Note: Descriptions are shown in the official language in which they were submitted.
CA 02368739 2002-O1-21
VEHICLE SEAT FASTENER ASSEMBLY
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The subject invention relates to a fastener assembly for a vehicle seat
to secure a
trim cover to a foam pad.
2. Description of the Prior Art
[0002] During the manufacture of automotive seat cushions and seat backs, a
trim cover is
typically affixed to a foam pad. As appreciated, most seat cushions and seat
backs include
trenches and other styling lines. Fasteners are usually mounted to the trim
cover and foam
pad along these style lines to secure the trim cover to the foam pad. These
fasteners also act
as a locator to assist in correctly positioning the trim cover over the foam
pad.
[0003] One such fastener for affixing the trim cover to the foam pad utilizes
hook and loop
fasteners, such as shown in U.S. Patent No. 5,236,243. lfn particular, the
hook fastener is
mounted to the trim cover and the loop fastener is mounted to a corresponding
area of the
foam pad. During installation, the hook fastener is overlaid upon the loop
fastener to secure
the trim cover to the foam pad. The hook and loop fasteners, however, are
expensive and
prone to misalignment. In addition, the hook and loop fasteners do not include
any type of
visual or mechanical alignment devices.
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[0004] Another common method, such as shown in U.S. Patent No. 4,865,383,
utilizes what
is known in the art as hog rings. The hog rings method :has a number of
preformed wires
conforming to the unique contours of the foam pad anal small rings or hooks
sewn or
otherwise mounted to the trim cover. During installation, the rings engage and
secure to the
wires which in turn secures the trim cover to the foam pad. Although the
material to
manufacture the rings and wires is inexpensive, the hog ring wires must be
custom designed
to conform to the various contours of each foam pad. In other words, there are
a number
of unique wires for both the seat cushion and seat back foam pads of each
seat. Further,
connecting the hog rings to the wires is a difficult assembly requiring a
large effort by the
installer. Finally, the hog ring method does not include any type of visual or
mechanical
alignment device.
[0005] Yet another design of the fasteners includes a plastic base molded into
the foam pad
and a plastic strip sewn to the trim cover. Examples of these fasteners are
shown in U.S.
Patent Nos. 3,794,378 and 5,964,017. Either the base or the strip has a
locking portion and
the other has a retaining portion. During installation of the trim cover over
the foam pad,
the locking portion engages the retaining portion to secure the trim cover to
the foam pad.
Although easier to install than the hog rings, these plastic fasteners also
have a number of
deficiencies. First, the fasteners are relatively stiff and therefore create
hard channels in the
seat which can be uncomfortable. Secondly, these stiff fasteners can have
difficulty
conforming to the contours of a seat cushion or seat back. Finally, the
plastic fasteners do
not include any type of visual or mechanical alignment devices.
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[0006] Accordingly, it would be desirable to provide a fastener assembly for a
trim cover
which is inexpensive to manufacture, can be used on a wide range of foam pad
designs,
provides a comfortable seating surface, prevents misalignment, and is easy to
install.
SUMMARY OF THE INVENTION ANI) ADVANTAGES
[0007] A fastener assembly for securing a trim cover to~ a contoured foam pad
of a seat.
The fastener assembly comprises a restraint portion secured to the trim cover
and a
locking portion secured to the foam pad. The locking portion includes a least
one clip for
selectively engaging the restraint portion to retain the restraint portion to
the locking
portion during a mounting of the trim cover over the foam pad. The locking
portion
further includes at least one base with the base having at least one flexible
section such
that the locking portion can be manipulated and conform to the contoured foam
pad.
[0008] The restraint portion also includes a plurality of apertures formed
therein.
Preferably, the locking portion includes at plurality of spaced clips. The
spaced clips
selectively engage and retain the restraint portion and extending into the
apertures to
provide a visual alignment feature between the restraint portion and the
locking portion
for properly aligning the trim cover with the foam pad during a mounting of
the trim cover
over the foam pad.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention will be readily appreciated
as the same
becomes better understood by reference to the following detailed description
when
considered in connection with the accompanying drawings wherein:
[0010] Figure 1 is a perspective view of an automotive seat incorporating a
fastener
assembly therein;
[0011] Figure 2 is a fragmentary perspective view of the seat further
illustrating the
fastener assembly;
[0012] Figure 3 is a perspective view of the fastener assembly including a
restraint portion
and a locking portion with the portions being disengaged;
[0013] Figure 4 is a top view of the fastener assembly illustrating the
flexibility of the
assembly;
[0014] Figure 5 is a side view of the fastener assembly further illustrating
the flexibility
of the assembly;
[0015] Figure 6 is a perspective of the fastener assembly with the restraint
portion engaged
with the locking portion;
[0016] Figure 7 is a cross sectional side view of the fastener assembly with
the restraint
portion disengaged from the locking portion;
[0017] Figure 8 is a cross sectional side view of the fastener assembly with
the restraint
portion engaged to the locking portion;
[0018] Figure 9 is a perspective view of a molding assembly having contoured
ridges;
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[0019] Figure 10 is a cross sectional side view of the molding assembly;
[0020) Figure 11 is a cross sectional side view of the molding assembly with
the locking
portion of the fastener assembly attached thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Referring to the Figures, wherein like numerals indicate like or
corresponding
parts throughout the several views, an automotive seat is generally shown at
20 in Figure
1. The seat 20 includes a seat back 22 and a seat cushion 24. Referring also
to Figure 2,
both the seat back 22 and seat cushion 24 are formed of a contoured foam pad
26 having
a contoured outer surface 28. A trim cover 30 at least partially covers the
outer surface 28
of the foam pad 26 as is known in the art. The trim cover 30 is typically a
combination of
sewn pieces which allow the trim cover 30 to conform to the contours of the
foam pad 26.
When the trim cover 30 is sewn together this creates seams or styling lines 32
in the trim
cover 30. The trim cover 30 may be cloth, vinyl, leather, or the like. In
addition, the seat
back 22 and seat cushion 24 may be of any suitable design or configuration.
[0022] As shown in Figure 2 and in phantom in Figure l; a number of fastener
assemblies
34 secure the trim cover 30 to the foam pad 26. The fastener assemblies 34
illustrated are
examples of one implementation for the subject invention. It should be
appreciated that
fastener assemblies 34 of the subject invention may be incorporated into any
component of
the seat 20 in any suitable configuration as is known to those in the seating
art. The fastener
assemblies 34 of the subject invention are particularly useful for leather
trim covers due to
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the limited capability of adhering leather to foam pads and for cloth trim
covers where the
trim cover is not molded in-place or bonded to the foam pad.
[0023] The foam pad 26 has at least one elongated groove 36 formed within the
foam pad
26 below the outer surface 28. As discussed in greater detail below, the
groove 36 is
designed to house the fastener assembly 34 such that thf; trim cover 30 can be
secured to
the foam pad 26 along the grooves 36. The grooves 36 also track the styling
lines 32 in
the trim cover 30. Hence, for example, there are three styling lines 32 in the
trim cover
30 for the seat bottom 24. Accordingly, there are preferably three grooves 36
formed in
the foam pad 26 of the seat bottom 24. Also, the groove 36 includes a
contoured section
38, which defines curves and valleys for the styling lines 32. Preferably, the
groove 36
will have multiple contoured sections 38 depending upon the shape, design, and
configuration of the foam pads 26 for the seat back 22 and seat bottom 24.
Even more
preferably, the contoured section 38 of the groove 36 is substantially
parallel to the
contoured outer surface 28 of the foam pad 26 such that the groove 36
maintains a
substantially even depth.
[0024] Referring also to Figures 3 and 6, the fastener assembly 34 is shown in
greater
detail. In particular, the fastener assembly 34 comprises a restraint portion
40 and a
locking portion 42. Figure 3 illustrates the restraint poriton 40 disengaged
from the
locking portion 42 and Figure 6 illustrates the restraint portion 40 engaged
with the
locking portion 42.
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[0025] The locking portion 42 includes at least one clip 44 for selectively
engaging the
restraint portion 40 to retain the restraint portion 40 to the locking portion
42 during a
mounting of the trim cover 30 over the foam pad 26. The clip 44 includes
opposing legs
46 with each of the legs 46 having a barb 48.
S [0026] The locking portion 42 further includes at least one base 50 with the
base 50
having at least one flexible section 52 such that the locking portion 42 can
be manipulated
and conform to the contoured foam pad 26. Preferably, the locking portion 42
includes
a plurality of bases 50 and a plurality of flexible sections 52. In addition,
the locking
portion 42 preferably includes a plurality of clips 44 with at least one clip
44 disposed on
each of the bases 50.
[0027] Each of the flexible sections 52 are further defined as a connecting
arm 52 with the
arm interlinking the bases SO to form a series of bases 50 and arms 52. The
most
preferred embodiment of the locking portion 42 includes the series of square
bases 50 and
rectangular arms 52 extending in an alternating fashion with one of the clips
44 centrally
disposed on each of the bases 50. The series of locking portions 42 creates a
elongated
flexible locking device which can be manipulated and corijPormed as shown in
Figures 4 and
5. In particular, Figure 4 illustrates that the locking portion 42 can easily
conform to
relatively sharp turns or curves in the grooves 36 and Figure 5 illustrates
that the locking
portion 42 can conform to rises and valleys in the grooves 36. Hence, the
locking portions
42 are versatile in conforming to virtually any design or configuration of a
complex surface
which may be found on a foam pad 26. This greatly improves the flexibility of
the design.
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It should be appreciated that the locking portion 42 nnay be of any suitable
design or
configuration so long as the flexible characteristics of the locking portion
42 are
maintained.
[0028] The bases 50, flexible sections 52, and clips 44 are preferably
integrally formed
of a polymeric material, i. e. , polypropylene, such that it may be easily
formed and
integrated within the foam pad 26.
[0029] The restraint portion 40 includes a plurality of apertures 54 formed
therein.
Preferably, there is a corresponding aperture 54 in the restraint portion 40
for each clip
44 on the locking portion 42. The apertures 54 provide a visual alignment when
the
restraint portion 40 is engaged with the plurality of clips 44 for properly
aligning the trim
cover 30 with the foam pad 26 during a mounting of the trim cover 30 over the
foam pad
26. Preferably, the restraint portion 40 includes a flexible fabric 56 having
a first end and
a distal end with the apertures 54 formed within the flexible fabric 56. The
flexible fabric
56 is of a particular material which provides a desired amount of tension
force. Hence, any
pulling or movement of the trim cover 30 will not rip or tear the fabric. The
restraint
portion 40 further includes a bulbous member 58 mounted to the distal end of
the flexible
fabric 56. Preferably, the bulbous member 58 is formed of a polymeric
material.
[0030] As best shown in Figures 2, 7, and 8, the restraint portion 40 is sewn
or otherwise
affixed to the trim cover 30. The restraint portion 40 is preferably sewn into
the seam 32
of the trim cover 30. Even more preferably, the first end of the flexible
fabric 56 is sewn
or otherwise secured to one of the seams 32 of the trim cover 30. The locking
portion 42
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is integrally molded into the grooves 36 of the foam pad 26 with the clips 44
extending into
the groove 36. As appreciated, the locking portion 42 could be mounted to the
foam pad 26
by other means such as adhesives or fasteners without deviating from the
subject invention.
[0031] As best shown in Figure 8, when the restraint portion 40 is interlocked
with the
locking portion 42, the apertures 54 within the fabric 56 allow the locking
clips 44 to
substantially encompass a corresponding portion of the bulbous member 58.
Preferably, the
fabric 56 and the bulbous member 58 are of a length that correlates to the
desired length of
the locking portion 42.
[0032] Turning to Figures 9 through 11, a molding device 60 in accordance with
the
subject invention is shown. The molding device 60 includes an upper mold (not
shown)
and a lower mold 62 with at least one of the upper and lower 62 molds having a
contoured
ridge 64. The lower mold 62 illustrated in Figure 9 has three contoured ridges
64, which
correspond to the three contoured ridges 64 of the foamy pad 26 for the seat
cushion 24.
[0033] Figure 10 illustrates a cross sectional view of the lower mold 62 about
one of the
ridges 64. A retaining flange 66 is mounted to the contoured center ridge 64
and extends
upwardly therefrom. As shown in Figure 11, the retaining flange 66 engages the
clip 44
of the locking portion 42 to position the locking portion 42 within the
molding device 60
and to maintain the clip 44 free of the foam pad 26. A, pocket 68 may also be
formed
within the ridge 64 such that the barbs 48 of the clip 44 extend into the
ridge 64.
[0034] The method of forming the foam pad 26 and mounting the trim cover 30 to
the
foam pad 26 is now discussed in greater detail. Initially, the molding device
60 is free of
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foaming material (not shown) which forms the foam pad 26. The locking portion
42 is
mounted to at least one of the upper and lower molds 62 such that the locking
portion 42
conforms to the contoured ridge 64. Preferably, the locking portion 42 is
mounted to the
retaining flange 66 such that the locking portion 42 conforms to the contoured
ridge 64.
Even more preferably, the series of bases 50 and clip;> 44 are mounted in the
molding
device 60 with the clips 44 mounted to the retaining flange 66 to conform the
entire
locking portion 42 to the contoured ridge 64 along a majority of the length of
the
contoured ridge 64. The clips 44 may be held into position on the retaining
flange 66 by
frictional forces. In addition, a bead or other projection (not shown) may be
provided on
the retaining flange 66 to assist in the retention of the clips 44.
[0035] The upper mold closes upon the lower mold 62 and the foaming material
is
introduced to the molding device 60 as is known in the seat manufacturing art.
The foam
pad 26 is then formed within the molding device 60. Thf: groove 36 is also
formed within
the foam pad 26 at the contoured ridge 64 during the forming of the foam pad
26 wherein
the groove 36 includes the contoured section 38 or sections. The base SO of
the locking
portion 42 is secured to the foam pad 26 within the contoured section 38 of
the groove 36
during the forming of the foam pad 26, see Figure 11. la should be appreciated
by those
skilled in the art that the forming of the groove 36 within the foam pad 26
and the securing
of the base 50 of the locking portion 42 to the foam pad 26 occur
simultaneously during
the step of forming the foam pad 26. With the clips 44 positioned on the
retaining flange
66, the clips 44 are protected from unwanted intrusion of foam material. It
should be
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appreciated that the presence of foam material between the clips 44 could
significantly
reduce the effective operation of the clips 44.
[0036] During the manufacture of the seat back 22 and seat cushion 24, the
foam pad 26 is
formed separately from the trim cover 30. Once the pieces of the trim cover 30
have been
made, the trim cover 30 is sewn together with the restraint portion 40 being
secured to the
trim cover 30. As discussed above, the restraint portion 40 can be sewn within
the seams
or style lines 32 of the trim cover 30.
[0037] The foam pad 26, with the locking portion 42, is then removed from the
molding
device 60. The trim cover 30 is overlaid onto the foam pad 26 with the seams
or style
lines 32 being generally aligned with the grooves 36 in the foam pad 26 such
that the
restraint portions 40 are positioned at least partially within the grooves 36,
see Figure 7.
The trim cover 30 is then manipulated and orientated to interlock the
restraint portion 40
with the clip 44 of the locking portion 42 to secure the trim cover 30 to the
foam pad 26.
Specifically, an installer visually aligns the first aperture _'i4 of the
restraint portion 40 with
the first clip 44 on the locking portion 42. Due to the relative positions of
the apertures 54
and clips 44, aligning the first aperture 54 and clip 44 automatically aligns
all of the
apertures 54 and clips 44 as well as the entire fastener assembly 34.
[0038] The installer then pushes downward on the seam or style line 32 which
pushes the
bulbous member 58 into engagement with the locking clips 44. The legs 46 of
the clips 44
deform slightly outward such that the bulbous memher 58 may pass between the
corresponding barbs 48. As appreciated, the clips 44 are substantially aligned
with the
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apertures 54 of the flexible fabric 56. Hence, the clips 44 are able to snap
back into position
such that the barbs 48 will substantially encapsulate the bulbous member 58,
see Figure 8.
This procedure is repeated for each seam or style line 32. Accordingly, each
of the restraint
portions 40 are then engaged with a corresponding locking portion 42. The
mechanical
engagement of the restraint portions 40 with the locking portions 42 creates a
secure
engagement between the trim cover 30 and the foam pad 26.
[0039] As discussed above, the fastener assembly 34 also ensures proper
alignment of the
seams or style lines 32 within the grooves 36 of the foam pad 26 which creates
an
aesthetically pleasing appearance. Due to the positioning of the fastener
assemblies 34 and
the apertures 54, the trim cover 30 is correctly positioned onto the foam pad
26 in both
horizontal directions as well as the vertical direction. The remaining
portions of the trim
cover 30 are then secured to the foam pad 26 as is known in the art.
[0040] Obviously, many modifications and variations of the present invention
are possible
in light of the above teachings and the invention may be practiced otherwise
than as
specifically described within the scope of the appended claims.
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