Seat assembly, clip, and manufacturing method

Abstract

To provide a seat assembly, a clip, and a method of manufacturing the same.SOLUTION: The clip is disposed in a cushion. The cushion may comprise a filament mesh structure. The clip has at least one barb that secures the clip to the cushion, and at least one retention feature that secures a trim cover to the clip.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Various embodiments relate to a seat assembly, a clip for securing a trim cover to a seat assembly, and a method of manufacture.

[0002] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 508,301, filed June 15, 2023, Danish Patent Application No. PA202370583, filed November 21, 2023, and U.S. Non-Provisional Patent Application No. 18 / 629,363, filed April 8, 2024, the disclosures of which are incorporated herein by reference in their entireties. Summary of the Invention

[0003] According to one aspect of the invention, a clip comprises a spine having a bottom surface, first and second retention features extending from the spine, and a first barb extending from at least one of the first retention feature and the spine, the first barb extending away from the bottom surface of the spine.

[0004] According to another aspect of the invention, a seat assembly includes a filament mesh structure having a first surface and a set of filaments, a trim cover, and a clip disposed within the filament mesh structure, wherein each member of the set of filaments is looped and coupled to at least one other member of the set of filaments. The clip includes a spine and a first clip portion, the first clip portion including first and second retention features extending from the spine to secure the trim cover to the clip, and first and second barbs securing the first clip portion to the filament mesh structure, the first and second barbs extending away from the spine toward the first surface of the filament mesh structure.

[0005] Further aspects of the invention are described below. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a perspective view of an example seat assembly. [Figure 2] FIG. 1 is a perspective view of an example cushion for a seat assembly. [Figure 3] 1 is a schematic diagram of an example of a manufacturing system for manufacturing a filament mesh structure for a cushion. [Figure 4] FIG. 1 is a perspective view of an example of a clip. [Figure 5] FIG. 5 is an end view of the clip shown in FIG. 4. [Figure 6] FIG. 5 is a plan view of a portion of the clip shown in FIG. 4. [Figure 7] 5 is a side view of a portion of the clip shown in FIG. 4. [Figure 8] 10 is a flowchart showing a method for manufacturing a clip and a method for attaching the clip to a cushion. [Figure 9] FIG. 1 is a simplified side view of a filament mesh structure. [Figure 10] FIG. 1 is a simplified side view of a filament mesh structure having slits. [Figure 11] FIG. 1 is a side view of a filament mesh structure with a clip, the clip shown in end view. [Figure 12] FIG. 1 is a simplified side view of a filament mesh structure with a trim cover secured to a clip. [Figure 13] FIG. 1 is a side view of a filament mesh structure with a clip, the clip being shown in side view. [Figure 14] FIG. 1 is a plan view of an example of a portion of a filament mesh structure having a clip. [Figure 15] 1A-1C are simplified side views of a filament mesh structure showing clips positioned at different heights within the filament mesh structure. DETAILED DESCRIPTION OF THE INVENTION

[0007] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0008] It should be understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The drawings are not necessarily drawn to scale. Some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to variously employ the embodiments according to the present disclosure.

[0009] "One or more" includes a function being performed by one element, a function being performed by two or more elements, e.g., in a distributed manner, multiple functions being performed by one element, multiple functions being performed by multiple elements, or any combination of the above.

[0010] Also, while terms such as "first," "second," and the like are used herein to describe various elements in some instances, it will be understood that these elements should not be limited by these terms. These terms are merely used to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various described embodiments. A first contact and a second contact are both contacts, but are not the same contact.

[0011] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will also be understood that the term "and / or," as used herein, is used to refer to and encompass any and all possible combinations of one or more of the associated listed items. Furthermore, it will be understood that the terms "comprising" or "including," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0012] As used herein, the term "when" is interpreted to mean "when," or "upon," or "in response to determining," or "in response to detecting," optionally depending on the context. Similarly, the phrases "when determined" or "when [specified condition or event] is detected" are interpreted to mean "upon determining," or "in response to determining," or "upon detecting [specified condition or event]," optionally depending on the context.

[0013] Referring to FIG. 1 , an example of a seat assembly 10 is shown. In some embodiments, the seat assembly 10 is a vehicle seat assembly for a land vehicle, such as a car, truck, or bus, or a non-land vehicle, such as an aircraft or watercraft. For example, the seat assembly 10 for a land vehicle can be shaped and sized as a front driver or passenger seat, a second-row, third-row, or other rear-row seat, and can include a bench-style seat, a bucket-style seat, or other seating styles. Furthermore, the seat assembly 10 can be a non-retractable seat or a retractable seat that is foldable or foldable and retractable within a cavity in the floor of the vehicle. Additionally, the seat assembly 10 can be configured for non-vehicle applications, such as furniture.

[0014] 1, the seat assembly 10 includes a seat bottom 20 and a seat back 22. It is contemplated that the seat back 22 may be omitted in some configurations, such as when the seat assembly 10 is configured as a motorcycle seat or perch.

[0015] The seat bottom 20 is configured to receive an occupant and support the occupant's pelvis and thighs. The seat bottom 20 includes a seat bottom frame 30, a cushion 32, and a trim cover .

[0016] The seat bottom frame 30 is a structure that supports the cushion 32. The seat bottom frame 30 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 bottom frame 30 includes a panel, seat pan, suspension mat, or suspension wires on which the cushion 32 is positioned.

[0017] The cushion 32 is disposed on the seat bottom frame 30. The cushion 32 is made from a compliant material that supports an occupant and distributes load forces from the occupant across the seat bottom frame 30. The cushion 32 and associated manufacturing methods are described in more detail below.

[0018] The trim cover 34 covers at least a portion of the cushion 32. Additionally, the trim cover 34 provides one or more visible exterior surfaces of the seat back 22. A seat occupant may be positioned on the trim cover 34 when seated in the seat assembly 10. The trim cover 34 may be made from any suitable material or materials, such as cloth, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 34 may include multiple trim panels assembled in any suitable manner, such as by fusing or stitching. The trim cover 34 may be attached to the seat bottom frame 30, the cushion 32, or both. For example, the trim cover 34 may include trim attachment features attached to the seat bottom frame 30, the cushion 32, or both, to prevent removal of the trim cover 34 and to help the trim cover 34 conform to the contours of the seat bottom frame 30, the cushion 32, or both. It is also contemplated that different types of trim attachment features may be employed to attach the trim cover 34 to the seat bottom frame 30 rather than the cushion 32 .

[0019] The seat back 22 is configured to support the back of a seat occupant. The seat back 22 is positioned adjacent to the seat bottom 20. For example, the seat back 22 may be positioned above and near the rear of the seat bottom 20. The seat back 22 extends generally upwardly away from the seat bottom 20. In some configurations, the seat back 22 is attached to the seat bottom 20 and may be pivotable relative to the seat bottom 20. In other configurations, the seat back 22 is not attached to the seat bottom 20. For example, the vehicle seat back may be attached to the vehicle body structure, such as in some second row seat assemblies. The seat back 22 includes a seat back frame 40, a cushion 42, a trim cover 44, and an optional headrest 46.

[0020] The seat back frame 40 is a structure that supports the cushion 42. The seat back frame 40 includes one or more structural members and can be made from any suitable material, such as a metal alloy, a polymeric material, a fiber-reinforced polymeric material, or a combination thereof. In some configurations, the seat back frame 40 includes a panel, pan, suspension mat, or suspension wires upon which the cushion 42 is positioned. It is also contemplated that the seat back frame 40 may be integrally formed with the seat bottom frame 30.

[0021] The cushion 42 is disposed on the seat back frame 40. The cushion 42 is made from a compliant material that supports an occupant and distributes load forces from the occupant to the seat back frame 40. It is contemplated that the cushion 42 may be integrally formed with the cushion 32 of the seat bottom 20 or may be separate from the cushion 32 of the seat bottom 20. The cushion 42 and related manufacturing methods are described in more detail below.

[0022] The trim cover 44 covers at least a portion of the cushion 42. Additionally, the trim cover 44 provides one or more visible exterior surfaces of the seat back 22. An occupant may place themselves on the trim cover 44 when seated in the seat assembly 10. The trim cover 44 may be made from any suitable material or materials, such as cloth, leather, synthetic leather, vinyl, or a combination thereof. The trim cover 44 may include multiple trim panels assembled in any suitable manner, such as by fusing or stitching. The trim cover 44 may be attached to the seat back frame 40, the cushion 42, or both. For example, the trim cover 44 may include trim attachment features attached to the seat back frame 40, the cushion 42, or both, to prevent removal of the trim cover 44 and to help the trim cover 44 conform to the contours of the seat back frame 40, the cushion 42, or both. It is contemplated that different types of trim attachment features may be employed to attach the trim cover 44 to the seat back frame 40 rather than to the cushion 42 .

[0023] If provided, the headrest 46 is configured to support the head of a seat occupant. The headrest 46 is located at the top of the seat back 22, i.e., at the end of the seat back 22 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 formed integrally with the seat back 22.

[0024] 2, an example of a cushion 50 is shown. For ease of reference, the cushion is generally designated by the reference numeral 50. It should be understood that the structure and description of the cushion 50 may be applicable to the cushion 32 of the seat bottom 20, the cushion 42 of the seat back 22, or both.

[0025] In some embodiments, the cushion 50 is a non-foamed component or includes at least one non-foamed component. Non-foamed components are primarily referred to as filament mesh structures, but may also be referred to as mesh cushions, mesh structures, or strand mesh. While FIG. 2 depicts the cushion 50 as a non-foamed component that does not include a foamed component or foam material, such as urethane foam or polyurethane foam, it is contemplated that the cushion 50 may also include a foamed component or foam material in addition to the non-foamed component to provide additional or localized cushioning for the seat occupant. For example, the foam material may be provided between the cushion 50 and a trim cover (e.g., trim covers 34, 44) disposed over the cushion 50, within the cushion 50, or a combination thereof. Reducing the amount of foam material provided in the cushion 50 or eliminating foam material from the cushion 50 can reduce weight and improve occupant support and comfort.

[0026] The cushion 50 will be described below in the context of the cushion 50 not including a foam material. In this context, the cushion 50 is made from filaments 52 of polymeric material that are randomly looped, bent, curled, or entangled and bonded together, as described in more detail below. Close-up views of a cushion with an example of filaments 52 are shown in Figures 11 and 13. The filaments 52 are bonded directly to other filaments 52, rather than indirectly bonded with a resin or other intermediate material.

[0027] The filaments 52, which may also be referred to as strands or threads, are made from any suitable material or materials. In some configurations, the filaments 52 are made from a polymeric or thermoplastic material, such as a thermoplastic resin that is polyamide-based, polyester-based, polyimide-based, polyolefin-based (e.g., polypropylene-based, polyethylene-based, etc.), polystyrene-based, or a combination thereof. As one example, a polyethylene-based filament may be made from linear low-density polyethylene (LLPDE). The filament material may be recyclable, unlike, or more easily recycled than, a foamed material. It is also contemplated that the filaments 52 may include reinforcing fibers, or the reinforcing fibers may not be made from a thermoplastic material.

[0028] In some configurations, the filament 52 may be a monofilament made from a single material. In some configurations, the filament 52 is made from multiple materials. As an example, a 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. It is contemplated that the cushion 50 may include a combination of monofilaments and non-monofilament filaments made from multiple materials.

[0029] The randomly looped, bent, looped, curled, or entangled filaments 52 are bonded together where one filament 52 contacts another filament 52, thereby resulting in a lightweight, breathable cushion (e.g., cushion 32 and / or 42) or mesh structure having openings or voids between the filaments 52. An example of a manufacturing system 60 for manufacturing the cushion or filament mesh structure is also shown in FIG. 3. In this example, the manufacturing system 60 includes a material supply 70, an extruder 72, and a funnel 74. The manufacturing system 60 also includes a cooling tank 76 and a material handling subsystem 78.

[0030] 3, material supply 70 holds the raw material to be extruded, such as solid beads, flakes, granules, pellets, or powder made from the materials described above. In some configurations, material supply 70 is configured as a container or hopper. Material supply 70 supplies the raw material to extruder 72.

[0031] The extruder 72 melts the feedstock material and extrudes it into a set of filaments 52. The extruder 72 can have any suitable configuration. In some configurations, the extruder 72 includes a barrel containing a rotatable screw and a heating element. The rotation of the screw moves the material through the barrel and helps heat the material due to friction generated as the screw rotates. The material exits the barrel in a pressurized molten state and is transported to a die 80 of the extruder 72.

[0032] The die 80, which may also be referred to as a die plate or extrusion die, has a plurality of through-holes or filament-forming openings through which molten material passes. A single filament 52 is extruded from each through-hole. The filament 52 falls downward from the die 80 under gravity into the funnel 74.

[0033] The funnel 74 consolidates or groups the filaments 52 into a more compact arrangement, where the filaments bend, curl, or loop, and each filament 52 contacts and bonds to at least one other filament 52. The funnel 74 has a funnel inlet and a funnel outlet that is smaller than the funnel inlet. Individual, separated filaments 52 enter the funnel inlet. The filaments 52 bend, curl, or loop, and move and contact as they accumulate. The filaments 52 slide down the funnel 74 toward the funnel outlet. Each member of the set of filaments 52 may be bonded to at least one other member of the set of filaments 52. Bonds are formed between the filaments 52 at the contact points, while openings or voids exist between the filaments 52 at other locations where one filament 52 does not contact or bond to another filament 52. The entangled and bonded filaments 52 pass through the funnel outlet of the funnel 74 and enter a cooling tank 76. For ease of reference, the joined filaments 52 are referred to as a filament mesh structure 90 .

[0034] The cooling tank 76 holds a liquid, such as water or a mixture of water and another fluid. The liquid in the cooling tank 76 supports the entangled and bonded filaments 52 and helps limit further compaction or consolidation of the filaments 52 into a more open or less porous arrangement, maintaining the desired porosity and density of the filament mesh structure 90. Thus, the liquid provides a degree of buoyancy or resistance that allows the filaments 52 to further bend, curl, or loop adjacent the surface of the liquid or within the funnel 74 to further build up the filament mesh structure 90. The liquid also cools the filaments 52 while they are in the liquid. For example, the liquid cools the filaments 52 from the outside, solidifying the filaments 52 and preventing them from bonding in additional locations. At this point, the filaments 52 become relatively rigid and are no longer in a plastic state, generally retaining their shape and no longer being moldable or reshapeable without being reheated.

[0035] The material handling subsystem 78 transports the filament mesh structure 90 through the cooling tank 76. The material handling subsystem 78 includes various rollers and conveyors that assist in moving the filament mesh structure 90 through and out of the liquid. In some configurations, a traction conveyor 92 is provided within the cooling tank 76 to assist in pulling the filament mesh structure 90 away from the funnel 74 and counteract the buoyancy of the filaments 52.

[0036] One or more other rollers, such as roller 94, keep the filament mesh structure 90 submerged in the liquid and guide the filament mesh structure 90 through the cooling tank 76. For example, roller 94 can guide the filament mesh structure 90 toward a conveyor belt 96 and shaker table 98 located outside the cooling tank 76. The shaker table 98 shakes the filament mesh structure 90 while it is on the conveyor belt 96 to remove the liquid. Alternatively, or in addition, the filament mesh structure 90 can be squeezed to remove the liquid, air can be blown toward the filament mesh structure 90 to remove the liquid from the filament mesh structure 90, or both.

[0037] 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 uninterrupted. Further processing of the filament mesh structure 90, such as cutting the filament mesh structure 90 into individual components or blanks for individual cushions, is provided after it exits the cooling tank 76. Such processing is performed by a cutting subsystem of the manufacturing system 60. The cutting subsystem can be of any suitable type. For example, the cutting subsystem can use a blade, knife, hot knife, saw, fluid jet, or the like to cut the filaments 52 of the filament mesh structure 90 into blanks. The cutting subsystem can also cut slits in the filament mesh structure 90 to receive clips, as described in more detail below. In some configurations, the filament mesh structure 90 is molded or shaped before cutting, after cutting, or both.

[0038] Referring to FIG. 4, an example of a clip 100 is shown. The clip 100 is configured to secure a trim cover to a cushion, such as cushion 50, including filament mesh structure 90, although it is contemplated that the clip 100 may also be provided with a cushion that includes or is made of foam. For ease of reference, the trim cover is generally designated by the reference numeral 102. The trim cover 102 may be the trim cover 34 of the seat bottom 20 or the trim cover 44 of the seat back 22. An example portion of the trim cover 102 is shown in FIG. 12.

[0039] With continued reference to FIG. 4 , clip 100 is made from any suitable material(s). In some configurations, clip 100 is made from a polymeric material. Clip 100 may be made from the same material as filament 52 or from a different material than filament 52. The polymeric material may be recyclable. Clip 100 is manufactured using any suitable process. For example, clip 100 may be molded or made using an additive manufacturing process such as 3D printing. It is contemplated that clip 100 may be made as a single, one-piece component that can be cut to the appropriate length to be attached to filament mesh structure 90.

[0040] The clip 100 includes one or more clip segments 110. In configurations having multiple clip segments 110, spines 112 are provided on the clip 100. In such configurations, the spines 112 interconnect the clip segments 110. The clip segments 110 are spaced apart such that a gap 114 is provided between one clip segment 110 and an adjacent clip segment 110. The clip 100 will be primarily described with reference to clips 100 having multiple clip segments 110.

[0041] 4 and 5, an example of a spine 112 is shown. The spine 112 is flexible, allowing the clip portions 110 to be positioned in various orientations relative to one another, as described in more detail below. The spine 112 may extend along a straight spine axis 120, i.e., be straight, when the spine 112 is in its free state, as shown in FIG. 4. The spine 112 includes a bottom surface 130 and a top surface 132.

[0042] The bottom surface 130 faces away from the clip portion 110. In some configurations, the bottom surface 130 extends the length of the clip 100.

[0043] The top surface 132 is disposed opposite the bottom surface 130. Thus, the top surface 132 faces the clip portion 110. In some configurations, the top surface 132 is segmented and extends from one clip portion 110 to an adjacent clip portion 110, i.e., is visible between the adjacent clip portions 110, 110.

[0044] 4 and 5, the spine 112 is positioned below the clip portion 110. It is also contemplated that the spine 112 may be positioned higher than shown in these figures. For example, rather than being positioned below one or more clip portions 110, the spine 112 may extend from a side of a first clip portion 110 facing an adjacent second clip portion 110 to a corresponding side of the adjacent second clip portion 110 facing the first clip portion 110. As an example, the spine 112 may be moved up from the position shown in FIG. 5 so that the top surface 132 shown in FIG. 5 becomes the bottom surface 130 and is hidden behind the clip portion 110 from the perspective shown.

[0045] Referring primarily to FIG. 5, clip portion 110 includes at least one retention feature 140 and at least one barb 142 .

[0046] The retaining feature 140 extends from the spine 112. In some configurations, the retaining feature 140 extends from the top surface 132 of the spine 112. In the configuration shown in FIG. 5, the clip portion 110 includes a first retaining feature 140 and a second retaining feature 140. For ease of reference, the first retaining feature 140 may be located on the left side in FIG. 5 and the second retaining feature 140 may be located on the right side.

[0047] The first and second retaining features 140, 140 each have an arm 150 extending away from the spine 112. For example, the arm 150 may extend away from the spine 112 in a first direction 152 relative to or along a central plane 154 of the clip portion 110. The central plane 154 may bisect the clip portion 110. In the illustrated configuration, the central plane 154 is located between the first and second retaining features 140, i.e., where the first retaining feature 140 meets the second retaining feature 140. The first direction 152 extends away from the spine 112, i.e., upward from the perspective shown in FIG. 5 . The central plane 154 may extend through the spine 112. For example, the central plane 154 may bisect the spine 112. The spine axis 120 may be disposed within the central plane 154 of the clip portion 110, such as when the clip 100 is in a free state.

[0048] The arms 150 of the first retaining feature 140 are spaced apart from the arms 150 of the second retaining feature 140. As such, the arms 150, 150 cooperate to at least partially define a cavity 156 therebetween.

[0049] In some configurations, the arms 150 include barbs 160 disposed at the distal ends of the arms 150. The barbs 160 of the arms 150 of the first retaining feature 140 can extend toward the barbs 160 of the arms 150 of the second retaining feature 140, thereby providing a narrower gap 162 between the barbs 160, 160 than adjacent portions of the cavity 156. The barbs 160, 160 help to retain and secure the trim attachment feature of the trim cover 102 within the cavity 156, as described in more detail below.

[0050] One or more barbs 142 are provided on the clip portion 110. The barbs 142 may extend from the retention features 140, the spines 112, or both. In FIG. 5, two barbs 142 are shown, with a first barb 142 extending from the first retention feature 140 and a second barb 142 extending from the second retention feature 140. In some configurations, the barbs 142 are spaced apart from the spines 112 and do not extend from the spines 112. In such configurations, the barbs 142 extend from the corresponding retention features 140 in a direction away from the central plane 154 and the cavity 156. Similarly, the barbs extending from the spines 112 may also extend in a direction away from the central plane 154, the cavity 156, or both.

[0051] The barbs 142 are disposed in a non-parallel and non-perpendicular relationship to the central plane 154. Furthermore, the barbs 142 are oriented to extend away from the bottom surface 130 of the vertebrae 112, i.e., upward from the perspective of FIG. 5 . Thus, the barbs 142 extend in the first direction 152 as their distance from the vertebrae 112 increases. Thus, the barbs 142 may extend further away from the bottom surface 130 as the barbs 142 extend away from the vertebrae 112 and the central plane 154. In the illustrated configuration, the first barbs 142 extend away from the second barbs 142. In this manner, the first barbs 142 and the second barbs 142 may extend in opposite directions relative to each other, i.e., relative to the central plane 154.

[0052] The spines 142 can extend away from the bottom surface 130 in a linear or non-linear manner. In FIG. 5 , each spine 142 is shown extending along a corresponding spine axis 170. The spine axis 170 intersects the central plane 154 at an acute angle 172, as shown in FIG. 5 , and can be disposed substantially perpendicular to the central plane 154 when viewed from above, i.e., in a planar view, as shown in FIG. 6 . The term “substantially perpendicular” is used herein to designate a characteristic or axis that is the same as or very close to perpendicular, including within ±3 degrees of being perpendicular to one another. In some configurations, the spine axis 170 intersects the central plane 154 at a location that does not intersect the spine 112, such as where the first retaining feature 140 meets the second retaining feature 140. It is also contemplated that the spines 142 may be curved or extend in a non-linear manner. For example, the barbs 142 or portions of the barbs 142 may extend along an arc or curve that may be upwardly curved or convex relative to the spine 112 from the perspective shown.

[0053] In some configurations, the spine 142 includes an upper surface 180 , a lower surface 182 , a first side 184 , and a second side 186 .

[0054] The upper surface 180 faces away from the spine 112. In some configurations, the upper surface 180 extends from the corresponding retaining feature 140. For example, the upper surface 180 may intersect or extend from the arm 150 of the corresponding retaining feature 140. As the upper surface 180 extends away from the corresponding retaining feature 140, it extends further away from the spine 112. The upper surface 180 may have a planar or non-planar configuration.

[0055] The lower surface 182 is disposed opposite the upper surface 180. Thus, the lower surface 182 faces the vertebrae 112. In some configurations, the lower surface 182 extends from the corresponding retention feature 140. In some configurations, the lower surface 182 intersects with, i.e., extends from, the vertebrae 112. The lower surface 182 may have a planar or non-planar configuration. As the lower surface 182 extends from the corresponding retention feature 140 and moves away from the retention feature 140, it extends further away from the vertebrae 112. In some configurations, the lower surface 182 has a longer length than the upper surface 180.

[0056] In some configurations, the lower surface 182 is disposed substantially parallel to the upper surface 180. As used herein, the term "substantially parallel" means the same as or very close to parallel, and includes features or axes within ±3 degrees of parallelism. When the lower surface 182 is disposed substantially parallel to the upper surface 180, the lower surface 182 does not intersect with the upper surface 180. In some configurations, the lower surface 182 and the upper surface 180 are disposed in a non-parallel relationship. For example, the lower surface 182 and the upper surface 180 may approach each other as the distance from the central plane 154 increases. It is contemplated that the lower surface 182 may intersect with the upper surface 180 in some configurations, such as at the distal end of the spine 142.

[0057] 5-7 , a first side 184 extends from a corresponding retaining feature 140. For example, as best shown in FIG. 5 , the first side 184 may extend from a protrusion 190 of the corresponding retaining feature 140 and may be spaced apart from an arm 150 of the retaining feature 140. It is also contemplated that the first side 184, or a portion thereof, may extend from the arm 150. The first side 184 extends from the upper surface 180 to the lower surface 182. As best shown in FIG. 6 , the first side 184 extends toward the second side 186 as the distance from the central plane 154 increases. For example, the first side 184 may extend toward, or become closer to, the corresponding spine axis 170 as the distance from the central plane 154 increases. It is contemplated that first side 184 may be planar or non-planar.

[0058] The second side 186 extends from the corresponding retention feature 140 and is disposed opposite the first side 184. For example, the second side 186 may extend from a protrusion 190 of the corresponding retention feature 140 or may be spaced apart from the arm 150 of the retention feature 140. It is also contemplated that the second side 186, or a portion thereof, may extend from the arm 150. The second side 186 extends from the upper surface 180 to the lower surface 182. The second side 186 extends toward the second side 186 as the distance from the central plane 154 increases. For example, the second side 186 may extend toward, or be closer to, the corresponding spine axis 170 as the distance from the central plane 154 increases. This configuration may facilitate attachment of the clip 100 to the cushion 50, as described in more detail below. It is contemplated that second side 186 may be planar or non-planar.

[0059] In some configurations, first side 184 intersects second side 186 at distal end 192 of spine 142. This can result in spine 142 having a triangular configuration when viewed from above when first side 184 and second side 186 have a vertically aligned planar configuration, as best shown in FIGURE 6. It is also contemplated that distal end 192 may be rounded or provided with a radius rather than following a straight edge.

[0060] Referring to Figure 8, there is shown a flow chart of a method for manufacturing and attaching clip 100 to cushion 50. The cushion is described in terms of the cushion being a filament mesh structure 90. Figures 9-12 show examples relating to the method steps.

[0061] At block 200, a filament mesh structure 90 is manufactured. The filament mesh structure 90 may be manufactured using the manufacturing system 60, as previously described. An example of a portion of the filament mesh structure 90 is shown in Figure 9. Figure 9 shows a simplified view of the filament mesh structure 90 without showing the individual filaments 52 for simplicity.

[0062] In block 202, slits 210 are provided in the filament mesh structure 90. In some configurations, the slits 210 are provided by the cutting subsystem of the manufacturing system 60, as previously described. Thus, the slits 210 can be provided by severing some of the filaments 52 in the filament mesh structure 90. An example of a slit 210 is shown in FIG. 10 . The slits 210 extend from a first surface 212 of the filament mesh structure 90 to a second surface 214 of the filament mesh structure 90 opposite the first surface 212. In some configurations, the slits 210 are partial cuts through the thickness of the filament mesh structure 90 and do not extend to the second surface 214. In some configurations, the slits 210 are provided by forming depressions in the filament mesh structure 90 without severing the filaments 52. For example, the slits 210 can be provided by molding or reshaping the filament mesh structure 90 to provide the slits 210, such as grooves or holes, extending from the first surface 212. As an example, the filament mesh structure 90 or the region of the filament mesh structure 90 where the slits 210 will be provided may be heated with a fluid (e.g., gas, liquid, or both) to soften the filament mesh structure so that the softened filaments 52 conform to the shape of a molding surface of a mold or other tool, such as a rod or bar, that is engaged against the first surface 212. Alternatively, the fluid may be supplied under pressure, such as through one or more nozzles, to simultaneously heat the filaments 52 and exert a force on the filaments 52 sufficient to form the slits 210. The filament mesh structure 90 may then be cooled to harden the filaments 52 and set the shape of the filament mesh structure 90 and slits 210.

[0063] In block 204, the clip 100 is inserted into the slit 210 and attached to the filament mesh structure 90. An example of clip 100 insertion is shown in FIG. 11. A tool 220 having an enlarged tip 222 is inserted through the gap 162 between the first and second retaining features 140 of the clip 100 toward the bottom of the cavity 156. The gap 162 is best seen in FIG. 5. The force exerted by the tool 220 causes the arms 150, 150 of the first and second retaining features 140, 140 to flex away from each other, thereby allowing the enlarged tip 222 to move past the barbs 160, 160 and into the cavity 156, temporarily securing the clip 100 to the tool 220.

[0064] The tool 220 and clip 100 are aligned with the slit 210. Relative movement between the tool 220 and the filament mesh structure 90 moves the clip 100 into the slit 210, such as by actuating the tool 220 and clip 100 toward the slit 210, as represented by the downward-pointing arrows. The force exerted by the tool 220 is sufficient to force the clip 100 into the slit 210, with the spines 112 entering the slit 210 before the arms 150 enter the slit 210. The barbs 142 act like wedges, causing the clip 100 to push the filaments 52 apart. The filaments 52 may be sufficiently flexible so that insertion of the clip 100 does not cut or sever the filament 52.

[0065] The clip 100 is inserted beyond the first surface 212 of the filament mesh structure 90, i.e., inserted deep enough so that the clip 100 is spaced from and does not extend beyond the first surface 212. Depending on the configuration of the slits 210, this positioning may result in some filaments 52 extending over the clip 100. For example, the filaments 52 may be positioned between the first surface 212 and the top region of the arms 150, which are located furthest from the spine 112. These filaments 52 may help provide cushioning to the occupant of the cushion so that the presence of the clip 100 is not noticeable to the occupant.

[0066] In some configurations, the clip 100 is spaced apart from and does not extend to the second surface 214 of the filament mesh structure 90 when the clip 100 is attached to the filament mesh structure 90. As a result, the clip 100 does not contact the second surface 214.

[0067] Upon insertion of clip 100, barbs 142 interact with filaments 52 such that at least some of the filaments 52 contact barbs 142, capturing the barbs 142 on the filaments 52 such that clip 100 is retained in filament mesh structure 90. At least some of the barbs 142 are received in voids or gaps 230 between the set of members of filaments 52. For clarity, only some of the gaps 230 are labeled in FIG. 11 . In other locations, barbs 142 contact one or more members of the set of filaments 52.

[0068] The looped or curled configuration of the filament 52 allows the filament 52 to contact the clip 100 at various locations. In some configurations, at least one member of the set of filament 52 contacts a first barb 142 and a second barb 142 of the clip portion 110. An example of this is filament 52' in FIG. 11 . In some configurations, at least one member of the set of filament 52 contacts at least one retention feature 140 and a barb 142 extending from the retention feature 140. Filament 52' also provides an example of this configuration. However, it should be understood that a filament may contact a retention feature and a corresponding barb with or without contacting another retention feature and / or its corresponding barb.

[0069] In some configurations, at least one member of a set of filaments 52 contacts multiple clip portions 110. An example of this is shown in FIG. 13, which is a side view of first and second clip portions 110 inserted into slits 210 in filament mesh structure 90, which are not clearly visible from the perspective shown. At least one member of a set of filaments 52, such as filament 52'', contacts first and second clip portions 110. In FIG. 13, first clip portion 110 may be the leftmost clip portion, and second clip portion 110 may be the rightmost clip portion. While the filament 52'' is shown looped or curled around and contacting the barbs 142 of the first clip portion 110 and the second clip portion 110, it should be understood that the filament 52'' need not form a closed loop around or encircle one or both barbs 142. For example, the filament 52 may extend above the barbs 142 and engage the upper surfaces 180, or may contact another side of the barbs 142, or a combination thereof. In some examples, a filament contacting the lower surfaces 182 of the barbs 142 can help limit downward movement or tilting of the clip 100, and a filament 52 contacting a side of the barbs 142, such as the first side 184 or the second side 186, can prevent or limit movement of the clip 100 in at least one direction along or within the slit 210.

[0070] Once the clip 100 is inserted into the filament mesh structure 90, the tool 220 is disengaged from the clip 100. For example, relative movement between the tool 220 and the filament mesh structure 90 in a direction opposite to that associated with the insertion of the clip 100 into the slit 210 causes the arms 150, 150 of the first and second retaining features 140, 140 to flex away from one another, thereby allowing the enlarged tip 222 to move past the barbs 160, 160 and out of the cavity 156, thereby disengaging the clip 100. The clip 100 remains secured within the filament mesh structure 90 due to the resistive or retaining force provided by the interaction of the filaments 52 with the clip 100.

[0071] 12 , a simplified depiction of the filament mesh structure 90, without showing the individual filaments 52 for simplicity, is shown along with a trim cover 102. In some configurations, the trim cover 102 is installed after the clips 100 are inserted into the slits 210 and secured to the filament mesh structure 90. For example, the trim cover 102 may include a trim attachment feature 240 that is inserted through the slits 210 and into the cavity 156. The trim cover 102 may be disposed on at least a portion of the first surface 212 of the filament mesh structure 90 or may extend across a portion of the first surface 212. The trim attachment feature 240 extends from one or more exterior panels of the trim cover 102, through the slits 210, and into the cavity 156.

[0072] When the trim mounting feature 240 is inserted into the slit 210 with sufficient force, the arms 150, 150 of the first retention feature 140 and the second retention feature 140 bend away from each other, thereby allowing the trim mounting feature 240 to enter the cavity 156.

[0073] The trim attachment feature 240 may be shaped to resist removal of the trim attachment feature 240 from the cavity 156. For example, the trim attachment feature 240 may have a tapered or arrow-like configuration that narrows to a tip. The trim attachment feature 240 may be wider closer to the trim cover panel or may otherwise be configured so that the barbs 160, 160 engage or grip the trim attachment feature 240 to help retain the trim attachment feature 240 within the cavity 156. It is contemplated that the trim attachment feature 240 may be inserted into the cavity 156 before the clip 100 is inserted into the filament mesh structure 90.

[0074] 14, a portion of cushion 50 is shown with clip 100 received in slit 210. Slit 210 has an example of a linear portion 250 and a non-linear portion 252. Non-linear portion 252 extends along an arc or curve. Clip 100 follows the path of slit 210 when clip 100 is installed due to the flexibility of spines 112. Thus, when clip 100 and its spines 112 are positioned within filament mesh structure 90, at least a portion of spines 112, such as the portion received in non-linear portion 252 of slit 210, is non-linear.

[0075] Referring to FIG. 15, a simplified depiction of the filament mesh structure 90, with the individual filaments 52 not shown for simplicity, is shown along with a portion of the clip 100. The spines 112 are flexible along curved paths in a plane, as well as out-of-plane along straight or curved paths. For example, the spines 112 can extend along an arc such that one or more clip segments 110 are positioned at different heights within the filament mesh structure 90. For ease of reference, the clip segments 110 in FIG. 15 are referred to, from left to right, as a first clip segment, a second clip segment, and a third clip segment.

[0076] In this example, the first clip portion is positioned higher than the second clip portion, thereby positioning the first clip portion further from the second surface 214 than the second clip portion, i.e., further from a horizontal reference plane 260 extending through the cushion than the second clip portion. The horizontal reference plane 260 is a reference or datum plane that can be located at or near the center of the cushion, such as midway between the first surface 212 and the second surface 214. The second clip portion is illustrated as being higher than the third clip portion. Furthermore, the second clip portion is illustrated as being disposed at an angle relative to the horizontal reference plane 260 and the first and third clip portions. It is also contemplated that adjacent clip portions 110 may be positioned at different heights but may be positioned in a common relationship relative to the horizontal reference plane 260. Thus, the present invention allows clip portions 110 to be positioned relative to one another along curved paths, straight paths, at different heights to follow the contours of the cushion, and allows clip portions 110 to be positioned at the same or different depths relative to first surface 212. This capability allows clip portions 110 to be inserted deep enough into the cushion while still following the contours of the cushion, helping to maintain occupant comfort.

[0077] The use of such clips on cushions allows the clips to be securely fastened to the cushion, thereby allowing the clips and associated trim covers to remain in the desired position, which helps maintain tension in the trim covers and avoids the formation of wrinkles or creases that can create an undesirable appearance. When clips are used on cushions having filament mesh structures, the clips can be removed and replaced, allowing for easy rework and reducing waste.

[0078] Item 1. A clip comprising a spine having a bottom surface, a first retention feature and a second retention feature extending from the spine, and a first barb extending from at least one of the first retention feature and the spine, wherein the first barb extends away from the bottom surface of the spine.

[0079] Item 2. The clip of item 1, wherein the first and second retaining features extend from a top surface of the spine, the top surface being positioned opposite a bottom surface of the spine.

[0080] Item 3. The clip of items 1 or 2, further comprising a second barb extending from at least one of the second retaining feature and the spine, the second barb extending away from the bottom surface of the spine.

[0081] Item 4. The clip of item 3, wherein the first barb and the second barb are spaced apart from the vertebral portion and do not extend to the vertebral portion.

[0082] Item 5. The clip of items 3 or 4, wherein the first barb extends away from the second barb.

[0083] Item 6. A clip as described in any one of items 1 to 5, wherein the first barb has a first side and a second side, the first side and the second side being disposed opposite each other and extending from the first retaining feature, and the first side and the second side being disposed so as to approach each other as the first side and the second side extend in a direction away from the first retaining feature.

[0084] Item 7. The clip of item 6, wherein the first side intersects the second side at a distal end of the first barb.

[0085] Item 8. A clip as described in any one of items 1 to 7, wherein the first barb has an upper surface and a lower surface, the upper surface and the lower surface being disposed opposite each other and extending from the first retaining feature, and the upper surface and the lower surface extending further away from the spine as the upper surface and the lower surface extend in a direction away from the first retaining feature.

[0086] Item 9. The clip of item 8, wherein the upper surface does not intersect with the lower surface.

[0087] Item 10. A seat assembly comprising: a filament mesh structure comprising a set of filaments and a first surface; a trim cover; and a clip disposed within the filament mesh structure, wherein each member of the set of filaments is looped and coupled to at least one other member of the set of filaments; the clip comprising a spine and a first clip portion, the first clip portion comprising first and second retention features extending from the spine to secure the trim cover to the clip, and first and second barbs securing the first clip portion to the filament mesh structure, the first and second barbs extending away from the spine toward the first surface of the filament mesh structure.

[0088] Item 11. The seat assembly of item 10, wherein the first barb is received in a gap between the set of members of the filament.

[0089] Item 12. The seat assembly of items 10 or 11, wherein the set of filament members contact the first barb and the second barb of the first clip portion.

[0090] Item 13. The seat assembly of any one of items 10-12, wherein the set of members of the filament contact the first barb and the first retention feature of the first clip portion.

[0091] Item 14. The seat assembly of any one of items 10 to 13, wherein the first and second barbs extend from the first and second retention features, respectively.

[0092] Item 15. A seat assembly as described in any one of items 10 to 14, wherein the filament mesh structure further comprises a slit extending from the first surface, and the clip is disposed within the slit, spaced apart from the first surface, and does not extend to the first surface.

[0093] Item 16. The seat assembly of item 15, wherein the filament mesh structure further comprises a second surface disposed opposite the first surface, and the slits and clips are spaced apart from the second surface and do not extend to the second surface.

[0094] Item 17. A seat assembly as described in any one of items 10 to 16, wherein the spine is straight when the spine is in a free state, and at least a portion of the spine is non-straight when the spine is disposed within the filament mesh structure.

[0095] Item 18. The seat assembly of any one of items 10 to 17, wherein the clip further comprises a second clip portion, the second clip portion extending from the spine and spaced apart from the first clip portion.

[0096] Item 19. The seat assembly of item 17, wherein the set of filament members contact the first clip portion and the second clip portion.

[0097] Item 20. The seat assembly of items 18 or 19, wherein the spine extends along an arc such that the first clip portion and the second clip portion are positioned relative to each other at different heights within the filament mesh structure.

[0098] While exemplary embodiments have been described above, it is not intended that these embodiments represent all possible forms of the invention. Rather, the terms used herein are terms of description rather than limitation, and it will be understood that various changes can be made without departing from the spirit and scope of the invention. In addition, features of various embodiments can be combined to form further embodiments of the invention.

Claims

1. a spine having a base; a first retaining feature and a second retaining feature extending from the spine; a first barb extending from at least one of the first retaining feature and the spine; Equipped with the first spine extends away from the bottom surface of the spine; the first spine includes a first side and a second side opposite the first side; as the first side and the second side extend in a direction away from the first retention feature, the first side and the second side extend toward each other to form a triangular configuration. clip.

2. 2. The clip of claim 1, wherein the first and second retaining features extend from a top surface of the spine, the top surface being disposed opposite the bottom surface of the spine.

3. 10. The clip of claim 1, further comprising a second barb extending from at least one of the second retaining feature and the spine, the second barb extending away from the bottom surface of the spine.

4. The clip of claim 3 , wherein the first barb and the second barb are spaced apart from the spine and do not extend to the spine.

5. The clip of claim 3 , wherein the first barb extends away from the second barb.

6. The clip of claim 1 , wherein the first side intersects the second side at a distal end of the first barb.

7. 2. The clip of claim 1, wherein the first barb comprises an upper surface and a lower surface, the upper surface and the lower surface being disposed opposite one another and extending from the first retaining feature, the upper surface and the lower surface extending further away from the spine as the upper surface and the lower surface extend in a direction away from the first retaining feature.

8. The clip of claim 7 , wherein the upper surface does not intersect the lower surface.

9. a filament mesh structure comprising a set of filaments and a first surface; Trim cover and a clip disposed within the filament mesh structure; Equipped with each member of the set of filaments is looped and connected to at least one other member of the set of filaments; The clip is a spine; a first clip portion; Equipped with The first clip portion first and second retention features extending from the spine to secure the trim cover to the clip; first and second barbs that secure the first clip portion to the filament mesh structure; Equipped with the first barbs and the second barbs extend away from the spines toward the first surface of the filament mesh structure; the first spine includes a first side and a second side opposite the first side; as the first side and the second side extend in a direction away from the first retention feature, the first side and the second side extend toward each other to form a triangular configuration. Seat assembly.

10. 10. The seat assembly of claim 9, wherein the first barb is received in a gap between members of the set of filaments.

11. 10. The seat assembly of claim 9, wherein the set of filaments contacts the first barb and the second barb of the first clip portion.

12. 10. The seat assembly of claim 9, wherein the set of filaments contacts the first barb and the first retention feature of the first clip portion.

13. 10. The seat assembly of claim 9, wherein the first and second barbs extend from the first and second retention features, respectively.

14. 10. The seat assembly of claim 9, wherein the filament mesh structure further comprises a slit extending from the first surface, the clip being disposed within the slit and spaced apart from the first surface and not extending to the first surface.

15. 15. The seat assembly of claim 14, wherein the filament mesh structure further comprises a second surface disposed opposite the first surface, the slit and the clip being spaced apart from the second surface and not extending to the second surface.

16. 10. The seat assembly of claim 9, wherein the spine is straight when the spine is in a free state, and at least a portion of the spine is non-straight when the spine is disposed within the filament mesh structure.

17. 10. The seat assembly of claim 9, wherein the clip further comprises a second clip portion, the second clip portion extending from the spine and spaced apart from the first clip portion.

18. 18. The seat assembly of claim 17, wherein the set of filaments contacts the first clip portion and the second clip portion.

19. 18. The seat assembly of claim 17, wherein the spine extends along an arc such that the first clip portion and the second clip portion are positioned relative to each other at different heights within the filament mesh structure.

Images