Vehicle seating system and method for producing same

A vehicle seating system and a method for producing a vehicle seating system may include a cushion made at least in part from a stranded-mesh material and configured to support a seated occupant. Also included may be a support structure configured to support the cushion and a trim-cover material configured to be disposed over at least a portion of the stranded-mesh material. The stranded-mesh material may include an integrated attachment arrangement configured to receive a fastening arrangement for securing the trim-cover material to the stranded-mesh material.

TECHNICAL FIELD

The present disclosure relates to a vehicle seating system and a method for producing a vehicle seating system.

BACKGROUND

Vehicle seating systems may be relatively simple structures—e.g., an assembly of a frame, one or more cushions, and a cover material. Conversely, they can be extremely complex systems that include electromechanical or pneumatic back support, occupancy sensors, seatbelt sensors, and myriad different types of sophisticated ventilation systems, just to name a few of the possible features. One component that is common to most of these seating systems is a cushion, and in many cases a number of different cushions to provide support and comfort to a seated occupant. Many of these cushions are made from a foam material, such as injection-molded polyethylene. Injection-molded polymeric foams can be configured to accommodate seating systems with different properties. For example, the density of the foam may be engineered to provide a desired amount of support for a seated occupant, and to accommodate various ancillary systems, such as a ventilation system.

One limitation of this configuration is that the weight of the seat cushion may increase significantly when the density of the foam is increased. To address this limitation, alternative materials are being increasingly used for vehicle-seat cushions. For example, a stranded-mesh material may be used to form at least part of the seat cushion, and depending on the material used and how the strands are integrated to form the mesh, a relatively low density stranded-mesh material may provide the same or similar support as a much higher density injection-molded foam material. One limitation of using a stranded-mesh material for a seat cushion is the difficulty in attaching a trim cover to this material. To avoid sagging and bagginess, trim covers are usually secured in several places inside the seat cushion. And unlike a relatively dense injection-molded foam, it may be difficult to integrate trim-cover fasteners into a stranded-mesh material. Therefore, a need exists for a system and method for overcoming the limitations of a stranded-mesh seat cushion.

SUMMARY

Embodiments described herein may include a vehicle seating system having a cushion made at least in part from a stranded-mesh material and configured to support a seated occupant. The seating system may also include a support structure configured to support the cushion, and a trim-cover material configured to be disposed over at least a portion of the stranded-mesh material. The stranded-mesh material may include an integrated attachment arrangement configured to receive a fastening arrangement for securing the trim-cover material to the stranded-mesh material.

Embodiments described herein may include a vehicle seating system that includes a stranded-mesh material forming a cushion configured to support a seated occupant and including an integrated attachment arrangement. The vehicle seating system may also include a support structure configured to support the cushion, and a trim-cover material configured to be disposed over at least a portion of the cushion. The integrated attachment arrangement may be configured to receive a fastening arrangement for securing the trim-cover material to the stranded-mesh material.

Embodiments described herein may include a method for producing a vehicle seating system that includes providing a cushion configured to support a seated occupant. The cushion may be formed at least in part from a stranded-mesh material having a plurality of integrated polymeric strands. The method may also include integrating an attachment arrangement in the stranded-mesh material, where the integrated attachment arrangement is configured to receive a fastening arrangement for securing a trim-cover material to the stranded-mesh material.

DETAILED DESCRIPTION

FIG.1shows a portion of a vehicle seating system10in accordance with embodiments described herein. More specifically,FIG.1shows a seat back12that includes a cushion14and a support structure, such as a seat frame16, configured to support the cushion14. Although the embodiment shown inFIG.1is illustrated and described in terms of a vehicle seat back, it is understood that embodiments described herein may also apply to a seat bottom. In the embodiment shown inFIG.1, the cushion14is made from a stranded-mesh material18, which is shown in more detail inFIG.2. As shown inFIG.1, there are several openings11,13,15in the cushion14. The openings11,13,15provide access to attachment features positioned within the stranded-mesh material18, which, as explained in more detail below in conjunction withFIGS.3-5, provide points of attachment for a trim-cover material.

In the embodiment shown inFIG.2, the stranded-mesh material18is made from a polymeric mesh20having a plurality of integrated polymeric strands22—for clarity, only some of the strands22are labeled. The stranded-mesh material18includes a first surface24and a second surface26positioned opposite to the first surface24. As shown inFIG.2, the first surface24is substantially closed, while the second surface26is substantially open. The substantially closed surface24may include small or even microscopic pores, but the majority of the surface24is closed and would need to be penetrated to access the polymeric mesh20below. One method for producing a closed surface on a polymeric mesh such as shown inFIG.2is to apply heat and force until at least some of the strands22melt into each other to form the surface24.

In the embodiment shown inFIG.2, a force of about 20 pounds and a temperature of about 450° F. is sufficient to create the substantially closed surface24. Different amounts of force and heat may be used for stranded-mesh materials made from different polymers or other materials, or for different densities and configurations of the integrated strands, such as the strands22. The stranded-mesh material18may be made from, for example, a linear low density polyethylene material, although other polymers and materials effective to provide the desired properties and functionality are contemplated. As described in more detail below, the substantially closed surface24may form a substrate for the stranded-mesh material18, which may be used for a number of things, including inhibiting liquid and gas penetration—including, for example, to make the surface airtight—and to facilitate attachment of a trim-cover material. Although the embodiment shown inFIG.2includes a substantially closed surface and a substantially open surface, other embodiments may have any number of substantially closed or substantially open surfaces, exclusively or in combination—including not just the top and bottom surfaces as shown inFIG.2, but also on one or more of the edge surfaces.

FIG.3shows a cross-sectional view of a portion of the cushion14, and in particular, a cross section of the stranded-mesh material18shown inFIG.2. The first and second surfaces24,26are reversed from the orientation shown inFIG.2. In practice, the first surface24, which as described above forms a type of substrate, may provide support for an attachment feature such as a trim clip28illustrated inFIG.3. The trim clip28may be bonded to the substrate24with heat and force, or by an adhesive. Alternatively, a trim clip may be attached to a stranded-mesh material by any other means effective to create a secure attachment. The trim clip28may be part of an integrated attachment arrangement30that also includes the aperture11in which the trim clip28is positioned. Although the aperture11is shown inFIG.3as an example, the other apertures13,15—seeFIG.1—may also include trim clips or other attachment features for securing a trim-cover material.

As shown inFIG.3, the second surface26of the stranded-mesh material18is the A-surface—i.e., it is configured to receive a trim-cover material over it. Conversely, the substrate24is configured as the B-surface positioned downward when used on a seat bottom and toward the back when used on a seat back. In the embodiment shown inFIG.3, the aperture32is disposed through a thickness (T) of the stranded-mesh material18, including through the first and second surfaces24,26. As shown inFIG.3, the thickness (T) is bounded by the first surface24and the second surface26. As described above, the trim clip28is attached to the second surface24of the stranded-mesh material18, and as shown inFIG.3, it extends into the aperture32, but is positioned below the second surface26.

As described above, embodiments described herein may include a fastening arrangement for securing a trim-cover material to the stranded-mesh material18.FIGS.4A-4Cshow several types of fastening arrangements that may be used. More specifically,FIG.4Ashows a fastening arrangement34that includes an arrow-type tie-down36, which may be sewn to a trim-cover material38along a sewing seam40. The arrow-type tie-down36may readily attach to the trim clip28shown inFIG.3. Similarly, a fastening arrangement42includes a tie-down44, shown inFIG.4B; it is also sewn to a trim-cover material46along a sewing seam48. Rather than having an arrowhead at its end, the tie-down44includes a round bead50that may also conveniently attached to a trim clip, such as the trim clip28shown inFIG.3. The fastening arrangements34,42may be used with other types of trim clips or attachment features, such as a T-shaped attachment feature that allows the arrowhead49or the round head50to be secured to it. Finally,FIG.4Cshows another type of fastening arrangement52, which is also attached to a trim-cover material54along a sewing seam56.

As shown inFIG.4C, the fastening arrangement52includes a fastener58that has neither an arrowhead nor a round head such as the tie-downs36,44. Rather, this type of fastening arrangement may be referred to as a “loose T” and may be effective for attaching the trim-cover material54to an attachment arrangement60integrated into a stranded-mesh material62such as shown inFIG.5. As shown inFIG.5, the stranded-mesh material62includes a substantially closed surface64and a substantially open surface66positioned opposite the surface64. The attachment arrangement60in this embodiment includes only an aperture68positioned through a thickness of the stranded-mesh material62, including through the surfaces64,66. As described above, the fastening arrangement52shown inFIG.4Cmay be used to secure the trim-cover material54to the stranded-mesh material62. In particular, ends of the fastener58may be inserted into spaces in the stranded-mesh material52, which keeps the trim-cover material54secured.

Although the embodiments described above are largely directed to a vehicle seating system, embodiments also contemplate a method for producing such a vehicle seating system. In at least some embodiments, the method may include providing a cushion formed at least in part from a stranded-mesh material, such as the material18illustrated and described above. The method may also include integrating an attachment arrangement, such as the attachment arrangements30,60illustrated inFIG.3andFIG.5, respectively. Embodiments of the method may also include forming a substantially closed surface on the stranded-mesh material by melting at least some of the integrated polymeric strands—see, e.g., the surface24inFIG.3. An aperture may be formed through a thickness of the stranded-mesh material, such as the aperture32shown inFIG.3. As described above, the aperture32is configured to receive a fastening arrangement, such as the trim clip28. Finally, embodiments of the method may include positioning a trim clip in the aperture and then attaching the trim clip to the substantially closed surface, such as illustrated inFIG.3and described above.