SEAT ASSEMBLY HAVING IMPROVED TRIM APPEARANCE AND METHOD AND TOOL FOR MAKING THE SAME

• US 20150175042A1
• Filed: 02/08/2013
• Published: 06/25/2015
• Est. Priority Date: 05/07/2012
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Galbreath, Ashford A., Ali, Asad S., Severinski, Paul S., Rock, Gary, Clauser, James B., Patterson, Louella Ann, Welch, Thomas A. Sr., Lymburner, Gregory Alan
• Granted Patent: US 10,160,357 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 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 engagable with an attachment member of the trim cover.

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 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.

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

8. The cushion assembly of claim 6, 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.

9. The cushion assembly of claim 8, wherein the access hole has a diameter that increases in a direction from the opening towards the bottom surface.

10. The cushion assembly of claim 8, 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.

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

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

13. A mold tool comprising:

a first mold half and a second mold half, the first and second mold halves forming a mold cavity when closed;

at least one elongated tool insert attached to one of the first mold half and the second mold half, the at least one tool insert having a base and a protruding portion extending from the base, the protruding portion having a first side wall and a second side wall and a tip;

wherein the protruding portion has a substantially constant width between the first and second side wall of up to about 5 mm along substantially an entire length of the elongated tool insert and is configured to form a trench in a molded part having a substantially constant width of up to about 5 mm.

14. The mold tool of claim 13, wherein the protruding portion has a width from about 2 mm to about 4 mm.

15. The mold tool of claim 13, wherein the protruding portion has a width of about 3 mm.

16. The mold tool of claim 13, wherein the protruding portion is configured to receive at least one trim clip female attachment portion having at least a first arm and a second arm.

17. The mold tool of claim 16, wherein the protruding portion has at least one notch defined in at least one of the first and second side walls configured to accept a protrusion of an arm of the female attachment portion, thereby providing a locating feature for attaching the female attachment portion.

18. The mold tool of claim 16, wherein the protruding portion has at least one pair of notches defined in the first and second side walls, the pair of notches being juxtaposed on each of the first and second side walls to accept a protrusion of an arm of the female attachment portion, thereby providing a locating feature for attaching the female attachment portion.

19. The mold tool of claim 17, wherein the at least one notch has a depth of 0.1 mm to 0.3 mm.

20. A cushion assembly comprising:

a 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;

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 engagable 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.