portion 606 and the shaft portion 207 protrude into the non-cushion component 206 through the cushion 100. Once protruding into the non-cushion component 206, the cushion 100 is coupled to the non-cushion component 206 by clipping the hole / orifice 205 defined by the non-cushion component 206 to the shaft portion 207.

[0044] In various embodiments, the fasteners 202 described herein can be made from any suitable material. For example, the fasteners 202 are made of thermoplastic polymers (e.g., polyolefins, polyethylene, polypropylene, polystyrene, polycarbonate, and / or polyvinyl chloride). In one improved embodiment, the fasteners 202 may be made of low-density or high-density polyethylene. In one modified example, the fasteners 202 are made from the same polymer material as the mesh member cushion 100 and / or its filaments 52, so that they can be recycled together with the cushion 100 and do not need to be removed. In one improved embodiment, the cushion 100 is bonded to the non-cushion component 206 via the fasteners 202 without adhesive. In other words, the cushion assembly 200 may be adhesive-free or substantially adhesive-free (i.e., less than 1% by weight, 0.5% by weight, or 0.1% by weight).

[0045] Referring again to Figure 4, the shape of the holding portion or anchor portion 302 is not particularly limited, but in various embodiments, for example, the width W of the protruding portion 207 s Width W is 2, 3, 5, or 10 times the width of . aThe retaining or anchoring portion 302 has a generally flat section that extends along the width of many polymer filaments 52, and the polymer filaments 52 three-dimensionally prevent the fastener 202 from moving along the first axis D1, as shown in Figure 6. For example, the retaining or anchoring portion 302 may be round, circular, rectangular, square, rhombic, triangular, S-shaped, or any other suitable shape. The shape of the protruding portion 207 is not particularly limited. For example, the shape may be round, cylindrical, hook-shaped, or pointed. In one improved embodiment, the protruding portion 207 has a shape and width that allows it to pass more easily through multiple polymer filaments 52 of the mesh member cushion 100. For example, the protruding portion 207 may have a pointed or rounded tip that allows it to penetrate the filaments 52 more easily. In one modified example, the protruding portion 207 is of a length that extends from the surface of the cushion 100, more preferably from the slot 210 through the surface 208 of the cushion 100, and even more preferably from the slot 210 through the surface 208 of the cushion 100 into the non-cushioning component 206. In various embodiments, the retaining portion or anchor portion 302 has a larger cross-sectional area along the XY direction than the protruding shaft portion 207 and the head portion 606. In one improved embodiment, the head portion 606 has a larger cross-sectional area than the protruding shaft portion.

[0046] Referring to Figure 12, a method 800 for manufacturing a cushion assembly is disclosed. The method 800 includes one or more steps of: extruding one or more cushion bodies (i.e., step 802); molding one or more fasteners as described herein (i.e., step 804); defining one or more slots in one or more cushion bodies (i.e., step 806); placing one or more fasteners in one or more slots (i.e., step 808); joining one or more fasteners to non-cushion components (i.e., step 810); and assembling the cushion assembly into a seat assembly for a vehicle or the like (i.e., step 812).

[0047] In various embodiments, one or more cushion bodies are unformed or non-formed mesh member cushions comprising multiple intertwined or woven polymer filaments as described above. In one improved embodiment, slots can be cut into the cushion after extrusion molding. Alternatively, a breaker plate die can be used to define cavities or slots within the cushion during extrusion molding. In one or more embodiments, fasteners can be made from the same polymer material as the cushion. Alternatively, the fasteners and cushions can be made from polymer materials that can be recycled together without separation. For example, the cushions and fasteners can be made from different grades of polymer material or polymer materials having similar melting points.

[0048] In one modified example, the fasteners are joined in place or together by pressing together to form a friction fit, screwing together, clipping together, snapping together, or by any other suitable mounting mechanism. For example, a fastener having a retaining or anchoring portion and a protruding portion is positioned in a cushion, such as a first slot in a first cushion, by moving the fastener laterally in a first direction through a slot until the fastener is in a desired or intended position (e.g., a predetermined position), and then extending or pushing the protruding portion through the cushion in a second direction different from the first direction until the protruding portion extends or penetrates through the first surface of the cushion. For example, the first direction and the second direction are perpendicular. In one improved embodiment, the protruding portion is pushed until the protruding portion is received and joined by a non-cushioning component such as a support structure (e.g., an armrest).

[0049] Alternatively, the protruding portion of the non-cushion component may be pressed to penetrate the mesh member cushion and coupled to a fastener positioned therein. In various embodiments, the fastener can be fastened in an adjustable manner, such as by a predetermined increment, to adjust the distance between the retaining or anchoring portion and the non-cushion component. For example, the fastener can be fastened so that the cushion and the non-cushion component are in contact with each other, as shown in Figures 8, 10, and 11. Alternatively, the fastener may be fastened so that a gap is defined between the cushion and the non-cushion component.

[0050] In one or more embodiments, the cushion assembly or a portion thereof is recycled (i.e., step 814). Since the cushion and one or more fasteners are made from compatible, similar, substantially similar, or the same material, it is not necessary to separate or remove the fasteners before recycling. In one modification, recycling involves cutting the cushion assembly into smaller parts or fragments by crushing, shredding, tearing, cutting, and / or grinding, etc. In one improved embodiment, the cushion assembly is melted into a polymer resin for reuse, for example, after a certain particle size is achieved or after a certain cutting period. In one or more embodiments, the polymer resin is filtered, purified, or de-purified after melting and before reuse. In one or more embodiments, multiple cushion assemblies are recycled without removing the fasteners. In yet another embodiment, one or more cushion assemblies can be made from recycled polymer resin.

[0051] According to a first embodiment of a cushion assembly described herein, the assembly comprises a mesh member having a first side defining a first surface and comprising a set of filaments of a thermoplastic material, each member of the set of filaments being looped and joined to at least one other member of the set of filaments; a carrier board defining a second surface adjacent to the first surface; and a fastener comprising a retaining portion disposed within the mesh member and a protruding portion projecting from the retaining portion through the first surface of the mesh member and the second surface of the carrier board, the protruding portion cooperating with the carrier board to fix the mesh member adjacent to the carrier board.

[0052] According to the second embodiment, the carrier board in either the first embodiment or the subsequent embodiment is an armrest.

[0053] According to the third embodiment, the carrier board of either the preceding or succeeding embodiment has a thickness of at least 3 mm.

[0054] According to the fourth embodiment, the carrier board of either the preceding or succeeding embodiment has a thickness of at least 5 mm.

[0055] According to the fifth embodiment, the carrier board of either the preceding or succeeding embodiment defines a hole sized to receive a fastener.

[0056] According to the sixth embodiment, the fastener of either the preceding or succeeding embodiment cooperates with the carrier board via an interlocking fit in a hole.

[0057] According to the seventh embodiment, the mesh member of either the preceding or succeeding embodiment is positioned closer to the trim cover than to the carrier board.

[0058] According to the eighth aspect, the carrier board in either the preceding or succeeding aspect defines a silhouette shape, and the mesh member defines the same silhouette shape.

[0059] According to the ninth aspect, the retaining portion of either the preceding or succeeding aspect is positioned within a slot defined by the mesh member.

[0060] According to the tenth embodiment, the slot in either the preceding or succeeding embodiment is provided with an inlet port, the inlet port being located on a second surface of a mesh member that is different from the first surface.

[0061] According to the eleventh embodiment, the retaining portion of either the preceding or succeeding embodiment has a larger cross-sectional area than the protruding portion.

[0062] According to the twelfth embodiment, the fastener in either the preceding or subsequent embodiment is made from a thermoplastic polymer material.

[0063] According to the 13th embodiment, the fastener in either the preceding or succeeding embodiment is made from a thermoplastic polymer material, and the set of filaments is made from the same thermoplastic polymer material.

[0064] According to the 14th embodiment, the vehicle seat assembly comprises either a preceding or succeeding assembly that is mounted on the frame.

[0065] According to the 15th embodiment, the fastener assembly comprises a retaining portion disposed within the cushion body and a protruding portion protruding from the retaining portion, the protruding portion being molded and sized to extend from a slot in the cushion body through a first side of the cushion body and engage with a support board, thereby fixing the protruding portion to the support board, the retaining portion being held within the cushion body, and fixing the cushion body to the support board.

[0066] According to the 16th aspect, the method includes arranging a fastener having a retaining portion in a slot defined by a cushion, and coupling the fastener to a rigid support such that the slot is located below the surface portion along a first side of the cushion, and the protruding portion extends into the rigid support through the cushion and the surface portion.

[0067] According to the 17th embodiment, the method of either the preceding or subsequent embodiment further includes molding the fastener and the cushion from the same polymer.

[0068] According to the 18th embodiment, the method in either the preceding or subsequent embodiment further includes recycling the cushion and fasteners.

[0069] According to the 19th embodiment, in either the preceding or subsequent embodiment, recycling includes cutting the cushion and fastener into smaller pieces and melting the smaller pieces to form a polymer resin.

[0070] According to the 20th aspect, the method of any of the preceding aspects further includes defining a slot from a second side of the cushion that is different from the first side.

[0071] While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The words used herein are descriptive, not restrictive, and it should be understood that various modifications may be made without departing from the scope of this disclosure. As stated above, features of various embodiments can be combined to form further embodiments of the invention, which may not be expressly described or illustrated. While various embodiments may have been described as offering advantages over or being preferable to other embodiments or prior art embodiments with respect to one or more desirable characteristics, those skilled in the art will recognize that one or more features or characteristics may be sacrificed to achieve desired overall system attributes, depending on the particular application and embodiment. These attributes may include, but are not limited to, cost, strength, durability, lifecycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Therefore, if any embodiment is described as undesirable over other embodiments or prior art embodiments with respect to one or more characteristics, these embodiments may not be outside the scope of this disclosure but may be desirable for a particular application.

Claims

1. A mesh member having a first side defining a first surface, comprising a set of filaments of a thermoplastic material, wherein each member of the set of filaments is looped and joined to at least one other member of the set of filaments, A carrier board defining a second surface adjacent to the first surface, An assembly comprising a fastener, the fastener having a holding portion disposed within the mesh member, and a protruding portion that protrudes from the holding portion through the first surface of the mesh member and the second surface of the carrier board, wherein the protruding portion cooperates with the carrier board to fix the mesh member adjacent to the carrier board.

2. The assembly according to claim 1, wherein the carrier board is an armrest.

3. The assembly according to claim 1, wherein the carrier board has a thickness of at least 3 mm.

4. The assembly according to claim 1, wherein the carrier board has a thickness of at least 5 mm.

5. The assembly according to claim 1, wherein the carrier board defines holes sized to receive the fasteners.

6. The assembly according to claim 5, wherein the fastener cooperates with the carrier board via a tight fit in the hole.

7. The assembly according to claim 1, wherein the mesh member is positioned closer to the trim cover than the carrier board.

8. The assembly according to claim 1, wherein the carrier board defines a certain contour shape, and the mesh member defines the same contour shape.

9. The assembly according to claim 1, wherein the retaining portion is located within a slot defined by the mesh member.

10. The assembly according to claim 9, wherein the slot is provided with an inlet port, and the inlet port is located on a second surface of the mesh member that is different from the first surface.

11. The assembly according to claim 1, wherein the retaining portion has a larger cross-sectional area than the protruding portion.

12. The assembly according to claim 1, wherein the fastener is made from a thermoplastic polymer material.

13. The assembly according to claim 1, wherein the fastener is made from a thermoplastic polymer material, and the set of filaments is made from the same thermoplastic polymer material.

14. A vehicle seat assembly comprising the assembly according to claim 1, which is mounted to a frame.

15. A fastening assembly comprising a retaining portion disposed within a cushion body and a protruding portion protruding from the retaining portion, wherein the protruding portion is shaped and sized to extend from a slot in the cushion body through a first side of the cushion body and engage with a support board, the protruding portion being fixed to the support board, the retaining portion being held within the cushion body, and the cushion body being fixed to the support board.

16. The fastener is positioned in a slot defined in the cushion, wherein the slot is located below the surface portion along the first side of the cushion. A method comprising connecting the fastener to the rigid support such that the protruding portion extends into the rigid support through the cushion and the surface portion.

17. The method according to claim 16, further comprising molding the fastener and the cushion from the same polymer.

18. The method according to claim 17, further comprising recycling the cushion and the fastener.

19. The method according to claim 18, wherein the recycling includes cutting the cushion and the fastener into smaller pieces and melting the smaller pieces to form a polymer resin.

20. The method according to claim 16, further comprising defining the first slot from a second side of the cushion different from the first side.

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