DK202370030A1

DK202370030A1 - Spiral wound trim attachment

Info

Publication number: DK202370030A1
Application number: DKPA202370030A
Authority: DK
Inventors: Hallock Joshua; Blair Sam; Abdella David
Original assignee: Lear Corp
Priority date: 2022-06-28
Filing date: 2023-01-19
Publication date: 2024-02-15

Abstract

A seat cover attachment apparatus is disclosed that includes a mesh pad, a seat cover, and a spiral retainer. The mesh pad is made of polymer fibers bonded together by melted portions of the polymer fibers and the mesh pad is formed into a seat cushion. The seat cover includes tiedown strips attached to the seat cover that define a plurality of holes. The spiral retainer secures the tie-down strips to the polymer fibers with the spiral retainer being wound through the holes and looped into the welded polymer fibers. A method of attaching a seat cover to a seat structure and a machine for attaching a seat cover to a seat base and a seat back are also disclosed.

Description

DK 2023 70030 A1 1

SPIRAL WOUND TRIM ATTACHMENT

TECHNICAL FIELD

[0001] This disclosure relates to an apparatus and a method for attaching a seat cover to a seat structure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIGURE 1 is a fragmentary perspective view of a mesh body with a seat cover tie down strip retained by a spiral retainer.

[0003] FIGURE 2 is a diagrammatic elevation view of a portion of a seat cover retained with a tie down strip that is held with a spiral retainer in the mesh body.

[0004] FIGURE 3 is a cross section view taken along the line 3-3 in Figure 2.

[0005] FIGURE 4 is a elevation view showing the mesh body being flexed to open a groove to receive the tie down strip prior to insertion of the spiral retainer.

[0006] FIGURE 5 is an exploded perspective view of the mesh body that defines a groove for receiving the tie down strip with the spiral retainer, and a guide comb used to align the spiral retainer with the holes defined in the tie down strip.

DETAILED DESCRIPTION

[0007] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments.

However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

DK 2023 70030 A1 2

[0008] It is to be understood that the disclosed embodiments are merely exemplary and that various and alternative forms are possible. 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 are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ embodiments according to the disclosure.

[0009] "One or more” includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

[0010] It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms.

These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0011] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or "comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

[0012] As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the

DK 2023 70030 A1 3 phrase "ifit is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean "upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

[0013] Referring to Figure 1, a portion of a seat structure 10 is illustrated that includes a mesh pad 12 that is made up of polymer fibers 14. The polymer fibers are thermoplastic fibers that are, in one embodiment, polyethylene fibers. The polymer fibers are spun and heated in a mold or die and formed into the shape of a seat base, seat back, or another padded trim piece.

[0014] A tie down strip 16 is attached by a spiral retainer 18. The tie down strip 16 defines a plurality of equally spaced holes 20 and includes a reinforcement bead 22. The spiral retainer 18 is rotated, or turned, as it is wound into the mesh pad 12, the holes 20 in the tie down strip 16 and around the reinforcement bead 22. The tie down strip 16 is retained in a groove 24 by the spiral retainer 18 to retain the seat cover 26 on the seat structure 10.

[0015] Referring to Figure 2, the seat structure 10 is shown in cross section the spiral retainer 18 is shown to have looped through the polymer fibers of the mesh pad. The spiral retainer 18 also engages the tie down strip 16 by being wound through the holes 20 and also encircles the reinforcement bead 22. The spiral retainer 18 includes a radial leg 23 that is engaged by a rotating tool to wind the spiral retainer 18 into the mesh pad 12 and the tie down strip. The tie down strip 16 1s disposed in the groove 24 and is connected to the seat cover 26 that is shown to be overlying the mesh pad 12.

[0016] Referring to Figure 3, that is a section through the tie down strip 16 the spiral retainer 18 is shown as it is looped through the welded polymer fibers 14 and the holes 20 defined by the tie down strip 16. The reinforcement bead 22 is disposed inside the spiral retainer 16.

[0017] Referring to Figure 4, the mesh pad 12 is shown being flexed to open the groove 24 to facilitate inserting the tie down strip 16 with the reinforcement bead 22 in the predetermined location in the bottom of the groove 24. The tie down strip is connected to the seat cover 26 that is folded over to provide access to the groove 24.

DK 2023 70030 A1 4

[0018] Referring to Figure 5, the component parts of the apparatus are shown. The mesh pad 12 is made up of the polymer fibers 14 and defines a groove 24. The spiral retainer 18 is shown adjacent to a guide comb 28 that includes a plurality of equally spaced teeth 30 that are separated by gaps 32. The gaps 32 correspond to the spacing between the holes 20 formed in the tie down strip 16. When the guide comb 28 and the tiedown strip 16 are placed in the groove 24, the gaps 32 defined between the teeth 30 are aligned with the holes 20. The helical wraps of the spiral retainer have the same spacing as the gaps 32 and holes 20 so that once the spiral retainer begins to be wound through the holes 20 it is fed through the holes. The spiral retainer 18 is also wound through the polymer fibers 14 that are randomly located in the mesh pad 12 but sufficiently packed together to firmly retain the tie down strip in the groove 24 defined by the mesh pad 12.

[0019] A machine for inserting the spiral retainer 18 is partially illustrated in Figure 5. The machine includes a fixture 34 for holding the mesh pad 12. The spiral retainer 18 is shown to be engaged by a rotating tool 36 that engages and rotates the radial leg 23. The guide comb 28 is aligned with the holes 20 in the tie down strip 16 and receives the spiral retainer 18 as it guides the spiral retainer 18 into the holes 20. At the same time, the spiral retainer winds through the polymer fibers 14 of the mesh pad 12.

[0020] According to one aspect of this disclosure, a method is disclosed for attaching a seat cover to a seat structure including a resilient seat cushion. The method includes the steps of selecting a mesh pad of welded polymer fibers and selecting a cover including tie down strips. The tie down strips are inserted into grooves defined in predetermined locations within the mesh pad. The tie down strip defines a plurality of equally spaced holes above a reinforcement bead that is attached to the tie down strip. A spiral retainer is turned through the welded polymer fibers of the mesh pad and around the reinforcement bead, through the tie down strips, and in the groove, wherein the spiral retainer is wound through the plurality of equally spaced holes and the welded polymer fibers to hold the tie down strips in the predetermined locations.

[0021] The above method in some embodiments includes forming the mesh pad into the shape of a seat cushion. According to one embodiment the tie down strips are sewn to the seat cover. One approach includes inserting a guide comb in the groove to align the equally spaced holes with gaps defined by the guide comb and a plurality of turns of the spiral retainer. The method further

DK 2023 70030 A1 comprises guiding the spiral retainer as the spiral retainer is turned into the mesh body, the holes and the groove.

[0022] According to another aspect of this disclosure, an apparatus comprising is disclosed the includes a mesh pad, a seat cover, and a spiral retainer. The mesh pad is made of polymer fibers bonded together by melted, such as welded, portions of the polymer fibers and the mesh pad is formed into a seat cushion. The seat cover includes tie-down strips attached to the seat cover that define a plurality of holes. The spiral retainer secures the tie-down strips to the polymer fibers with the spiral retainer being wound through the holes and the spiral retainer being looped into the welded polymer fibers, such as into the melted portions of polymer fibers.

[0023] The seat cover in one embodiment is formed by sewing together a plurality of sections of cover material and attaching the plurality of sections of cover material to the tie down strips. The mesh pad of polymer fibers defines a plurality of grooves recessed into the mesh pad. In some embodiments the tie down strips are plastic strips that include a bead reinforcement. The tie down strips each include a bead reinforcement and a flexible flange that are sewn or ultrasonically welded to an edge of the seat cover. The tie down strips in some embodiments each include a bead reinforcement and a flexible flange that are formed as a combination.

[0024] The mesh pad defines grooves, the seat cover includes segments of flexible sheet material that are sewn together with the tie down strips that are received in the grooves and the tie down strips are disposed in the grooves with a guide comb when the spiral retainer is wound through the groove to secure the tie down strips to the welded polymer fibers. The welded polymer fibers hold the spiral retainer in the mesh body.

[0025] According to another aspect of this disclosure, a machine is disclosed for attaching a seat cover to a seat structure that includes a mesh pad of polymer fibers. The machine includes a fixture that receives the mesh pad of polymer fibers bonded together in a form of a seat cushion, a seat cover including tie down strips defining a plurality of holes, and a guide. The polymer fibers may be bonded together by melting, such as welding, the polymer fibers, such as portions of the polymer fibers, together. A rotary tool includes a spiral retainer that is rotated into the fixture and a groove defined by the mesh pad. The spiral retainer is wound into the plurality of holes and

DK 2023 70030 A1 6 through the welded polymer fibers of the mesh pad to hold the tie down strip in a predetermined location in the mesh pad.

[0026] Other potential features of the machine are that the machine also includes a guide comb including a plurality of teeth that define tooth gaps. The guide comb includes a plurality of teeth that define tooth gaps that are spaced apart by the distance between each of the plurality of holes.

The tie down strips include a plastic reinforcement bead and a flexible flange that are attached to the seat cover.

[0027] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms according to the disclosure. In that regard, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure.

Additionally, the features of various implementing embodiments may be combined to form further embodiments according to the disclosure. For example, the terms “welded polymer fibers”, “melted portions of polymer fibers”, and “polymer fibers bonded together” may herein be used interchangeably to describe polymer fibers bonded together by melting, such as welding, the polymer fibers.

Claims

DK 2023 70030 A1 7 CLAIMS

1. A method comprising: selecting a mesh pad of welded polymer fibers, the mesh pad defining a plurality of grooves in predetermined locations; selecting a cover including tie down strips; inserting at least one of the tie down strips into at least one of the grooves defined in the mesh pad, wherein each of the tie down strips defines a plurality of equally spaced holes above a reinforcement bead that is attached to the tie down strip; and turning a spiral retainer through the welded polymer fibers of the mesh pad and around the reinforcement bead, through the tie down strip, and in the groove, wherein the spiral retainer is wound through the plurality of equally spaced holes and the welded polymer fibers to hold the tie down strips in the predetermined locations.

2. The method according to the preceding claim further comprising: forming the mesh pad into the shape of a seat cushion.

3. The method according to any preceding claim further comprising: sewing the tie down strips to the cover, wherein the cover is a seat cover.

4. The method according to any preceding claim further comprising: inserting a guide comb in the groove to align the equally spaced holes, with gaps defined by the guide comb, and a plurality of turns of the spiral retainer.

5. The method according to any preceding claim further comprising: inserting a mandrel into the spiral retainer, and guiding the spiral retainer as the spiral retainer is turned into the mesh body.

6. A vehicle seat made according to the method of any of the preceding claims.

7. An apparatus comprising: a mesh pad of polymer fibers bonded together by melted portions of the polymer fibers, wherein the mesh pad is formed into a seat cushion;

DK 2023 70030 A1 8 a seat cover including tie-down strips attached to the seat cover, wherein the tie down strips define a plurality of holes; and a spiral retainer securing the tie-down strips to the polymer fibers with the spiral retainer being wound through the holes and the spiral retainer being looped into the welded polymer fibers.

8. The apparatus according to claim 7, wherein the seat cover is formed by sewing together a plurality of sections of cover material and attaching the plurality of sections of cover material to the tie down strips.

9. The apparatus according to any one of the claims 7-8, wherein the mesh pad of polymer fibers defines a plurality of grooves recessed into the mesh pad.

10. The apparatus according to any one of the claims 7-9, wherein the tie down strips are plastic strips that include a bead reinforcement.

11. — The apparatus according to any one of the claims 7-10, wherein the tie down strips each include a bead reinforcement and a flexible flange that are sewn to an edge of the seat cover.

12. The apparatus according to any one of the claims 7-11, wherein the tie down strips each include a bead reinforcement and a flexible flange that are formed as a combination.

13. The apparatus according to any one of the claims 7-12, wherein the mesh pad defines grooves, the seat cover includes segments of flexible sheet material that are sewn together with the tie down strips, wherein the tie down strips are received in the grooves and the tie down strips are disposed in the grooves with a guide comb when the spiral retainer is wound through the groove to secure the tie down strips to the welded polymer fibers.

14. The apparatus according to any one of the claims 7-13, wherein the welded polymer fibers hold the spiral retainer in the mesh body.

15. The apparatus according to any one of the claims 7-14, wherein the polymer fibers are polyethylene.

DK 2023 70030 A1 9

16. A machine comprising: a fixture that receives a mesh pad of polymer fibers bonded together in a form of a seat cushion, a seat cover including tie down strips defining a plurality of holes, and a guide; and a rotary tool including a spiral retainer that is rotated into the fixture and a groove defined by the mesh pad, wherein the spiral retainer is wound into the plurality of holes and through the welded polymer fibers of the mesh pad to hold the tie down strip in a predetermined location in the mesh pad.

17. The machine according to claim 16 further comprising: a guide comb including a plurality of teeth that define tooth gaps.

18. The machine according to any one of claims 16-17, wherein the guide comb includes a plurality of teeth that define tooth gaps that are spaced apart by the distance between each of the plurality of holes.

19. The machine according to any one of claims 16-18, wherein the tie down strip includes a plastic reinforcement bead and a flexible flange that are attached to the seat cover.

20. The machine according to any one of claims 16-19, wherein the polymer fibers are thermoplastic polymer fibers.