Cushion assembly

Abstract

To provide a cushion assembly.SOLUTION: A assembly having a unitary mesh of expanded thermoplastic resin strands with an aperture formed are bundled is provided. The assembly is further provided with a trim cord inserted within the aperture of the unitary mesh. The trim cord is installed in the aperture by one or more of the following: being inserted into the aperture; welding the trim cord to the unitary mesh of expanded thermoplastic resin strands; and a first segment of the expanded thermoplastic resin strands being welded to a second segment of the expanded thermoplastic resin strands at least partially over the aperture.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] [Cross-reference to Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023, to Danish Patent Application No. PA202470202, filed on July 30, 2024, and to U.S. Patent Application No. 18 / 980,826, filed on December 13, 2024. The disclosure contents of those applications are hereby incorporated by reference in their entireties into this specification.

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023, and to Danish Patent Application No. PA202470202, filed on July 30, 2024. The disclosure contents of those applications are hereby incorporated by reference in their entireties into this specification.

[0003] This application claims priority to U.S. Provisional Patent Application No. 63 / 613,925, filed on December 22, 2023. The disclosure content of that application is hereby incorporated by reference in its entirety into this specification.

[0004] Various embodiments relate to a cushion formed from an integral mesh of foamed thermoplastic resin strands.

Summary of the Invention

[0005] According to one aspect of the present invention, a bundled mesh of foamed thermoplastic resin strands having apertures formed therein, a trim cord inserted into the apertures of the bundled mesh, and An assembly is provided in which the trim cord is installed within the aperture by one or more of the following: the trim cord is inserted into the aperture; the trim cord is welded to a bundled mesh of foamed thermoplastic strands; or a first segment of the foamed thermoplastic strands is welded to a second segment of the foamed thermoplastic strands, at least partially covering the aperture.

[0006] According to another aspect of the present invention, A mesh of bundled foamed thermoplastic resin strands with an aperture formed therein, A trim cord inserted into a bundled mesh aperture, wherein a first segment of a foamed thermoplastic resin strand is welded to a second segment of a foamed thermoplastic resin strand, at least partially covering the aperture; An assembly comprising the above is provided. [Brief explanation of the drawing]

[0007] [Figure 1] This is a front perspective view of a seat assembly according to one embodiment. [Figure 2] This is a top perspective view of the cushion assembly of the seat assembly shown in Figure 1, according to one embodiment. [Figure 3] This is a top perspective view of the cushion assembly of the seat assembly shown in Figure 1, according to another embodiment. [Figure 4] This is a front perspective view of the manufacturing process of the cushion assembly of the seat assembly shown in Figure 1, according to another embodiment. [Figure 5] This is a side elevation view of the manufacturing process of the cushion assembly shown in Figure 4, which is an intermediate manufacturing step. [Figure 6] This is a side elevation view of the manufacturing process of the cushion assembly shown in Figure 4, which is illustrated in a different manufacturing step. [Figure 7] Figure 4 is a side elevation view of the assembled cushion assembly. [Figure 8]Figure 7 is a front elevation view of the cushion assembly. [Figure 9] This is a front view of the trim cover of the cushion assembly shown in Figure 1 according to one embodiment. [Figure 10] Figure 9 is an exploded front perspective view of the cushion assembly. [Modes for carrying out the invention]

[0008] Next, embodiments will be referenced in detail. Examples are shown in the accompanying drawings. In the following detailed description, numerous specific details are given in order to provide a full understanding of the various described embodiments. However, it will be obvious to those skilled in the art that various described embodiments can be carried out without these specific details. In other cases, known methods, procedures, components, circuits, and networks are not described in detail so as not to unnecessarily obscure the aspects of the embodiments.

[0009] It should be understood that the embodiments disclosed are illustrative only and that various alternative forms are possible. The drawings are not necessarily drawn to exact scale, and some features may be exaggerated or minimized to illustrate the details of certain components. Accordingly, certain structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds to teach those skilled in the art how to employ the embodiments relating to this disclosure in various ways.

[0010] "One or more" includes a function being performed by one element, a function being performed by two or more elements, for example in a distributed manner, multiple functions being performed by one element, multiple functions being performed by multiple elements, or any combination of the above.

[0011] Furthermore, while terms such as "first," "second," etc., are used herein in some instances to describe various elements, it will be understood that these elements should not be limited by these terms. These terms are used merely to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first segment may be referred to as the second segment, and similarly, the second segment may be referred to as the first segment. The first segment and the second segment are both segments, but they are not the same segment.

[0012] The terms used in the descriptions of the various embodiments described herein are for the purpose of describing specific embodiments only and are not intended to limit them. Where used in the descriptions of the various embodiments and in the appended claims, singular nouns ("a", "an", and "the") are intended to include plural nouns unless the context clearly indicates otherwise. Furthermore, where used herein, the terms "and / or" are intended to refer to and encompass any possible combination of one or more of the related enumerated items. In addition, where used herein, the terms "equipped with" or "containing" specify the presence of a specified feature, complete, step, operation, element, and / or component, but are not intended to exclude the presence or addition of one or more other features, complete, step, operation, element, component, and / or groups thereof.

[0013] Where used herein, the term “when” shall be interpreted, at the discretion of the context, to mean “when,” “as soon as,” “as soon as,” “as in determining,” or “as in determining.” Similarly, the phrases “when it is determined” or “when [the specified condition or event] is detected” shall be interpreted, at the discretion of the context, to mean “as soon as it is determined,” “as in determining,” “as soon as [the specified condition or event] is detected,” or “as in determining [the specified condition or event].”

[0014] Figure 1 shows a seat assembly 20 as a vehicle seat assembly 20 according to one embodiment. While the vehicle seat assembly 20 is illustrated and described, any seat assembly 20 can be used. The seat assembly 20 can be used in land vehicles, aircraft, ships, etc. The seat assembly 20 can also be used as an office chair, comfort chair, etc.

[0015] The illustrated seat assembly 20 includes a seat bottom 22, a seat back 24, and a headrest 26. The seat bottom 22 is provided with a seat bottom cushion 28 that supports the pelvis and thighs of the seated occupant. The seat back 24 includes a seat back cushion 30 that supports the back and shoulders of the seated occupant. A trim cover 32 is provided to cover the seat cushions 28 and 30, concealing them and providing a uniform and smooth contact surface for the occupant.

[0016] Generally referring to Figure 2, a cushion assembly 34 removed from the seat assembly 20 is shown. In the illustrated embodiment, the cushion assembly 34 includes a cushion body 35 formed from a single mesh of foamed thermoplastic resin strands 36. The cushion body 35 can be manufactured according to the teachings in U.S. Patent Application Publication No. 2023 / 0191678 by Blair et al., published to Lear Corporation on June 22, 2023. The cushion body 35 may be formed from a foam material according to another embodiment. The cushion assembly 34 provides support to the occupant on the seat assembly 20. The cushion assembly 34 is elastically deformable and provides comfort to the occupant while supporting them.

[0017] The cushion assembly 34 is a non-foam component or includes at least one non-foam component. Non-foam components are mainly referred to as mesh members, but may also be referred to as strand members, loop members, entangled members, filament mesh structures, mesh structures, strand meshes, loop meshes, entangled meshes, or mesh cushions. In Figure 2, the cushion assembly 34 is shown as a non-foam component that does not include foam components or foam materials such as urethane or polyurethane foam, but it is intended that the cushion assembly 34 may include foam components or foam materials in addition to the non-foam components to provide additional or localized cushioning to the seat occupant. For example, foam material may be provided between the cushion assembly 34 and the trim cover 32 placed on top of the cushion assembly 34, within the cushion assembly 34, or in a combination thereof. Reducing the amount of foam material provided in the cushion assembly 34 or removing foam material from the cushion assembly 34 can reduce weight and improve the support and comfort of the seat occupant. In addition, removing foam material can facilitate the recycling of the cushion assembly 34.

[0018] The following describes the cushion assembly 34 in a situation where the cushion assembly 34 does not include a foam material. In this context, the cushion assembly 34 is made of filaments 36 of a polymeric material that are randomly looped, bent, twisted, or intertwined and integrally joined, as will be discussed in detail later. The filaments 36 are joined directly to another filament 36 rather than being joined indirectly with a resin or other intermediate material.

[0019] The filaments 36, which can also be referred to as strands or threads, are made of any suitable single or plural materials. In some configurations, the filaments 36 are made of a polymeric material or a 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, the polyethylene-based filament may be made of linear low-density polyethylene (LLPDE). The filament material can be recyclable, unlike the foam material, or can be recycled more easily than the foam material. It is also contemplated that the filaments 36 may contain reinforcing fibers and that the reinforcing fibers may not be made of a thermoplastic material.

[0020] In some configurations, the filaments 36 can be monofilaments made of a single material. In some configurations, the filaments 36 are made of multiple materials. As an example, the filaments 36 made of multiple materials can include a core made of a first thermoplastic material and a sheath that surrounds the core and is made of a second thermoplastic material different from the first thermoplastic material. It is contemplated that the cushion assembly 34 may include a combination of monofilaments and filaments made of multiple materials that are not monofilaments.

[0021] Randomly looped, bent, looped, twisted, or intertwined filaments 36 are joined together where one filament 36 comes into contact with another filament 36, thereby resulting in a lightweight, breathable cushion assembly 34 or mesh structure having openings or gaps between the filaments 36.

[0022] The cushion assembly 34 is installed within the trim cover (Figure 1). To attach the cushion assembly 34 to other seat components, the cushion assembly includes a trim cord 40. The trim cord 40 can be attached to other seat components such as the seat frame and seat suspension. The trim cord 40 can also be used to attach other components, such as the trim cover 32, to the cushion assembly 34. The trim cord 40 can be formed from any suitable material, such as a structural and flexible material, for example, polyethylene. Alternatively, the trim cord 40 may be formed from steel wire.

[0023] An aperture or opening 38 is formed in the cushion assembly 34. In the illustrated embodiment, the aperture 38 is a slot or groove 38 formed along the length of the body 35. When another cushion body 35 is stacked on top of the cushion body 35, the groove 38 can be concealed along its length by having an aperture opening at the end of the groove 38. The trim cord 40 is inserted into the groove 38. To retain the trim cord 40 within the cushion body 35, according to the illustrated embodiment, the trim cord 40 is welded to the body 35 at a weld 39 in the groove 38. The trim cord 40 can be welded by friction welding, ultrasonic welding, heat riveting, etc., so that the trim cord 40 is joined to the body 35 and becomes integrated with the body 35. Alternatively, additional weld material 39 may be melted and deposited to cool and join the trim cord 40 to the body 35. According to another embodiment, the trim cord 40 is welded to the cushion body 35 without additional adhesive.

[0024] Referring to Figure 3, another cushion assembly 56 is shown removed from the seat assembly 20. The cushion assembly 56 includes a cushion body 60 formed from a single mesh of foamed thermoplastic resin strands 36. The cushion body 60 may also be formed from a common foam material according to another embodiment. The cushion assembly 56 may be the same as the cushion assembly 34 in Figure 2, or it may be a different cushion assembly 56 as shown.

[0025] The cushion assembly 56 includes a trim cord 58 that is joined to the cushion body 60 at a connecting portion 62. According to one embodiment, the connecting portion 62 is a heat-sealed portion that partially melts the trim cord 58 and the cushion body 60 to join the trim cord 58 to the cushion body 60. According to another embodiment, the connecting portion 62 is a welded portion 62.

[0026] An aperture 64 is formed in the cushion assembly 56, and a trim cord 66 is inserted into the aperture 64. The trim cord 66 can be made of polyethylene material. The aperture 64 is shown as a groove 64. Figure 3 shows another method of installing the trim cord 66 in the aperture 64 according to one embodiment. A segment 42 of the foamed thermoplastic strand is welded to the integral mesh of the foamed thermoplastic strand 36, at least partially covering the aperture 64. In the illustrated embodiment, a first segment 52 of the foamed thermoplastic strand is welded to a second segment 54 of the foamed thermoplastic strand, at least partially covering the aperture 64.

[0027] Figures 4 to 6 show a method and system for inserting a trim cord 68 into the aperture 70 of a cushion body 72. The cushion body 72 can be formed from foam, an extruded thermoplastic mesh, or any suitable material. A linear actuator assembly 74 is provided for attaching the trim cord 68 to the cushion body 72. The linear actuator assembly 74 can be used without welding the trim cord 68 to the cushion body 72. The linear actuator assembly 74 includes a pair of bases 76 that provide a pair of guides. A pair of sliders 78 are mounted on the bases 76 so as to translate relative to the bases 76. A pair of linear actuators, such as pneumatic cylinders 80, are mounted on the bases 76 and connected to the ends of the sliders 78 so as to extend and retract the sliders 78 relative to the bases 76. Each slider 78 is fitted with an elongated end effector 82. A pair of bases 76, sliders 78, linear actuators 80, and end effectors 82 are illustrated and described, but any number can be used to install any number of trim cords 68.

[0028] Figures 4 and 5 show the linear actuator assembly 74 in the idle position, thereby presenting the cushion body 72 close to the end of the end effector 82. In Figure 6, the linear actuator 80 extends the slider 78 from the base 76 so that the end effector 82 is inserted into the cushion body 72. In the extended position in Figure 6, the end effector 82 releases the trim cord 68 into the cushion body 72. The linear actuator 80 then retracts to the idle position in Figures 4 and 5.

[0029] Figures 7 and 8 show the cushion body 72 with the trim cord 68 installed. The aperture 70 of the bundled mesh 36 has internal dimensions, and the trim cord 68 has external dimensions, such as a cross-section, that are smaller than the internal dimensions of the aperture 70. In some embodiments, the cross-section of the trim cord 68 is greater than 3 millimeters and less than 5 millimeters. In some embodiments, the internal dimensions 44 of the aperture 70 are at least 5 millimeters larger than the cross-section of the trim cord 68. Furthermore, in some embodiments, the internal dimensions of the aperture 70 are less than 10 millimeters. In some embodiments, the internal dimensions of the aperture 70 are 100 percent to 166 percent larger than the cross-section of the trim cord 68.

[0030] Figure 9 shows trim covers 32 of a seat assembly 20 in various embodiments. Figure 10 shows a cushion body 72 together with the trim cover 32 of the seat assembly 20. The trim cover 32 is attachable to trim cords 68. In some embodiments, the trim cover 32 is provided with a number of clips 48 sewn to the trim cover 32. The clips 48 are sized to receive the trim cords 68 and hold the trim cords 68 in an integrated or bundled mesh 36. The trim cover 32 may also be provided with a fastener assembly 50 attached to the trim cover 32. The fastener assembly 50 is sized to receive the trim cords 68 and hold the trim cords 68 in a bundled mesh 36.

[0031] The fastener assembly 50 includes a strip or wire 44 sewn to the trim cover 32. According to some embodiments, the wire 44 may be a metal wire 44. The fastener assembly 50 also includes a plurality of hog rings 46, which are rings having discontinuous loops and which are deformed by a tool to close the loops and provide a fastener-type connection. The hog rings 46 connect the wire 44 to the trim cord 68. The hog rings 46 are placed around the wire 44 and the trim cord 68 and closed. According to another embodiment, the hog rings 46 may be placed around the wire 44 and closed, and then the trim cord 68 may be placed inside the closed hog rings 46.

[0032] According to paragraph 1, an assembly is provided which may or may not be combined with any of the following items, comprising an integrated or bundled mesh of foamed thermoplastic strands having an aperture formed therein. A trim cord is inserted into the aperture of the bundled mesh. The trim cord is placed in the aperture by one or more of the following: the trim cord is inserted into the aperture; the trim cord is welded to the bundled mesh of foamed thermoplastic strands; or a first segment of the foamed thermoplastic strands is welded to a second segment of the foamed thermoplastic strands, at least partially covering the aperture.

[0033] According to paragraph 2, an assembly is provided as described in either the preceding or succeeding paragraph, wherein the trim cord is welded to a region of a bundled mesh of foamed thermoplastic strands within grooves formed in the integral mesh.

[0034] According to paragraph 3, an assembly is provided as described in either the preceding or following paragraph, wherein the trim cord is welded to a bundled mesh of foamed thermoplastic strands.

[0035] According to paragraph 4, an assembly is provided which, as described in either the preceding or succeeding item, has a trim cord welded without adhesive.

[0036] According to paragraph 5, an assembly is provided as described in either the preceding or following paragraph, wherein segments of foamed thermoplastic resin strands are welded to a bundled mesh of foamed thermoplastic resin strands, at least partially covering the aperture.

[0037] According to paragraph 6, an assembly is provided as described in either the preceding or following paragraph, wherein the aperture of the assembled mesh has an internal dimension, and the trim code has a cross-section smaller than the internal dimension of the aperture.

[0038] According to paragraph 7, an assembly is provided which has a trim cord cross-section greater than 3 millimeters, as described in either the preceding or succeeding paragraph.

[0039] According to paragraph 8, an assembly is provided which has a trim cord cross-section smaller than 5 millimeters, as described in either the preceding or succeeding paragraph.

[0040] According to paragraph 9, an assembly is provided as described in either the preceding or succeeding paragraph, wherein the inner dimensions of the aperture of the assembled mesh are at least 5 millimeters larger than the cross-section of the trim cord.

[0041] According to paragraph 10, an assembly is provided which, as described in either the preceding or succeeding item, has an internal dimension of the aperture of the assembled mesh that is less than 10 millimeters.

[0042] According to paragraph 11, an assembly is provided, as described in either the preceding or succeeding paragraph, wherein the internal dimensions of the aperture of the bundled mesh are 100 percent to 166 percent larger than the cross-section of the trim cord.

[0043] According to paragraph 12, an assembly is provided, comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive a trim cord and hold the trim cover in a bundled mesh, as described in either the preceding or following paragraph.

[0044] According to paragraph 13, an assembly is provided, comprising a trim cover, a wire sewn to the trim cover, and at least one ring for attaching a trim cord to the wire, as described in either the preceding or following paragraph.

[0045] According to paragraph 14, an assembly is provided, comprising a trim cover and at least one fastener sewn to the trim cover, wherein the fastener is sized to receive a trim cord and hold the trim cover in a bundled mesh, as described in either the preceding or following paragraph.

[0046] According to paragraph 15, an assembly is provided which may be combined with or may not be combined with either of the preceding or succeeding items, comprising a bundled mesh of foamed thermoplastic strands having an aperture formed therein. A trim cord is inserted into the aperture of the bundled mesh, and a first segment of the foamed thermoplastic strand is welded to a second segment of the foamed thermoplastic strand, at least partially covering the aperture.

[0047] According to paragraph 16, an assembly is provided as described in either the preceding or following paragraph, wherein the trim cord is welded to a bundled mesh of foamed thermoplastic strands.

[0048] According to paragraph 17, an assembly is provided which, in which the trim cord is welded without adhesive, as described in either the preceding or following paragraph.

[0049] According to paragraph 18, an assembly is provided comprising a bundled mesh of foamed thermoplastic strands, which may or may not be combined with either of the preceding or succeeding items. A trim cord is attached to the bundled mesh and welded to the bundled mesh of foamed thermoplastic strands.

[0050] According to paragraph 19, an assembly described in either the preceding or following paragraph is provided, wherein the trim cord is welded without adhesive.

[0051] According to paragraph 20, an assembly is provided, comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive a trim cord and hold the trim cover in a bundled mesh, as described in either the preceding or following paragraph.

[0052] According to paragraph 21, an assembly is provided, comprising a trim cover and at least one fastener sewn to the trim cover, wherein the fastener is sized to receive a trim cord and hold the trim cover in a bundled mesh, as described in either the preceding or following paragraph.

[0053] According to paragraph 22, an assembly of either the preceding or succeeding item is provided, comprising a trim cover, a wire sewn to the trim cover, and at least one ring for attaching a trim cord to the wire.

[0054] According to paragraph 23, any combination of any of the preceding items is provided.

[0055] While exemplary embodiments have been described above, these embodiments are not intended to represent all possible forms of the Disclosure. In this regard, the language used herein is descriptive, not restrictive, and can be modified in various ways without departing from the spirit and scope of the Disclosure. Furthermore, features of various embodiments can be combined to form further embodiments of the Disclosure.

Claims

1. A mesh structure formed by bundled foamed thermoplastic resin strands, in which an aperture is formed, The trim code inserted within the aperture of the aforementioned combined mesh structure, Equipped with, An assembly in which the trim cord inserted within the aperture is welded to a bundled mesh structure of foamed thermoplastic strands, and a first segment of the foamed thermoplastic strands is welded to a second segment of the foamed thermoplastic strands such that it at least partially covers the aperture, which is integrated with the trim cord.

2. The assembly according to claim 1, wherein the trim cord is welded without adhesive.

3. The assembly according to claim 1, wherein the aperture of the assembled mesh structure has an internal dimension, and the trim cord has a cross-section smaller than the internal dimension of the aperture.

4. The assembly according to claim 3, wherein the cross-section of the trim cord is larger than 3 millimeters.

5. The assembly according to claim 3, wherein the cross-section of the trim cord is less than 5 millimeters.

6. The assembly according to claim 3, wherein the inner dimension of the aperture of the assembled mesh structure is at least 5 millimeters larger than the cross-section of the trim cord.

7. The assembly according to claim 3, wherein the inner dimension of the aperture of the assembled mesh structure is less than 10 millimeters.

8. The assembly according to claim 3, wherein the inner dimensions of the aperture of the assembled mesh structure are 100 percent to 166 percent larger than the cross-section of the trim cord.

9. The assembly according to claim 1, further comprising a trim cover and at least one clip sewn to the trim cover, wherein the clip is sized to receive the trim cord and to hold the trim cover to the assembled mesh structure.

10. The assembly according to claim 1, further comprising a trim cover, a wire sewn to the trim cover, and at least one ring for attaching the trim cord to the wire.

11. The assembly according to claim 1, further comprising a trim cover and at least one fastener sewn to the trim cover, the fastener being sized to receive the trim cord and to hold the trim cover in the assembled mesh structure.

12. A mesh structure made up of bundled foamed thermoplastic resin strands, An assembly comprising: a trim cord attached to the bundled mesh structure, the trim cord being welded to the bundled mesh structure of foamed thermoplastic strands, wherein a segment of the foamed thermoplastic strand is welded to the foamed thermoplastic strand such that it at least partially covers the bundled mesh structure of the foamed thermoplastic strand, which is integrated with the trim cord.

13. The assembly according to claim 12, wherein the trim cord is welded without adhesive.

14. The assembly according to claim 12, further comprising a trim cover and at least one clip sewn to the trim cover, the clip being sized to receive the trim cord and to hold the trim cover to the assembled mesh structure.

Images