Automated groove forming apparatus and assembly for attaching a trim cover to a cushion assembly

Abstract

To provide a cushion assembly which has trenches and fasteners and does not have foamability, and a method and assembly for manufacturing the same.SOLUTION: A cushion may be manufactured from a body of entangled polymer strands and have foamability. A manufacturing system may include dies like die bars having a plurality of orifices that cooperate with a plurality of receptacles, and actuators for discharging a plurality of fasteners from said receptacles through said dies into said cushion. In a refinement, said dies may be heated such that a skinned over membrane is created in said cushion to retain said plurality of fasteners. A trim cover may cooperate with said plurality of fasteners such that it is attached to said cushion.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] A foam-free cushion assembly having a groove (e.g., cavity, channel, or depression) and a fastener disposed therein is disclosed. Methods of making the same and the assembly are also disclosed. Summary of the Invention [Means for solving the problem]

[0002] According to one aspect of the invention, a cushion assembly is formed by a method comprising the steps of heating a die bar defining a plurality of orifices; engaging a first cushion with the die bar to define channels in the first cushion; driving a plurality of fasteners from a plurality of hollow jackets cooperating with the die bar with one or more actuators through the plurality of orifices into the first cushion; and removing the die bar from the first cushion so that the plurality of orifices are positioned within the channels in the first cushion.

[0003] According to another aspect of the invention, an assembly includes a die defining a cavity in a cushion and defining an orifice, a receptacle cooperating with the die and aligned with the orifice, the receptacle positioned to receive a fastener, and an actuator driving the fastener from the receptacle, through the orifice, and into the cushion so that the fastener is positioned within the cavity of the cushion.

[0004] According to another aspect of the invention, a system includes one or more robotic arms; a plurality of die bars disposed on the one or more robotic arms, the die bars defining a plurality of orifices, the die bars defining channels in the cushion assembly when the die bars are heated and engage the cushion assembly; a plurality of hollow jackets cooperating with the die bars to receive a plurality of fasteners, each fastener of the plurality of fasteners being aligned with a respective orifice of the plurality of orifices; and an actuator disposed to drive the fasteners from the plurality of hollow jackets through the plurality of orifices and into the cushion assembly such that the fasteners are disposed in the channels. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 2 is a perspective view of a cushion assembly and a manufacturing assembly for manufacturing the cushion assembly. [Figure 2] FIG. 10 is a partial cross-sectional view of a manufacturing assembly engaging a cushion prior to actuation. [Figure 3] FIG. 10 is a partial cross-sectional view of a manufacturing assembly engaging a cushion after actuation. [Figure 4] FIG. 10 is a top view of a manufacturing assembly that engages with a cushion assembly. [Figure 5] FIG. 5 is a top view of the cushion of FIG. 4 after engagement by a manufacturing assembly. [Figure 6] FIG. 1 is an exploded view of a portion of a manufacturing assembly. [Figure 7] FIG. 10 is a front view of the cushion and cushion assembly prior to engagement. [Figure 8] FIG. 10 is a front view of the cushion and cushion assembly during engagement. [Figure 9] 10 is a flowchart illustrating a method for manufacturing a cushion assembly. [Figure 10] FIG. 2 is a partial cross-sectional perspective view of a seat assembly. [Figure 11] FIG. 1 is a perspective view of one embodiment of a fastener. [Figure 12] FIG. 1 is a perspective view of a foam cushion having grooves. DETAILED DESCRIPTION OF THE INVENTION

[0006] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the present invention.

[0007] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and that other embodiments may take various alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the embodiments of the present invention. As those skilled in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments not explicitly shown or described. The combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired for particular applications or implementations.

[0008] Furthermore, unless otherwise specified, all numerical values ​​in this disclosure should be understood as modified by the word "about" in describing the broader scope of this disclosure. Practice within the stated numerical limits is generally preferred. Also, unless otherwise specified, percent, "portion," and ratio values ​​are by weight. The term "polymer" includes "oligomer," "copolymer," "terpolymer," and the like. A statement that a group or class of materials is suitable or preferred for a given purpose means that mixtures of any two or more members of that group or class are equally suitable or preferred. Molecular weights provided for any polymer refer to number-average molecular weights. A 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 the components of the mixture after mixing.

[0009] The initial definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the abbreviation originally defined. Unless expressly stated to the contrary, measurements of a property are determined by the same techniques as previously or subsequently referenced for the same property.

[0010] This disclosure is not limited to the specific embodiments and methods described below, as specific components and / or conditions may vary. Further, the terminology used herein is used only for the purpose of describing particular embodiments and is not intended to be limiting in any way.

[0011] The terms "substantially" or "generally" can be used herein to describe the disclosed or claimed embodiments. The terms "substantially" or "generally" can modify a value or relative property disclosed or claimed in this disclosure. In such cases, "substantially" or "generally" can mean that the value or relative property it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of the value or relative property.

[0012] It should also be understood that integer ranges explicitly include 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. Similarly, when any range is called out, intermediate numbers that are increments of 10 from the difference between the upper and lower limits can be used as alternative upper or lower limits. For example, if the range is 1.0 to 2.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as the lower or upper limit.

[0013] Referring to FIG. 1 , a manufacturing assembly 100 for manufacturing a molded assembly, such as a cushion assembly 200, is disclosed. As a refinement, the cushion assembly 200 is disposed within a seat assembly 300, as shown in FIG. 10 . For example, the seat assembly 300 is for a vehicle (e.g., a motorcycle, an automobile, a locomotive, an aircraft, and / or a watercraft). The manufacturing assembly 100 includes a die 102 having one or more orifices 104 in which corresponding receptacles 106 and / or actuators 108 are disposed. The cushion assembly 200 includes a cushion 202, such as a foam or non-foam cushion. As a refinement, the cushion 202 is not foam, i.e., includes a body comprised of a plurality of intertwined and / or entangled polymer strands such that it is not foam, as shown in FIG. 12 . In an alternative embodiment, the manufacturing assembly is used to define one or more grooves 204 (e.g., multiple, two, three, four, etc.) in the cushion 202 and to place one or more fasteners 206 (e.g., multiple, two, three, four, etc.) in each groove 204 (i.e., constrained channel) of the cushion 202. The fasteners 206 cooperate with, for example, a trim cover 304 to secure the trim cover 304 to the cushion assembly 200. In an alternative embodiment, the one or more grooves 204 extend along the cushion such that, when placed in a vehicle seat, they extend from the seat front toward the seat back.

[0014] Referring to FIG. 10 , a seat assembly 300 includes a seat frame 302 that supports the cushion assembly 200 and a trim cover 304 disposed over the cushion assembly 200. In a variation, the seat assembly 300 includes a seat bottom 306, a seat back 308, and a headrest 310. In a refinement, the trim cover 304 cooperates with the cushion assembly 200 via one or more fasteners 206. For example, in various embodiments, the fastener 206 has a piercing portion 208 and a cooperating portion 210, as shown in FIG. 11 . In a refinement, the piercing portion 208 has a tapered tip, such as a pointed tip 205, and one or more retention members 209, such as a ridge or flat protrusion extending along the periphery. In various embodiments, the cooperating portion 210 includes a clip 207 for attaching the fastener 206 to the trim cover 304. In a variant, the trim cover 304 has corresponding fasteners 206 that cooperate with the fasteners 206 of the cushion assembly 200. For example, the fasteners of the trim cover 304 fit into clips 207 of the fasteners 206 disposed within the cushion assembly 200.

[0015] In various embodiments, the cushion 202 is foam-free or foam-free. For example, the cushion 202 is made of a body of entangled or intertwined polymer strands / filaments, as described in U.S. Patent Application No. 17 / 741,639, filed May 11, 2022, which is incorporated herein by reference in its entirety. In a refinement, the foam-free cushion's channels 204 are bounded by skinned sidewalls 212 and floor portions 214 (i.e., individual strands are deformed by pressure, heat, etc.) to form membranes (sidewall membrane and bottom membrane). In various embodiments, the membranes have a minimum thickness of at least 1.75 mm, more preferably at least 2.0 mm, and even more preferably at least 2.25 mm, thereby sufficiently retaining one or more fasteners 206. In one or more embodiments, the fasteners 206 are Christmas tree fasteners with clips 207 at their ends, preventing them from being retained in the foam cushion unless a skinned membrane is formed. In yet another embodiment, the thickness adjacent one or more fasteners 206 is at least 1.75 mm, more preferably at least 2.0 mm, and even more preferably at least 2.25 mm. As a refinement, fasteners 206 are made from a material having a low melting and / or softening point (e.g., less than 150°C, more preferably less than 250°C, and even more preferably less than 350°C), such as a plastic (e.g., polyethylene, polypropylene, polystyrene, polyurethane, polyvinyl chloride, polyacrylate, acrylic, polyolefin).

[0016] In one or more embodiments, the manufacturing assembly or system 100 includes a die 102, such as one or more die rods, that define one or more grooves 204 in the cushion 202; a receptacle 106 that cooperates with the die 102 to receive the fasteners 206 prior to placement within the cushion 202; and one or more actuators 108 that cooperate with the receptacle 106 and / or the fasteners 206 to place them within the cushion 202. In a refinement, the manufacturing assembly or system 100 includes a heating element 216 in communication with the die 102 to heat the die 102 during operation. In the refinement, the die 102 is heated to or above a threshold temperature. In various embodiments, an ultrasonic heater is used. For example, the die 102 is heated to at least 100°C, more preferably at least 105°C, and even more preferably at least 110°C. In various embodiments, the die includes a heat conductor, such as a metal (e.g., steel, aluminum, iron, or copper). In a refinement, the die 102 has a thermal conductivity of at least 25 W / m·K, more preferably at least 50 W / m·K, and even more preferably at least 100 W / m·K. In yet another embodiment, the manufacturing assembly 100 includes an adapter, such as an adapter plate, as an end effector for attaching the manufacturing assembly 100 to an automated system. For example, the manufacturing assembly 100 cooperates with the automated system. The manufacturing assembly 100 cooperates, for example, with one or more robotic arms 218 to move the die 102 into and out of engagement with the cushion 202. In a variation, the robotic arms 218 apply a pressure of at least 60 N, more preferably at least 75 N, and even more preferably at least 80 N, to the cushion 202. In various embodiments, the heat and / or pressure deforms, shapes, cuts, and / or engraves, etc., the cushion 202 to define the one or more grooves 204.

[0017] In various embodiments, the die 102 includes one or more orifices 104 extending from a first side to a second side of the die 102 and sized to allow the fastener 206 to pass through the die 102. In a refinement, a receptacle 106 is disposed over and / or aligned with each orifice 104, such that the receptacle 106 can receive and hold the fastener 206 until the fastener 206 is disposed within the cushion 202. The one or more receptacles 106 cooperate with the die 102. For example, the receptacle 106 is attached or secured to the die 102 by adhesive, fasteners, or the like. In an alternative embodiment, the receptacle 106 is a hollow jacket sized to accommodate the fastener 206. For example, the receptacle 106 is cylindrical. In various embodiments, the hollow jacket is insulated to protect the fastener 206 from the heat of the heated die 102. For example, the hollow jacket includes an insulating material such as ceramic, plastic, mineral wool, fiberglass, polystyrene, cellulose, and / or polyurethane foam. As an improvement, the hollow jacket has a thermal conductivity of 10 W / m·K or less, more preferably 1 W / m·K or less, and even more preferably 0.1 W / m·K or less.

[0018] In various embodiments, the receptacles 106 cooperate with one or more actuators 108. The one or more actuators 108 are positioned such that, upon actuation, the fasteners 206 are displaced into the cushion 202 and retained therein. An actuator 108, such as a solenoid actuator, is positioned adjacent each receptacle 106 opposite the orifice 104. In a refinement, each actuator 108 includes a piston protruding therefrom. The actuator 108 is positioned such that the piston drives the fasteners 206 from the receptacle 106, through the orifice 104, and into the cushion 202, such that when the robot arm 218 removes the die 102 from the cushion 202, the one or more fasteners 206 are positioned within the grooves 204 and retained within the cushion 202.

[0019] In one or more embodiments, the automation system is in communication with a controller (not shown) having a non-transitory computer-readable medium having computer-executable instructions thereon. In variations, the controller also includes a processor. In various embodiments, the controller controls the automation. For example, the controller is programmed to heat the die 102 and engage / disengage the die 102 with one or more cushions 202. In a refinement, the die 102 is heated to a threshold temperature before engaging the cushions 202. In some embodiments, the controller is programmed to engage / disengage the die with a plurality or series of cushions. In one or more embodiments, the controller also actuates one or more actuators 108 while engaging the cushions to place one or more fasteners 206 within the cushions. In a refinement, a plurality or series of fasteners are placed within a corresponding plurality or series of cushions. In yet other embodiments, a fastener cartridge or hopper is in communication with one or more receptacles 106, with one or more fasteners being dispensed into the receptacle of each cushion.

[0020] Also disclosed is a method of preparing a cushion having fasteners disposed therein. In one or more embodiments, the method includes preparing and / or providing a cushion body (i.e., step 410), heating a die (i.e., step 420), engaging the die with a first cushion body (i.e., step 430), disposing a plurality of fasteners on the cushion body (i.e., step 440), disengaging the cushion body (i.e., step 450), and fastening a trim cover to the cushion (i.e., step 460). In various embodiments, the method is repeated for a plurality or series of cushion bodies (e.g., a first cushion body, a second cushion body, a third cushion body, etc.). In a refinement, the die includes one or more die bars (e.g., multiple die bars), each including a plurality of orifices extending through the die from a first side to a second side (e.g., from top to bottom).

[0021] In one or more embodiments, the cushion body is non-expandable, i.e., made from multiple entangled and / or intertwined polymer strands / filaments, as described above and as identified in U.S. Patent Application No. 17 / 741,639. In a variant, the non-expandable cushion body is manufactured by extruding a resin through an extrusion die having multiple openings, such that multiple molten polymer strands are formed. The polymer strands are then dispensed from a first medium, such as air, through a funnel into a first medium, such as water, where they become intertwined and entangled in the polymer strand body.

[0022] In a variant, the die bar is heated by a heating element. For example, ultrasonic heating is used to heat the die, and once the die reaches a temperature of at least 100°C, more preferably at least 105°C, and even more preferably at least 110°C, it engages with the cushion body. In various embodiments, during engagement, the die is applied with a pressure / force of 60 N, more preferably 75 N, and even more preferably 80 N to define a number of grooves / channels corresponding to the number of die bars. In one or more embodiments, the die bar engages with the cushion body for at least 10 seconds, more preferably at least 12 seconds, and even more preferably at least 15 seconds. In a variant, the die is engaged with the cushion body by a robotic arm that heats the die and applies the die to the cushion with the appropriate pressure / force and in the correct position.

[0023] In various embodiments, the plurality of fasteners are disposed within corresponding grooves / channels in the cushion body. In a refinement, the plurality of fasteners are ejected from a receptacle, such as a hollow jacket having insulating properties, through the die into the cushion body while the die is engaged with the cushion body. For example, the fasteners are ejected by one or more corresponding solenoid actuators. After the fasteners are ejected and driven into the cushion body, the die is released from the cushion body such that the plurality of fasteners remain at least partially disposed within the cushion body. In a refinement, a robotic arm releases the die (e.g., a die bar) from the cushion body.

[0024] In one or more embodiments, the controller is programmed to execute computer-readable instructions to operate the robotic arm to heat, engage, and disengage the die. The instructions also activate the actuator to eject multiple fasteners into the cushion body. In various embodiments, the controller automates the method so that multiple cushions can be precisely and efficiently shaped and prepared with little or no human intervention. In an alternative embodiment, a trim cover cooperates with the multiple fasteners. For example, a trim cover may be attached and secured to the cushion body via the multiple fasteners.

[0025] In one or more embodiments, the processor comprises one or more devices selected from a high-performance computing system comprising a high-performance core, a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a state machine, a logic circuit, an analog circuit, a digital circuit, or any other device that manipulates signals (analog or digital) based on computer-executable instructions present in memory. In a variation, the memory comprises a single memory device or multiple memory devices, including, but not limited to, random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. In a refinement, the non-volatile memory / storage comprises one or more persistent data storage devices, such as a hard drive, an optical drive, a tape drive, a non-volatile solid-state device, cloud storage, or any other device capable of persistently storing information.

[0026] In one or more embodiments, the executable code / instructions may reside in software modules. In a refinement, software modules include operating systems and applications. In various embodiments, software modules are compiled or interpreted from computer programs written using various programming languages ​​and / or technologies, including, but not limited to, Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, and PL / SQL, alone or in combination. Non-volatile storage may also include data that supports functions, features, calculations, and processes.

[0027] In some embodiments, the above-described systems include computer-readable storage media that are not transient in nature, and in various refinements include volatile or nonvolatile, removable and non-removable tangible media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data. In variations, computer-readable storage media further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid-state memory technology, portable compact disc read-only memory (CD-ROM) or other optical storage devices, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired information and that can be read by a computer. In various embodiments, the computer-readable program instructions may be downloaded to a computer, another type of programmable data processing device, or another device form of computer-readable storage medium, or to an external computer or external storage device via a network.

[0028] In one or more embodiments, computer-readable program instructions stored on a computer-readable medium can be used to cause a computer, other type of programmable data processing apparatus, or other device to function in a particular manner, such that the instructions stored on the computer-readable medium produce an article of manufacture that includes instructions that perform the functions, acts, and / or operations described herein. The functions, acts, and / or operations described herein may be reordered, processed serially, and / or simultaneously.

[0029] While exemplary embodiments have been described above, it is not intended that these embodiments describe 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 modifications can be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form further embodiments of the invention.

[0030] According to a first aspect of the method described herein, the method includes heating a die (e.g., a die bar) defining a plurality of orifices; engaging the die with a first cushion to define channels in the first cushion; using one or more actuators cooperating with a receptacle to drive a plurality of fasteners from a plurality of hollow jackets cooperating with the die through the plurality of orifices into the first cushion; and releasing the die from the first cushion such that the plurality of fasteners remain disposed within the first cushion, such as within the channels.

[0031] According to a second aspect, the die and first cushion of the first aspect are engaged by a robotic arm.

[0032] According to a third aspect, the method of either the previous or subsequent aspect, wherein the steps are embodied as computer-executable instructions on a non-transitory computer-readable medium and executed by a processor in cooperation with the robotic arm, the die, the heating element, and one or more actuators.

[0033] According to a fourth aspect, the method of either the previous or subsequent aspect includes securing a trim cover to the first cushion via a plurality of fasteners.

[0034] According to a fifth aspect, the method of either the previous or subsequent aspect includes the steps of engaging a second cushion with a die to define channels in the second cushion, driving a second plurality of fasteners with one or more actuators from the plurality of hollow jackets through the plurality of orifices into the second cushion, and disengaging the die from the second cushion such that the second plurality of fasteners remain disposed in the channels of the second cushion.

[0035] According to a sixth aspect of the assembly described herein, the assembly includes a die (e.g., a die bar) that defines a cavity (e.g., a groove / channel) in the cushion, a receptacle that cooperates with the die and is aligned with the orifice, and an actuator that drives a fastener from the receptacle through the orifice and into the cushion so that the fastener is disposed in the cavity of the cushion. The die includes an orifice that extends from a first side to a second side of the die. The receptacle is disposed on the die to receive the fastener. The fastener includes a clip for attachment to a trim assembly. The actuator is a solenoid actuator.

[0036] According to a seventh aspect, the die of any of the above or below aspects cooperates with a heating member to heat the die.

[0037] According to an eighth aspect, the receptacle of any of the above or following aspects is insulated or includes a thermal insulator to reduce the heat received by the fastener from the die so that the die does not melt or deform due to thermal energy.

[0038] According to a ninth aspect, the heating element includes ultrasonic heating.

[0039] According to a tenth aspect, the assembly of any of the above or following aspects includes an adapter, such as an adapter plate, for attachment as an end effector to an automated assembly.

[0040] According to an eleventh aspect, the actuator is a solenoid actuator.

[0041] According to a twelfth aspect, the fastener of any of the above or following aspects cooperates with the trim cover to fasten the trim cover to the cushion.

[0042] According to a thirteenth aspect, the assembly of any of the above or following aspects cooperates with an automated system for engaging the die with the cushion to define the cavity.

[0043] According to a fourteenth aspect of the system disclosed herein, the system includes one or more robotic arms, a plurality of die bars defining a plurality of orifices, a plurality of hollow jackets that cooperate with the die bars to receive a plurality of fasteners, and an actuator arranged to drive the plurality of fasteners from the plurality of hollow jackets into a cushion assembly. The plurality of die bars are arranged on the one or more robotic arms such that when the plurality of die bars are heated and engage the cushion assembly, the die bars form recessed channels in the cushion assembly. The plurality of hollow jackets align with respective orifices of the plurality of orifices such that each fastener of the plurality of fasteners is also aligned with its respective orifice. The actuator is arranged to drive each fastener from the hollow jacket through a respective orifice of the die bar and into the recessed channel of the cushion.

[0044] According to a fifteenth aspect of the system of any of the above or below aspects, the system includes a heating member that heats the plurality of die bars.

[0045] According to a sixteenth aspect of the system of any of the above or below aspects, the system includes a controller programmed to heat a plurality of die bars, engage the plurality of die bars with the cushion assembly after a threshold temperature is reached, and actuate an actuator to drive a fastener into a recessed channel of the cushion assembly.

[0046] According to a seventeenth aspect of the fastener of any of the above or following aspects, the fastener cooperates with the trim cover to attach the trim cover to the cushion assembly.

[0047] According to an eighteenth embodiment of the die of any of the above or below embodiments, the die is thermally conductive or comprises a thermal conductor, and the receptacle / hollow jacket is thermally insulating or comprises a thermal insulator.

[0048] According to a 19th aspect of the present invention, the die of any of the above or following aspects comprises iron, aluminum, and / or copper, and the receptacle / hollow jacket comprises plastic, fiberglass, and / or foam.

[0049] According to a twentieth aspect of the cushion assembly of either the previous or next aspect, the cushion assembly includes a cushion body of entangled and / or intertwined polymer strands such that a recessed channel is formed within the cushion body.

[0050] This application claims the benefit of U.S. Patent Application No. 18 / 176,164, filed February 28, 2023, the disclosure of which is incorporated by reference in its entirety.

Claims

1. heating a die bar defining a plurality of orifices; engaging a first cushion with the die bar to define a channel in the first cushion; driving a plurality of fasteners from a plurality of hollow jackets cooperating with the die bar through the plurality of orifices into the first cushion with one or more actuators; and removing the die bar from the first cushion so that the plurality of orifices are positioned within the channels of the first cushion.

2. 10. The method of claim 1, wherein the cushion assembly comprises a plurality of intertwined polymer strands forming a cushion body defining the channel therein, the channel being bounded at least in part by a skin and a plurality of fasteners disposed within the skin that bound the channel, the plurality of fasteners being arranged to cooperate with a trim cover.

3. 3. The method of claim 2, wherein the skin has a thickness of at least 1.75 millimeters.

4. 3. The method of claim 2, wherein the skin has a thickness of at least 2.0 millimeters.

5. 3. A method of forming the cushion assembly of claim 2, comprising: The method of forming a cushion assembly, wherein the plurality of fasteners extend through the skin.

6. a die defining a cavity in the cushion and defining an orifice; a receptacle cooperating with the die and aligned with the orifice, the receptacle being positioned to receive a fastener; an actuator that drives the fastener from the receptacle, through the orifice, and into the cushion so that the fastener is disposed within the cavity of the cushion.

7. 7. The assembly of claim 6, The die assembly cooperates with a heating element for heating the die.

8. 8. The assembly of claim 7, The assembly wherein the receptacle is insulated to reduce heat from the die to the fastener.

9. 8. The assembly of claim 7, wherein said heating element is a supersonic heater.

10. 7. The assembly of claim 6, wherein the actuator is a solenoid actuator.

11. 7. The assembly of claim 6, wherein the fastener cooperates with a trim cover to secure the trim cover to the cushion.

12. 7. An automated system cooperating with the assembly of claim 6 for engaging the cushion with the die to define the cavity.

13. one or more robotic arms; a plurality of die bars disposed on the one or more robotic arms, the die bars defining a plurality of orifices, the die bars defining recessed channels in the cushion assembly when the die bars are heated and engaged with the cushion assembly; a plurality of hollow jackets that cooperate with the die bar to receive a plurality of fasteners, each fastener of the plurality of fasteners being aligned with a respective orifice of the plurality of orifices; an actuator positioned to drive the plurality of fasteners from the plurality of hollow jackets, through the plurality of orifices, and into the cushion assembly so that the plurality of fasteners are disposed within the recessed channels.

14. 14. The system of claim 13, further comprising a non-transitory computer-readable medium, the non-transitory computer-readable medium storing computer software having computer-executable instructions executable on a computer by a processor associated with the one or more robotic arms and the actuators.

15. 14. The system of claim 13, further comprising a heating element for heating the plurality of die bars.

16. 14. The system of claim 13, further comprising: a heating element for heating the plurality of die bars; heating the plurality of die bars; engaging the plurality of die bars with the cushion assembly after a threshold temperature is reached; The system further comprises a controller programmed to drive the actuator into the recessed channel of the cushion assembly.

17. 14. The system of claim 13, wherein the fastener cooperates with a trim cover to attach the trim cover to the cushion assembly.

18. 14. The system of claim 13, wherein the plurality of die bars comprises a heat conductor and the plurality of hollow jackets comprises a thermal insulator.

19. 14. The system of claim 13, wherein the plurality of die rods comprises iron, aluminum, and / or copper, and the plurality of hollow jackets comprises plastic, fiberglass, and / or foam.

20. 14. The system of claim 13, wherein the cushion assembly includes a cushion body of intertwined polymer strands, and the recessed channel is formed within the cushion body.

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