Seat assembly having improved trim appearance and method and tool for making the same

• US 10,160,357 B2
• Filed: 02/08/2013
• Issued: 12/25/2018
• Est. Priority Date: 05/07/2012
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Galbreath, Ashford A., Ali, Asad S., Lymburner, Gregory Alan, Severinski, Paul S., Rock, Gary, Clauser, James B., Patterson, Louella Ann, Welch, Sr., Thomas A.
• Primary Examiner(s): McPartlin, Sarah B
• Application Number:
  US14/397,611
• Publication Number:
  US 20150175042A1
• Time in Patent Office: 2,146 Days
• Field of Search: 2972181, 2972183, 2972185, 29745248, 29745258, 29745259, 2974526
• CPC Class Codes: B29C 44/02 for articles of definite length, i.e. discrete articles
• CPC Class Codes: B29L 2031/3002 Superstructures characterized by combining metal and plastics, i.e. hybrid parts
• CPC Class Codes: B60N 2/5825 by hooks, staples, clips, snap fasteners or the like
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: B60N 2/64 Back-rests or cushions B60N2/2222 takes precedence

Abstract

A seat assembly having improved trim appearance is provided as well as a method and mold tool for making the seat assembly. In certain embodiments, the seat assembly has at least one narrow trench having a substantially constant width of up to 5 mm, which provides for better tolerances when installing a trim cover on the cushion and provides improved appearance and comfort. In certain embodiments, the mold tool has at least one tool insert that is configured to create the at least one narrow trench with a substantially constant width in the cushion.

Claims

1. A cushion assembly comprising:

a polyurethane cushion having a top surface and a bottom surface, the top surface being configured to receive a trim cover and having defined therein at least one trench having first and second opposing side walls and a bottom wall, the first and second side walls having a substantially constant width therebetween of up to about 5 mm; and

at least two trim clips spaced apart in the substantially constant width trench at least partially embedded in the bottom wall of the trench and having a trim cover attachment member projecting into the trench to be engageable with an attachment member of the trim cover,

wherein the bottom wall of the trench has defined therein at least one opening adjacent to one of the at least two trim clips and extending from the bottom wall of the trench through to the bottom surface,

wherein the bottom surface has defined therein at least one access hole juxtaposed with the opening in the bottom wall of the trench to allow a tool to have access to the opening, and

wherein the access hole has a diameter that increases in a direction from the opening towards the bottom surface.

2. The cushion assembly of claim 1, wherein the trench width is from about 2 mm to about 4 mm.

3. The cushion assembly of claim 1, wherein the trench width is about 3 mm.

4. The cushion assembly of claim 1, wherein the trim clips include a base embedded in the bottom wall of the trench and the trim cover attachment member is substantially U-shaped having a first arm and a second arm, each arm being at least partially disposed in one of the first and second side walls of the trench.

5. The cushion assembly of claim 4, wherein the first and second arms of the trim cover attachment member each have a protrusion extending into the trench to retain the attachment member of the trim cover.

6. The cushion assembly of claim 1, wherein the opening is a generally rectangular-shaped slit.

7. The cushion assembly of claim 1, wherein the width of the trench is smaller than the width of the tool such that the trench is configured to deform to receive the tool when it is inserted into the access hole.

8. The cushion assembly of claim 1, wherein at least 3 clips are spaced apart in the substantially constant width trench.

9. The cushion assembly of claim 1, wherein the clips are spaced from 50 mm to 300 mm apart.

10. The cushion assembly of claim 1, wherein the cushion and the bottom wall of the trench are made of polyurethane and the bottom wall of the trench being disposed between the top and bottom surfaces of the cushion.

11. A cushion assembly comprising:

a polyurethane cushion having a top surface and a bottom surface, the top surface being configured to receive a trim cover and having defined therein at least one trench having first and second opposing side walls and a bottom wall spaced between the top and bottom surfaces, the first and second side walls having a substantially constant width therebetween of up to about 5 mm;

at least two clips spaced apart in the substantially constant width trench and at least partially embedded in the bottom wall of the trench, each of the clips having a trim cover attachment member projecting into the trench to be engageable with an attachment member of the trim cover;

at least one slit defined in the bottom wall of the trench adjacent to each of the at least two clips, the slit extending from the bottom wall of the trench through to the bottom surface; and

at least one tapered access hole defined in the bottom surface of the cushion juxtaposed with the slit to allow a tool to have access to the slit, the access hole having a diameter that increases in a direction from the slit towards the bottom surface.

12. A cushion assembly comprising:

a polyurethane cushion having a top surface and a bottom surface, the top surface being configured to receive a trim cover and having defined therein at least one trench having first and second opposing side walls and a bottom wall made of polyurethane, the first and second side walls having a substantially constant width therebetween of up to about 5 mm; and

at least two trim clips spaced apart in the substantially constant width trench at least partially embedded in the bottom wall of the trench and having a trim cover attachment member projecting into the trench to be engageable with an attachment member of the trim cover;

wherein the bottom wall of the trench has defined therein at least one opening adjacent to one of the at least two trim clips and extending from the bottom wall of the trench through to the bottom surface, with the at least one opening having a width of 1-5 mm,

wherein the bottom surface has defined therein at least one access hole juxtaposed with the opening in the bottom wall of the trench to allow a tool to have access to the opening, and

wherein the width of the trench is smaller than the width of the tool such that the trench is configured to deform to receive the tool when it is inserted into the access hole.

13. The cushion assembly of claim 12, wherein the trench width is from about 2 mm to about 4 mm.

14. The cushion assembly of claim 12, wherein the trim clips include a base embedded in the bottom wall of the trench and the trim cover attachment member is substantially U-shaped having a first arm and a second arm, each arm being at least partially disposed in one of the first and second side walls of the trench, with the trim clips being connected to each other.

15. The cushion assembly of claim 12, wherein the opening is a generally rectangular-shaped slit.

16. The cushion assembly of claim 15, wherein the bottom surface has defined therein at least one access hole juxtaposed with the opening in the bottom wall of the trench to allow a tool to have access to the opening.

17. The cushion assembly of claim 12, the bottom wall of the trench being disposed between the top surface and the bottom surface of the cushion, and the trim cover attachment member being lockingly engageable with the attachment member of the trim cover.