Fasteners and fastening methods for non-foamed cushions
Fasteners with retainer and projection designs securely attach non-foamed cushions made of polymer strands, addressing the challenge of securing these materials and enabling recyclable, adhesive-free assembly.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- LEAR CORP
- Filing Date
- 2023-10-13
- Publication Date
- 2026-05-21
AI Technical Summary
Conventional fasteners struggle to securely fasten non-foamed cushions made of intertwined polymer strands, as they lack effective mechanisms to engage with these materials.
The use of fasteners with retainer or anchor portions and projections that intertwine with and penetrate the polymer strands, allowing secure attachment without adhesives, and can be made from the same polymer material as the cushions for ease of recycling.
The fasteners effectively secure non-foamed cushions without adhesives, ensuring durability and facilitating recycling by integrating with the same polymer material, thus providing a secure and sustainable fastening solution.
Smart Images

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Abstract
Description
Technical Field
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 422,708, filed on November 4, 2022, and the priority of Danish Patent Application No. PA202370420, filed on August 16, 2023, the entire disclosures of which are incorporated herein by reference.
[0002] This disclosure relates to a cushion assembly, a fastener for securing a cushion, and a method of fastening a cushion. More specifically, a non-foamed cushion assembly of intertwined polymer strands and a fastener therefor are disclosed.
Brief Description of the Drawings
[0003] [Figure 1] It is a perspective partial cross-sectional view of one embodiment of a sheet assembly. [Figure 2] It is a front view of first and second non-foamed or non-foaming cushions with first and second fasteners disposed thereon. [Figure 3] It is a front view of the first and second fasteners of FIG. 2 coupled to each other. [Figure 4] It is an enlarged view of the first and second fasteners coupled to each other. [Figure 5] It is a schematic perspective view of first and second cushions with first and second fasteners disposed thereon. [Figure 6] It is a perspective view of the first and second fasteners of FIG. 5 coupled to each other. [Figure 7] It is a front perspective view of one embodiment of a first fastener. [Figure 8] It is a front perspective view of one embodiment of a second fastener. [Figure 9] It is a front perspective view of one embodiment of a third fastener. [Figure 10] It is a front perspective view of one embodiment of fourth and fifth fasteners. [Figure 11] It is a front perspective view of one embodiment of a sixth fastener. [Figure 12] This is a flowchart showing how to assemble a seat assembly. [Modes for carrying out the invention]
[0004] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or minimized to illustrate details of particular components. Accordingly, certain structural and functional details disclosed herein should not be construed as limiting, but merely as representative grounds for teaching those skilled in the art to employ various embodiments of the present invention. As those skilled in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments not expressly illustrated or described. Combinations of illustrated features provide representative embodiments for typical uses. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired for specific uses or implementations.
[0005] Unless otherwise expressly indicated in the examples or elsewhere, all numerical values in this specification indicating the quantity of materials or conditions of reaction and / or use should be understood as modified by the word "approximately" when describing the broadest scope of the invention. It is generally preferred to carry out the work within the numerical limits stated. Also, unless otherwise expressly indicated, percentage, "partial" and ratio values are by weight. The term "polymer" includes "oligomer," "copolymer," "terpolymer," etc. A description of a group or class of materials suitable or preferred for a given purpose in relation to the invention means that mixtures of any two or more members of the group or class are equally suitable or preferred. The molecular weight provided for any polymer refers to the number-average molecular weight. A description of components in chemical terms refers to the components when added to any combination identified in the description and does not necessarily exclude chemical interactions between components of the mixed mixture. The first definition of an acronym or other abbreviation applies to all subsequent use of the same abbreviation in this specification and is mutatis mutandis to the usual grammatical variations of the abbreviation initially defined. Also, unless otherwise expressly stated, the measurement of properties is determined by the same technique as referred to earlier or later for the same property.
[0006] Since certain components and / or conditions can vary, the present invention is not limited to the specific embodiments and methods described below. Furthermore, the terms used herein are used solely for the purpose of describing specific embodiments of the present invention and are not intended to limit them in any way.
[0007] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context explicitly indicates otherwise. For example, a singular reference to a component is intended to include multiple components.
[0008] The terms “substantially,” “generally,” or “about” may be used herein to describe embodiments disclosed or claimed. The terms “substantially,” “generally,” or “about” may be used to modify values or relative characteristics disclosed or claimed herein to indicate within manufacturing tolerances and / or within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of values or relative characteristics.
[0009] With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” if any of these three terms is used herein, the subject matter disclosed and claimed may include the use of any of the other two terms.
[0010] It should also be understood that an integer range explicitly includes all integers in between. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range from 1 to 100 includes 1, 2, 3, 4, ..., 97, 98, 99, and 100. Likewise, when any range is mentioned, the numbers in between, which are the increments obtained by dividing the difference between the upper and lower bounds by 10, can be taken as alternative upper or lower bounds. For example, if the range is from 1.1 to 2.1, the following numbers could be chosen as lower or upper bounds: 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0.
[0011] Figure 1 shows a seat assembly 100 for a vehicle (e.g., automobile, motorcycle, train, aircraft, ship). In one or more embodiments, the seat assembly 100 includes a cushion assembly 104 and a trim cover 102 positioned on a frame 106. In a modified example, the frame 106 supports the cushion assembly 104 as well as the occupant. In an improved example, the frame 106 supports other components such as a massage assembly, a ventilation assembly, a temperature control assembly, a sensor assembly, and / or an electronic assembly. In an improved example, the cushion assembly 106 includes one or more cushions, such as a first cushion 108 (e.g., the bottom of the seat) and a second cushion 110 (e.g., the seat back).
[0012] In one or more embodiments, the trim cover 102 is positioned to be in contact with the occupant. For example, the trim cover 102 may be made of leather, synthetic leather, woven fabric, polyurethane, and / or polyester. In various embodiments, the seat frame 102 may be made of a rigid material such as metal, plastic, wood, or a combination thereof. For example, a seat frame 106 made of steel and / or aluminum may be used.
[0013] In various embodiments, unlike conventional cushions which are generally molded foams, one or more cushions are composed of non-foaming or non-foaming materials such as multiple entangled and / or intertwined polymer strands defining one or more cushion bodies, as shown, for example, in Figures 2-4. In other words, some of the various polymer strands intertwine with some of the other polymer strands so that the multiple polymer strands function as a single unit, piece, cushion, pillow, pad, or mat. In variations, the polymer strands are any suitable polymer material, such as thermoplastic polymers (e.g., polyolefins, polyethylene, polypropylene, polystyrene, polycarbonate, and / or polyvinyl chloride). For example, the polymer strands may be low-density or high-density polyethylene. Hereinafter, this cushion may simply be referred to as a non-foaming or non-foaming cushion. The application identified by application number 17 / 741,639, filed on 11 May 2022, further describes non-foaming or non-foaming cushions, which are incorporated herein by reference in their entirety. While the term cushion is used herein, it should be understood that non-foaming or non-foaming bodies of polymer strands may also be called pads or pillows.
[0014] The structure of non-foaming or non-foaming cushions may be difficult to fasten with conventional fasteners designed to secure foam, for example. Therefore, in one or more embodiments, the cushion assembly 200 includes one or more fasteners, as shown in Figures 2 to 11. In improved examples, one or more fasteners secure one or more cushions in place and / or connect the cushions to one another. For example, the cushion assembly 200 includes a first (e.g., male) fastener 202 located on a first cushion 204 and a second (e.g., female) fastener 206 located on a second cushion 208. In various embodiments, each cushion or cushion body has sides defining a surface or surface portion and slots beneath the surface or surface portion. For example, the first cushion 204 includes a first side (e.g., top) defining a first surface having a first slot 210 beneath a first surface (e.g., top), and the second cushion 208 includes a second side (e.g., bottom) defining a second surface having a second slot 212 beneath a second surface (e.g., bottom). In one or more embodiments, the first and / or second slots 210, 212 are cut into the cushion after extrusion. Alternatively, the slots may be defined by the breaker plate die during extrusion. The surfaces or surface portions described herein relate to cushion bodies formed by polymer strands, rather than individual polymer strands. For example, as shown in Figure 2, the first cushion 204 has a first surface 214 corresponding to a first surface plane defined by axes X and Y. While cushions are shown herein as rectangular or cubic, the shape and size of cushions are not particularly limited thereto, and surfaces are not limited to planar. In the improved version, the first and second fasteners are joined so that the surfaces of the first and second cushions are adjacent to each other.
[0015] In the modified example shown in Figure 4, the fastener 300 has a retainer or anchor portion 302 that serves to hold or secure the fastener 300 in a plurality of polymer strands. In the improved example, the fastener 300 also includes a projection 304 extending from the retainer or anchor portion 302. In various embodiments, the projection 304 is configured to be received by another fastener, such as those shown in Figures 8-9 and 11. For example, the projection 304 may include a fastening mechanism 306 such as a screw (i.e., spiral lamp), a clip (e.g., Christmas tree clip), a clasp, a hook, a rivet, a snap, or any other known fastening mechanism. In one or more embodiments, the fastener 300 is configured to cooperate with a second fastener by joining together as shown in Figures 4 and 6.
[0016] Referring to Figure 8, for example, the second fastener 400 has a retainer or anchor portion 402 that functions to hold or secure the second fastener 400 to, for example, a second non-foaming or non-foaming cushion. The second fastener 400 is configured to receive the first fastener 300. In various embodiments, the second fastener 400 includes a projection 404 extending from the retainer or anchor portion 402, the projection 404 including a fastening mechanism 406 corresponding to the fastening mechanism 306 of the first fastener 300. For example, the projection 404 of the second fastener 400 can define a cavity 408, i.e., a hollow bottle configured to receive the projection 304 of the first fastener 300. In yet another embodiment, as shown in Figure 9, the second fastener 500 includes a retainer or anchor portion 502 defining an orifice 504 configured to receive the first fastener 300. For example, in some embodiments, the projection 304 of the first fastener 500 includes a screw (i.e., a spiral ramp), and the second fastener 400 / 500 is configured to receive the screw. For example, the hollow bin of the second fastener 400 includes a groove corresponding to a screw for joining the first and second fasteners 300, 400. In yet another example, the first fastening mechanism 306 is a Christmas tree clip, and the hollow bin of the second fastener 400 includes one or more openings for receiving the clip. In an improved example, as shown in Figure 11, the retainer or anchor portion 702 of the fastener 700 includes a plurality of barbs 704. In other words, any embodiment described herein may include a spiked retainer or anchor portion to more securely hold or fasten it to the cushion. For example, the retainer or anchor portion 702 is configured to receive another fastener through an opening 706 and includes a number of spikes 704.
[0017] In yet another embodiment, referring to Figure 10, the fastener 600 includes a retainer or anchor portion 602 and a protruding shaft portion 604 extending therefrom. In a modified example, the fastener 600 also includes a head portion 606 positioned on the shaft portion 604 opposite to the retainer or anchor portion 602. In an improved example, the head portion 606 is located on the shaft portion with dimensions W s Larger than or greater than dimension W h The head portion 606 has (for example, width). The head portion 606 is configured to prevent the second fastener from slipping or sliding off the shaft portion. In one or more embodiments, the second fastener 608 is configured to cooperate with the shaft portion 604, such as by coupling to the shaft portion 604 (e.g., snapping and / or clipping). For example, the first fastener 600 is positioned on the first cushion such that the head portion 606 and the shaft portion 604 protrude through the first cushion into the second cushion. Once protruding into the second cushion, the second fastener 608 clips onto the shaft portion 604 so that the two cushions are connected to each other. In an improved example, the protruding portion of the first fastener 600 is coupled to the second fastener 608 by sliding or lateral movement along a second axis B defined by the second fastener, defining a first axis A. In other words, fasteners can be joined by engaging them from non-parallel or substantially perpendicular directions (for example, within ±10°, ±20°, ±30°, or ±45° from the perpendicular).
[0018] In various embodiments, the fasteners described herein may be made of any suitable material. For example, the fasteners are made of thermoplastic polymers (e.g., polyolefins, polyethylene, polypropylene, polystyrene, polycarbonate, and / or polyvinyl chloride). In improved examples, the fasteners are low-density or high-density polyethylene. In modified examples, the fasteners are made of the same polymer material (i.e., polymer strands) as the cushions so that they can be reused with the cushions and do not need to be removed. In improved examples, the cushions are joined together without adhesive via the fasteners described herein. In other words, the cushion assembly may be adhesive-free or substantially adhesive-free (i.e., less than 1%, 0.5%, or 0.1% by weight).
[0019] Referring to Figure 3, the shape of the retainer or anchor portion is not particularly limited, but in various embodiments, for example, the width W of the protruding portion sIt has a width Wa that is 2 times, 3 times, 5 times, or 10 times, and as shown in FIG. 3, it extends along the width of many polymer strands and includes a generally flat portion that three-dimensionally suppresses the movement of the fastener along the first axis D1. For example, the retainer or anchor portion is circular, rectangular, square, diamond-shaped, triangular, S-shaped, or any other suitable shape. The shape of the protruding member is not particularly limited. For example, the shape can be cylindrical, hook-shaped, or pointed. In an improved example, the protruding portion has a shape and width that allows multiple polymer strands to pass through more easily. For example, the protruding portion includes a pointed or rounded tip to more easily penetrate the strand. In a modified example, the protruding portion extends from the surface of the first cushion, more preferably extends through the surface of the first cushion from a slot, more preferably extends through the second (e.g., adjacent) surface of the second cushion from a slot through the surface of the first cushion, and even more preferably, the protruding portion has a length that extends from the first slot of the first cushion through the surface of the first cushion through the second (e.g., adjacent) surface of the second cushion to the second slot of the second cushion. In various embodiments, the retainer or anchor portion has a cross-sectional area larger than the protruding shaft portion and the head portion along the axis B, as shown in FIG. 10. In an improved example, the head portion has a cross-sectional area larger than the protruding shaft portion.
[0020] Referring to FIG. 12, a method 800 for manufacturing a cushion assembly is disclosed. The method 800 includes one or more of the steps of extruding one or more cushion bodies (i.e., step 802), molding one or more fasteners as described herein (i.e., step 804), defining one or more slots in one or more cushion bodies (i.e., step 806), placing at least one of the one or more fasteners in the one or more slots (i.e., step 808), joining the one or more fasteners to a position or to each other (i.e., step 810), and assembling the cushion assembly into a seat assembly for a vehicle or the like (i.e., step 812).
[0021] In various embodiments, the one or more cushion bodies are non-foamed or non-foaming cushions that include a plurality of entangled or interwoven polymer strands as described above. In an improvement, the slots can be cut into the cushion after they are extruded. Alternatively, a breaker plate die may be used to define cavities or slots in the cushion during extrusion. In one or more embodiments, the fasteners can be made of the same polymer material as the cushion. Alternatively, the fasteners and the cushion may be made of a polymer material that can be recycled together without separation. For example, the cushion and the fasteners are polymer materials of different grades or polymer materials having similar melting points. <开
[0022] In a modified example, the fasteners are positioned or joined to one another by screwing them together, clipping them together, snapping them together, or by any other suitable mounting mechanism. For example, a first fastener having a retainer or anchor portion and a projection is placed in a first cushion, such as in a first slot of a first cushion, and moves through the slot in a first direction until it is in a desired or intended position (e.g., a predetermined position), and then extends or is pushed through the cushion in a second direction different from the first direction until the projection extends through or penetrates the first surface of the cushion. For example, the first and second directions are perpendicular. In an improved example, the projection is pushed until it penetrates the surface (e.g., the second surface) of a second cushion (e.g., an adjacent cushion), and is joined to a second fastener placed in a second cushion, such as in a slot of a second cushion.
[0023] In one or more embodiments, the second fastener is positioned in the second cushion by moving laterally along the slot in a third direction, which may be the same as or substantially similar to the first direction. The second fastener is moved to a position corresponding to the first fastener. In improved examples, the second fastener is moved in a fourth direction different from the third direction (e.g., opposite to the second direction) to connect with the first fastener, for example, on a projection of the first fastener. Alternatively, the second fastener may be moved laterally in the third direction until it is connected to the first fastener, for example, by clipping or snapping onto a protruding shaft portion of the first fastener. Thus, in some embodiments, the first fastener may be pushed through the surface and the second cushion until it reaches the slot of the second cushion. In other embodiments, the projection of the first fastener is pushed through the first cushion, and the projection of the second fastener is pushed through the second cushion until they meet and connect. In various embodiments, the fasteners may be fixed in an adjustable manner, such as by a predetermined increment, to adjust the distance between the first retainer or anchor portion and the second retainer or anchor portion. For example, the fasteners may be fixed so that the cushions are in contact with each other, as shown in Figure 4. Alternatively, the fasteners may be fixed so as to define the gap 216, as shown in Figure 3.
[0024] In one or more embodiments, the cushion assembly or a portion thereof is recycled. Since the cushion and fasteners are made of interchangeable, similar, substantially similar, or the same material, it is not necessary to separate or remove the fasteners before recycling. In variations, recycling includes shearing the cushion assembly into smaller parts or fragments by grinding, smashing, tearing, shredding, and / or milling. In improved examples, the cushion assembly is melted into a polymer resin so that it can be reused, for example, after a certain particle size is achieved or after a certain shearing period. In one or more embodiments, the polymer resin is filtered, refined, or purified after melting and before reuse. In one or more embodiments, multiple cushion assemblies are recycled without removing the fasteners. In yet another embodiment, one or more cushion assemblies can be manufactured from the recycled polymer resin.
[0025] According to a first embodiment of the cushion assembly described herein, the assembly includes a first body comprising a plurality of first polymer strands, a first fastener disposed on the first body, a second body comprising a plurality of second polymer strands, and a second fastener disposed on the second body and configured to cooperate with the first fastener. In a modified example, the first body includes a first side surface defining a first surface, and the second body includes a second side surface defining a second surface. In an improved example, the first fastener includes a retainer portion configured to be disposed on the first body, and a projection extending from or projecting from the retainer portion through the first surface so that the second fastener cooperates with the projection to connect the first and second cushions to each other.
[0026] According to the second embodiment, the first body of either the first embodiment or the subsequent embodiment defines a first slot located beneath the first surface of the first body, and the first fastener is positioned in the first slot.
[0027] According to the third embodiment, the second body of either the preceding or succeeding embodiment defines a second slot located beneath the second surface of the second body, and the second fastener is positioned in the second slot.
[0028] According to the fourth embodiment, the projection of either the preceding or succeeding embodiment is configured to extend through the second surface of the second body to the second slot.
[0029] According to the fifth embodiment, the second fastener in either the preceding or succeeding embodiment is configured to receive the projection of the first fastener.
[0030] According to the sixth embodiment, the second fastener in either the preceding or succeeding embodiment includes a retainer portion.
[0031] According to the seventh embodiment, the first fastener or the second fastener in either the preceding or succeeding embodiment is barbed.
[0032] According to the eighth aspect, the second fastener in either the preceding or subsequent aspect comprises a retainer portion and a corresponding projection extending from the retainer portion of the second fastener through a second surface and configured to receive a projection of the first fastener.
[0033] According to the ninth aspect, the first fastener in either the preceding or subsequent aspect comprises a shaft portion and a head portion facing a retainer portion, the head portion having a larger dimension than the shaft portion such that the second fastener cooperates with the shaft portion to engage the first fastener and the second fastener with each other.
[0034] According to the tenth embodiment, the retainer portion of either the preceding or succeeding embodiment (i.e., the first and / or second fastener) has a cross-sectional area larger than the cross-sectional area of the projection.
[0035] According to the eleventh embodiment, the fastener in either the preceding or subsequent embodiment includes a thermoplastic polymer material.
[0036] According to the twelfth embodiment, the polymer strand of either the preceding or succeeding embodiment comprises the same thermoplastic polymer material as the fastener.
[0037] According to the 13th embodiment, the cushion assembly of either the preceding or succeeding embodiment may be positioned in a vehicle seat assembly and supported by a seat frame.
[0038] According to the fourteenth aspect, the cushion assembly includes a first cushion and first and second fasteners. In a modified example, the first cushion includes a first side surface defining a first surface and a first slot located beneath the first surface. In an improved example, the first fastener includes a retainer portion located in the first slot and a projection extending or protruding from the retainer portion through the cushion and the first surface, and the second fastener is configured to cooperate with the projection of the first fastener.
[0039] According to the 15th embodiment, the cushion assembly of either the preceding or subsequent embodiment includes a second cushion such that a second fastener is positioned on the second cushion and the first and second cushions are connected when the first and second fasteners are coupled to each other.
[0040] According to the 16th embodiment, the first cushion and the second cushion of either the preceding or succeeding embodiment are connected to each other without adhesive.
[0041] According to the 17th embodiment, the second cushion in either the preceding or subsequent embodiment includes a second side defining a second surface and a second slot positioned below the second surface such that a second fastener is placed in the second slot.
[0042] According to the 18th embodiment, the first and / or second cushion in either the preceding or subsequent embodiment is the body of a polymer strand.
[0043] According to the 19th embodiment, a method for connecting cushions includes placing a first fastener on a first cushion, placing a second fastener on a second cushion, and connecting the first and second fasteners to each other. In a modified example, the first fastener includes a retainer portion and a projection configured to penetrate the first cushion and the first surface portion of the first cushion. In an improved example, the second fastener is configured to be connected to the first fastener and includes a retainer portion. In one or more embodiments, the first and second fasteners cooperate to connect the first and second cushions to each other.
[0044] According to the 20th embodiment, the first fastener in either the preceding or succeeding embodiment is positioned in a first slot of the first cushion below the first surface portion of the first cushion, and the second fastener is positioned in a second slot of the second cushion below the second surface portion of the second cushion.
[0045] According to the 21st embodiment, the method in either the preceding or succeeding embodiment includes defining a first slot in the first cushion and a second slot in the second cushion.
[0046] According to the 22nd aspect, the first and second slots of either the preceding or succeeding aspect are defined by cutting out the first and second cushions.
[0047] According to the 23rd embodiment, the first and second slots in either the preceding or succeeding embodiment are defined by breaker plates used to push out the first and second cushions.
[0048] According to the 24th aspect, the method in either the preceding or subsequent aspect includes extending a projection through the first surface to the second surface so as to penetrate the second surface and be coupled to the second fastener.
[0049] According to the 25th embodiment, the first and / or second cushion in either the preceding or subsequent embodiment includes a plurality of polymer strands.
[0050] According to the 26th embodiment, the method of either the preceding or succeeding embodiment includes forming the first and second fasteners from the same polymer as the polymer strand described above.
[0051] According to the 27th embodiment, the method in either the preceding or subsequent embodiment includes recycling the first and / or second cushions without removing the first and / or second fasteners.
[0052] According to the 28th embodiment, recycling in either the preceding or subsequent embodiment includes shearing into smaller fragments and melting them to form a polymer resin.
[0053] According to the 29th embodiment, the method in either the preceding or subsequent embodiment includes assembling first and second cushions on a seat frame of a vehicle seat.
[0054] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms that are covered by the claims. The terms used in the specification are descriptive, not restrictive, and it should be understood that various modifications can be made without departing from the scope of the disclosure. As stated above, features of various embodiments can be combined to form further embodiments of the invention that cannot be expressly described or illustrated. While various embodiments could be described as being advantageous or preferable to other embodiments or prior art embodiments with respect to one or more desired features, those skilled in the art will recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes that depend on a particular application and embodiment. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. Thus, insofar as any embodiment can be described as being undesirable to other embodiments or prior art embodiments with respect to one or more features, these embodiments may not be outside the scope of the disclosure and may be desirable for a particular application.
Claims
1. A plurality of first polymer strands defining a first body including a first side surface defining a first surface, A first fastener comprising a retainer portion disposed within the first main body and a protruding portion that extends from the retainer portion through the first surface, A cushion assembly comprising, A second plurality of polymer strands defining a second body, including a second side surface defining a second surface, A second fastener is disposed within the second body and configured to cooperate with the protruding portion so that the first body and the second body are connected to each other, A cushion assembly characterized by the following features.
2. The cushion assembly according to claim 1, wherein the first body defines a first slot beneath the first surface, and the first fastener is positioned within the first slot.
3. The cushion assembly according to claim 2, wherein the second body defines a second slot beneath the second surface, and the second fastener is positioned within the second slot.
4. The cushion assembly according to claim 3, wherein the protrusion is configured to extend through the second surface of the second body to the second slot.
5. The cushion assembly according to claim 1, wherein the second fastener is configured to receive the protrusion of the first fastener.
6. The cushion assembly according to claim 1, wherein the second fastener includes a retainer portion, and the retainer portion of the first or second fastener has spikes.
7. The cushion assembly according to claim 1, wherein the second fastener includes a retainer portion and a corresponding projection extending from the retainer portion of the second fastener through the second surface and configured to receive the projection of the first fastener.
8. The cushion assembly according to claim 1, wherein the first fastener includes a shaft portion and a head portion facing the retainer portion, and the head portion has a larger dimension than the shaft portion so that the second fastener cooperates with the shaft portion to engage the first and second fasteners with each other.
9. The cushion assembly according to claim 7, wherein the retainer portion of the first fastener and / or the second fastener has a cross-sectional area larger than the cross-sectional area of the protruding portion of the first fastener and / or the second fastener.
10. The cushion assembly according to claim 1, wherein the fastener comprises a thermoplastic polymer material.
11. The cushion assembly according to claim 10, wherein the polymer strand comprises the same thermoplastic polymer material.
12. A vehicle seat assembly comprising a frame supporting the cushion assembly according to any one of claims 1 to 11.
13. A first cushion including a first side surface defining a first surface and a first slot located beneath the first surface, A first fastener comprising a retainer portion disposed within the first slot and a protruding portion extending from the retainer portion through the first surface, A cushion assembly comprising, A second fastener configured to cooperate with the aforementioned protrusion, A second cushion, wherein the second fastener is positioned within the second cushion such that the first and second cushions are connected to each other when the first and second fasteners are joined together. A cushion assembly characterized by the following features.
14. The cushion assembly according to claim 13, wherein the first and second cushions are connected to each other without adhesive.
15. The cushion assembly according to claim 13 or 14, wherein the second cushion includes a second side surface defining a second surface and a second slot located beneath the second surface, and the second fastener is located within the second slot.
16. The cushion assembly according to claim 13, wherein the first cushion is the body of a polymer strand.
17. A first fastener is placed within a first cushion defining a first surface portion, including a first retainer portion and a projection configured to extend through the first surface portion. The second fastener, which includes a second retainer portion, is positioned within a second cushion defining the second surface portion, and is configured to be coupled to the first fastener. The protruding portion extends through the first surface portion to the second fastener, and the first and second fasteners are connected to each other so as to connect the first and second cushions to each other. A method for connecting cushions, including [this].
18. The method according to claim 17, wherein the first fastener is disposed in a first slot of the first cushion below the first surface portion of the first cushion, and the second fastener is disposed in a second slot of the second cushion below the second surface portion of the second cushion.
19. The method according to claim 18, further comprising defining the first slot in the first cushion and the second slot in the second cushion.