Quick-connect trim carrier attachment

A quick-connect assembly for a vehicle seating assembly includes a seatback structure. A suspension assembly includes a plurality of outwardly extending flex members. A removable trim carrier is disposed over upper and lower components and is removably coupled to distal ends of the plurality of outwardly extending flex members by a friction-fit connection. A cushion is operably coupled with the trim carrier. An external peripheral gap is defined between the passenger support and the seatback structure.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle seating assembly, and more particularly to a vehicle seating assembly with a quick-connect trim carrier attachment.

BACKGROUND OF THE INVENTION

Vehicle seating assemblies typically includes a cover stock material disposed over a cushion of the seat or seatback to support a passenger. Commonly, upon assembly, the cover stock material is sewn into a sock-like configuration that is stretched and pulled over the cushion and other portions of the seating assembly, such as the entire seat or seatback. Accordingly, these seating assemblies can be difficult to reupholster and can be easily damaged when accessing components within the seat or seatback.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a quick-connect assembly for a vehicle seating assembly includes a seatback. A suspension assembly includes a plurality of outwardly extending flex members. A removable trim carrier is disposed over upper and lower components and is removably coupled to distal ends of the plurality of outwardly extending flex members by a friction-fit connection. A passenger support is operably coupled with the trim carrier. An external peripheral gap is defined between the passenger support and the seatback.

According to another aspect of the present invention, a vehicle seating assembly includes a seatback. First and second suspension components each include at least two outwardly extending flex members. A trim carrier includes a plurality of engagement members removably coupled with a securing feature disposed on the distal ends of the flex members. An external peripheral gap is defined between the seatback and the trim carrier.

According to yet another aspect of the present invention, a vehicle seating assembly includes a seatback. An upper suspension assembly includes outwardly extending flex members operably coupled to an upper trim carrier. A lower suspension assembly includes outwardly extending flex members operably coupled to a lower trim carrier. A passenger support is operably coupled with the upper and lower trim carriers. An external peripheral gap is defined between the upper and lower trim carriers and the seatback.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring toFIGS. 1-13, reference numeral10generally designates a quick-connect assembly for a vehicle seating assembly12that includes a seatback14. A suspension assembly16includes a plurality of outwardly extending flex members18. A removable trim carrier20is disposed over upper and lower components22,24and is removably coupled to distal ends26of the plurality of outwardly extending flex members18by a friction-fit connection28. A cushion30is operably coupled with the trim carrier20. An external peripheral gap32is defined between the trim carrier20and the seatback14.

Referring now toFIG. 1, the vehicle seating assembly12is positioned in a driver's side location of a vehicle34. The vehicle seating assembly12includes a seat36that is pivotally coupled with the seatback14about a recliner mechanism38for pivotally adjusting the seatback14relative to the seat36. The seat36is slideably coupled with a floor40of the vehicle34about a track assembly42. The track assembly42is configured to allow the vehicle seating assembly12to be adjusted in a forward and rearward direction relative to the vehicle34. It is understood that the vehicle seating assembly12may be positioned at various locations throughout the vehicle34other than the illustrated position, such as the passenger side location, a mid-row location, and a rear seat location. It is also conceivable that the seat36may not include the track assembly42and may be fixedly or alternatively coupled with the floor40of the vehicle34.

As illustrated inFIG. 2, the seatback14of the vehicle seating assembly12has a head restraint44coupled with a top portion46of the seatback14to support a passenger's head. The suspension assembly16is coupled with the seatback14between the head restraint44and the seat36. The suspension assembly16includes a first suspension component48positioned above a second suspension50component, such that the first suspension component48may be referred to as the upper component22and the second suspension component50may be referred to as the lower component24. The quick-connect assembly10includes a passenger support52is removably coupled with the suspension assembly16to support a passenger's back. More specifically, an upper segment54and a lower segment56of the passenger support52are removably coupled, respectively, with the upper component22and the lower component24of the suspension assembly16. It is conceivable that the suspension assembly16may be alternatively shaped and/or positioned on the seatback14and may include more suspension components or a single suspension component spanning over the seatback14. Accordingly, it also conceivable that the passenger support52may vary in shaped and/or position on the seatback14and may include more or fewer segments, consistent with or divergent from the number of suspension components. In addition, it is contemplated that the head restraint44may be integrated with the top portion46of the seatback14or may otherwise not be included on the vehicle seating assembly12.

As shown in the embodiment illustrated inFIG. 3, the seatback14includes a seatback structure58that has a first side support60and a second side support62extending upward in generally parallel alignment from a recliner bracket64to a top portion46of the seatback14. The first and second side supports60,62pivotally couple with the recliner brackets64about the recliner mechanism38and curve upward and rearward from the recliner brackets64to provide a curved shape that is similar to a passenger's spinal column. The side supports60,62are more robust proximate the recliner bracket64and taper as they extend upward to couple with the top portion46of the seatback14that extends generally orthogonally between the first and second side supports60,62. The seatback structure58includes a metal frame66that is substantially enclosed with a polymer trim shroud68generally concealing the edge portions of the metal frame66. It is conceivable that the seatback structure58may be alternatively shaped and/or configured with an alternative combination of components and materials.

The suspension assembly16, as illustrated inFIG. 3, couples with and generally extends forward from the seatback structure58to removably couple with the passenger support52and define the external peripheral gap32(FIG. 2) between the passenger support52and the seatback structure58. The first suspension component48of the suspension system generally includes a first arm70, a second arm72, and a central body74disposed there between. The first and second arms70,72each have a pair of finger-shaped flex members18, wherein two of the flex members18laterally extend from the arms70,72and two of the flex members18vertically extend from the arms70,72. The flex members18each include a securing feature at the distal ends26thereof. The central body74of the first suspension component48is coupled with a pivot bar78that laterally extends between and pivotally couples with the first and second side supports60,62of the seatback structure58to allow the first suspension component48to pivot forward and rearward about the pivot bar78. It is conceivable that the pivot bar78may be operably coupled with a motor to adjustably pivot the pivot bar78and the upper component22forward and rearward relative to seatback structure58. The second suspension component50includes a first side portion80and a second side portion82that are separate and distinct from each other. The first and second side portions80,82each have three outwardly extending finger-shaped flex members18. The distal end26of each flex member18has a securing feature76disposed thereon. It is also contemplated that the suspension assembly16may include more, fewer, or alternatively shaped flex members18extending from the seatback14to removably engage the passenger support52. For instance, the first and second side portions80,82may each include a single fin-shaped flex member18interconnecting and substantially eliminating the three separate finger-shaped flex members18.

Still referring to the embodiment shown inFIG. 3, the upper segment54and the lower segment56of the passenger support52, each include a trim carrier20and a cushion30. The trim carrier20removably couples to the securing features76on the distal ends26of the flex members18by a friction-fit connection28(FIG. 2). The trim carrier20includes a substantially polymer-based material that is formed to have an open matrix84defining a pattern of resilient elements configured to support the weight of a passenger, to provide ventilation, and to conform to the contour of a passenger's back. It is contemplated that the trim carrier20may lack openings or include a varied shape and arrangement of the open matrix84. As shown, the trim carrier20has two separate molded plastic panels, one for each of the upper and lower segments54,56of the passenger support52. However, it is conceivable that the upper and lower segments54,56may be a single piece and the trim carrier20may include a living hinge to allow for pivotal movement of the suspension assembly16.

The cushion30, as illustrated inFIG. 3, is disposed over and operably coupled with the trim carrier20. The cushion30includes an upper piece86positioned over the upper segment54of the trim carrier20proximate the first suspension component48. Similarly, the cushion30includes a lower piece87positioned over the lower segment56of the trim carrier20proximate the second suspension component50. It is conceivable that the cushion30may be a single integral piece that is disposed over the trim carrier20or may include further divisions and portions. The cushion30may include a matrix of woven fibers that have open areas to allow ventilation, an open-cell foam, a closed-cell foam, and other alternative flexible and/or breathable materials. The cushion30includes a cover stock88disposed over at least the exterior portion of the cushion30. The cover stock88may conceivably be comprised of fabric, leather, pleather, vinyl, or other vehicle upholstery materials as generally understood in the art. Further, it is conceivable that the cushion30may simply include a cover stock88without a foam material or other flexible portion that is configured to provide a cushioned support over the trim carrier20.

Referring now to the embodiment illustrated inFIG. 4, the passenger support52includes a plurality of engagement members90spaced on a periphery92of the trim carrier20to removably couple with the securing features76on the flex members18. The upper segment54of the passenger support52includes two engagement members90on opposing sides of the trim carrier20to align with securing features76disposed on the distal ends26of the flex members18of the upper component22. Similarly, the lower segment56of the passenger support52includes three engagement members90on opposing sides of the trim carrier20to align with securing features76disposed on the distal ends26of the flex members18of the lower component24. The engagement members90each define a keyhole slot94configured to removably couple a keyed protuberance96on the plurality of outwardly extending flex members18. The keyhole slots94on each of the upper and lower segments54,56are positioned in generally vertical parallel alignment with each other to allow for the friction-fit connection28(FIG. 2) with the securing feature76, as described in more detail below. It is contemplated that engagement members90may be alternatively positioned or constructed to engage the securing features76.

As shown inFIGS. 5-6, the keyhole slot94of the engagement member90includes an upper region98and a lower region100that each extend through the trim carrier20to define an aperture. The lower region100is defined on opposing sides by a first pliable element102and a second pliable element104, each having a curvature bordering the lower region100. A base surface106horizontally extends between the bottom ends of the first and second pliable elements102,104to further define the lower region100. A first locking protrusion108and a second locking protrusion110each extend inward toward the other between the upper region98and the lower region100of the keyhole slot94. A third pliable element112and a fourth pliable element114extend upward from the locking protrusions108,110at a curvature that borders the upper region98to couple with a keystone element116centrally located at the uppermost portion of the keyhole slot94. The pliable elements102,104,112,114each define a deformation aperture118between the pliable element102,104,112,114and an outer portion120of the engagement member90. Accordingly, the deformation apertures118are disposed about a perimeter of the engagement member90. It is conceivable that a single end of the pliable elements102,104,112,114may be coupled with the outer portion120of the engagement member90to similarly define the deformation apertures118. In addition, the upper and lower regions98,100of the keyhole slot94may be alternatively shaped and constructed from the illustrated embodiment.

The securing feature76, as shown inFIGS. 7-8, includes a paddle shaped backing plate122on the distal end26of the flex member18. The keyed protuberance96orthogonally extends forward from a central portion of the backing plate122. The keyed protuberance96has a disc shaped bulbous end124with a forward facing surface126in parallel alignment with a planar extent of the backing plate122. The bulbous end124is coupled to the backing plate122with a connection member128. The connection member128has a cross section with a plus sign shape, such that a vertically extending portion130of the connection member128has a width substantially equal to a horizontally extending portion132. The widths of both the vertically and horizontally extending portions130,132are less than the diameter of the bulbous end124. It is contemplated that the connection member128, the bulbous end124, and other portions of the securing feature76may be alternatively shaped to correlate with and form the friction-fit connection28with the engagement member90.

Referring to the embodiment shown inFIGS. 9-9A, the friction-fit connection28is initiated by the bulbous end124of the keyed protuberance96being centrally aligned with the lower region100of the keyhole slot94, such that a longitudinal extent of the vertically extending portion130of the connecting member128divides the keyhole slot94into substantially mirror image halves. The bulbous end124of the keyed protuberance96is then centrally inserted into the lower region100of the keyhole slot94by applying a forward linear force134to the flex member18and/or an opposing rearward linear force to trim carrier20. The linear force134moves the keyed protuberance96to an inserted position136within the keyhole slot94. It is contemplated that the various engagement members90and securing features76may be separately or simultaneously aligned and inserted to form the friction-fit connection28.

As illustrated inFIGS. 10-10A, the bulbous end124has a slightly greater diameter than the lateral distance between the first and second pliable elements102,104that border the lower region100of the keyhole slot94. Accordingly, the first and second pliable elements102,104elastically deform laterally, as shown inFIG. 10A, into the deformation apertures118upon applying the linear force134to insert the bulbous end124. An edge portion138of the bulbous end124slides and overcomes the first and second pliable elements102,104, allowing the first and second pliable elements102,104to release and laterally move inward toward the connection member128of the keyed protuberance96. The width of the horizontally extending portion132of the connection member128is generally less than the lateral distance between the first and second pliable elements102,104. Thus, the first and second pliable elements102,104are permitted to release and laterally move inward to regain the original curvature in close proximity to the connection member128, while the edge portion138of the bulbous end124moves into abutting contact with the base surface106. As such, the keyed protuberance96reaches the inserted position136, having the pliable elements102,104retained between the bulbous end124of the keyed protuberance96and the backing plate122and generally securing the trim carrier20to the flex member18. It is conceivable that the lower region100of the keyhole slot94or the keyed protuberance96may be alternatively shaped or constructed to form the friction-fit connection28.

The inserted position136, as also illustrated inFIGS. 11-12, causes at least a tactile and audible cue from the pliable elements102,104overcoming the bulbous end124of the keyed protuberance96to move into abutting contact with the backing plate122, among other abutting engagements. In addition, the forward facing surface126of the bulbous end124is in generally planar alignment with the outer portion120of the engagement member90, so as not to protrude into the cushion30(FIG. 3) of the passenger support52and disrupt a passenger. Also, it is shown that a depth140of the first and second pliable elements102,104are similar to the length of the connection member128of the keyed protuberance96to provide a generally secure friction-fit connection28in the lower region100of the keyhole slot94. It is also conceivable that the inserted position136causes a visual cue that indicates engagement of the engagement member90to the securing features76.

Referring now toFIGS. 13-13A, the keyed protuberance96is moved from the inserted position136(FIG. 9) upward in the keyhole slot94to a locked position142, substantially occupying the upper region98thereof. To move to the locked position142an upward linear force144is applied to the flex member18and/or an opposing downward linear force is applied to the trim carrier20. In the locked position142, the edge portion138of the bulbous end124moves into abutting contact with the keystone element116of the engagement member90, thereby restricting further upward movement of the keyed protuberance96. The horizontally extending portion132of the connection member128similarly moves over the first and second locking protrusions108,110and into abutting contact with the upward facing surfaces146of the first and second locking protrusions108,110, thereby preventing downward movement of the keyed protuberance96. Thus, in the locked position142, the securing feature76is restricted from vertical movement and maintains the friction-fit connection28. It is conceivable that the keyhole slot94and the keyed protuberance96may be shaped or constructed such that alternative forces and resulting movements may place them in a friction-fit connection28.

As shown inFIGS. 14-14A, the width of the horizontally extending portion132of the connection member128is greater than the lateral distance between the first and second locking protrusions108,110. Accordingly, the upward linear force144must be great enough to elastically deform the horizontally extending portion132of the connection member128and/or the first and second locking protrusions108,110, allowing the keyed protuberance96to slide from the lower region100to the upper region98of the keyhole slot94. The first and second locking protrusions108,110each include a slanted surface148that angles inward proximate the upper region98of the keyhole slot94, such that the connection member128slides on the slanted surface148to gradually flex the connection member128and/or the first and second locking protrusions108,110as keyed protuberance96moves upward. After the connection member128overcomes the locking protrusions108,110, the elastic deformation subsides and the features regain the original shapes, as illustrated. The horizontal upward facing surfaces146of the first and second locking protrusions108,110align with each other and engage the horizontally extending portions132of connection member128, causing at least a tactile and audible cue. Thus, the locking protrusions108,110are retained between the backing plate122and the lower portion of the bulbous end124, securing the keyed protuberance96from forward and rearward displacement. It is also conceivable that the locked position142also generates a visual cue.

As further illustrated inFIGS. 15-16, the third and fourth pliable elements112,114bordering the upper region98of the keyhole slot94on opposing sides of the keystone element116are retained between the backing plate122and the bulbous end124. As such, the locked position142provides a secure connection between the flex member18and the trim carrier20, retaining the connection from forces in all directions. To remove the keyed protuberance96from locked position142in the upper region98of the keyhole slot94, a forward linear force on the trim carrier20and/or a rearward linear force on the flex member18will flex the locking protrusions108,110rearward and the third and fourth pliable elements112,114into corresponding deformation apertures118. It is contemplated that the keyed protuberance96is easier to remove from the keyhole slot94in inserted position136(FIG. 9) than in the locked position142. It is also conceivable that the keyed protuberance96may be moved from the locked position142to the inserted position136(FIG. 9) before removing the keyed protuberance96from the keyhole slot94.

The trim carrier20, as shown inFIG. 17, is engaged with the suspension assembly16in the locked position142, having each securing feature76in a friction-fit connection28with each engagement member90. It is conceivable that the various engagement members90and securing features76may be separately or simultaneously moved between the inserted position136(FIG. 9) and the locked position142. It is also conceivable that the upper segment54of the trim carrier20may be separately removed from the upper suspension component22or that the lower segment56of the trim carrier20may be separately removed from the lower suspension component24for individual replacement or repair.

It is contemplated that the keyhole slot94and the keyed protuberance96may be alternatively shaped and/or arranged, such that the keyed protuberance96may still be inserted in a two step process to establish the friction-fit connection28, with a snap-on and snap-off capability between the trim carrier20and the suspension system16. For instance, the keyhole slot94may generally include an alternatively shaped or oriented upper region98, referred to as a secondary region, and/or an alternatively shaped or oriented lower region100, referred to as a primary region, to allow a two step process to establish the friction-fit connection28. The keyed protuberance96may be inserted into such a primary region in a first step and moved to the secondary region in a second step to establish the friction-fit connection28between the trim carrier20and the seatback structure58. The primary region in this first step provides a holding function for the trim carrier20and the secondary region in this second step provides a locking function for the trim carrier20. As explained above, the friction-fit connection28may be undone and the trim carrier20may be removed from the flex members18by reversing the two step process. More specifically, the friction-fit connection28can be undone by moving the keyed protuberance96from the secondary region to the primary region, releasing the locking function, and then removing the keyed protuberance96from the primary region, discharging the holding function and detaching the trim carrier20proximate the keyed protuberance96.