Abstract:
Disclosed herein are apparatus for attaching covering material to interior components of a vehicle. One embodiment is a speaker grille for concealing a speaker in the interior of a vehicle. The speaker grill comprises a first surface and a second surface opposite the first surface. At least one projection extends from the second surface. The projection has a base at the second surface and a distal end opposite the base and a retention member extending directly from the projection at a location proximate to the base and spaced apart from the distal end. The retention member has a retention surface spaced apart from and substantially parallel to the second surface. A covering overlies the first surface and defines an aperture through which the projection extends. A portion of the covering is positioned between the second surface of the substrate and the retention member.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 11/875,316, filed on Oct. 19, 2007, and incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This application pertains in general to the attachment of covering material to the interior components of a vehicle. 
       BACKGROUND 
       [0003]    Components of the interior of motor vehicles are in some cases covered by a fabric or other material. For example, a speaker grille may be covered by audio fabric. A seat can be covered by upholstering. In some cases, it is desirable to provide a clean, wrinkle-free application of the covering material. With speakers, for example, this is traditionally achieved by using a large number of staples to secure the peripheral edge of the audio fabric to the backside of the speaker grille. The process of using staples to secure a covering material to a substrate is a labor intensive and poses a risk of damage, warranty claims, and squeak-and-rattle noise. Alternatively, the audio fabric can be glued to the backside of the speaker grille; however, glue can compromise the transmissiveness of audio fabric. 
       SUMMARY 
       [0004]    Disclosed herein are apparatus for attaching covering material to interior components of a vehicle. One embodiment is a speaker grille for concealing a speaker in the interior of a vehicle. The speaker grill comprises a first surface and a second surface opposite the first surface. At least one projection extends from the second surface. The projection has a base at the second surface and a distal end opposite the base and a retention member extending directly from the projection at a location proximate to the base and spaced apart from the distal end. The retention member has a retention surface spaced apart from and substantially parallel to the second surface. A covering overlies the first surface and defines an aperture through which the projection extends. A portion of the covering is positioned between the second surface of the substrate and the retention member. 
         [0005]    Another embodiment disclosed herein is a speaker housing assembly comprising a speaker housing defining a speaker opening and at least one mounting aperture. A speaker grille overlays the speaker opening and includes a first surface, a second surface opposite the first surface, and at least one projection extending from the second surface and through the mounting aperture. The projection has a base at the second surface and a distal end opposite the base and a clip member extending from the projection at the distal end. A retention member extends from the projection at a location proximate to the base and spaced apart from the distal end. A covering overlies the first surface and defines an aperture through which the projection extends, with a portion of the covering being positioned between the second surface of the substrate and the retention member. 
         [0006]    Another embodiment disclosed herein is a speaker housing assembly comprising a speaker housing including a periphery which defines a speaker opening and a plurality of mounting apertures disposed about the periphery. A speaker is disposed in the speaker opening and mounted to the housing. A speaker grille overlays the speaker opening to conceal the speaker and includes a first surface, a second surface opposite the first surface, a peripheral edge surrounding the first and second surfaces, a central portion positioned inward from the peripheral edge, a plurality of projections extending from the second surface at a location between the peripheral edge and the central portion and corresponding to each of the mounting apertures, and a covering overlying the first surface and the peripheral edge and having a plurality of covering apertures corresponding to the plurality of projections and through which each of the projections extend. Each projection has a base at the second surface positioned on a first side of the corresponding mounting aperture, a distal end opposite the base positioned on a second side of the corresponding mounting aperture opposite the first side, a clip member and a retention member. The clip member extends from the distal end and extends away from the central portion and has a mounting ramp surface for guiding installation of the projection through the corresponding mounting aperture from the first side to the second side and a mounting retention surface for preventing movement of the distal end the projection through the corresponding mounting aperture from the second side to the first side. The retention member extends from each projection at a location proximate to the base and is spaced apart from the distal end. The retention member has a covering retention surface extending toward the central portion, and a covering guide ramp surface for guiding the covering toward the covering retention surface, such that a portion of the covering is positioned between the covering retention surface and the second surface to preventing movement of the covering toward the distal end. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views. 
           [0008]      FIG. 1  is a perspective view of an example of a speaker grille assembly with two cutaways, one illustrating the first side of the speaker grille and the other illustrating fabric secured over an anchor member, and a speaker housing. 
           [0009]      FIG. 2  is a perspective view of the second side of the speaker grille shown in  FIG. 1  with the speaker grille lying atop fabric and illustrating how the fabric is wrapped over the anchor members. 
           [0010]      FIG. 3  is a perspective view of the second side of a speaker grille having anchor members in the form both clip towers and standoffs. 
           [0011]      FIG. 4  is a cross-sectional view corresponding to line A-A in  FIG. 1  of a clip tower where the retention member is a single-sided triangular boss. 
           [0012]      FIG. 5  is a cross-sectional view corresponding to line A-A in  FIG. 1  of a standoff where the retention member is a double-sided triangular boss. 
           [0013]      FIG. 6  is a cross-sectional view corresponding to line A-A in  FIG. 1  of a barb. 
           [0014]      FIG. 7  is a cross-sectional view corresponding to line A-A in  FIG. 1  of a standoff where the retention member is a plurality of serrations. 
           [0015]      FIG. 8  is a perspective view of an assembly where the retention member is an elongated flange and the fabric has elongated slits. 
           [0016]      FIG. 9  is a perspective view of the seat cushion assembly with the second side of the seat cushion substrate facing up. 
           [0017]      FIG. 10  is a perspective view of the seat cushion assembly in  FIG. 9  and a vehicular seat configured to receive the substrate. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0018]    The disclosed examples illustrate a novel technique for applying fabric to a substrate, such as a speaker grille or seat cushion found in a vehicle.  FIGS. 1-8  illustrate a speaker grille assembly  10  for use in the interior of a vehicle, while  FIGS. 9 and 10  illustrate a seat cushion assembly  110 . Referring to  FIG. 1 , speaker grille assembly  10  includes a speaker grille  12  having a first side  14  and a second side  16 . Anchor members  18  project from second side  16  of speaker grille  12 . A fabric  60  includes a plurality of apertures  62 . Apertures  62  outline a central portion  64  of fabric  60 . Fabric  60  is wrapped around speaker grille  12 , with central portion  64  overlaying first side  14  and anchor members  18  inserted through apertures  62 . A vehicular speaker housing  80  includes a plurality of mating receptacles  82  around the perimeter of an opening  84 . Housing  80  can enclose a speaker  86 . Speaker grille assembly  10  is attached to speaker housing  80  by inserting anchor members  18  into mating receptacles  82 . 
         [0019]    While the present example features speaker grille  12  as a substrate, fabric  60  as a covering material, and vehicular speaker housing  80  as a housing, other elements would also be suitable. The substrate could be a seat cushion substrate  112  as discussed below, a floor panel, a trim panel, a trunk liner, a fold-out center armrest in a backseat, or any other substrate known to those in the art. The housing could be a vehicle seat  180 , a housing in a door, a housing in the dashboard, a housing in the trunk, a housing in the floor, a housing in the armrest, or any other housing known to those of skill in the art. 
         [0020]    In  FIG. 2 , speaker grille  12  is shown with its second side  16  facing up and lying atop unwrapped fabric  60 . Speaker grille  12  can be a planar or curved stratum. The size and shape of speaker grille  12  can correspond to the size and shape of opening  84  in speaker housing  80 . Speaker grille  12  can be made of a wide range of materials, including plastic, metal, wood, composite, or any other materials known to those skilled in the art. If made of molded plastic, speaker grille  12  and anchor members  18  can be molded integrally. Ribs (not shown) can be formed on the second side  16  of speaker grille  12  for additional strength or stiffness. Speaker grille  12  can include a perforated sound opening  36  in order to transmit sound from speaker  86  within housing  80 . The size, shape, and location of sound opening  36  can correspond with the size, shape, and location of speaker  86  in speaker housing  80 . Alternatively, a large portion of speaker grille  12  can be perforated regardless of the size, shape, and location of speaker  86 . 
         [0021]    The size of fabric  60  may be determined on the basis of the area of first side  14  of speaker grille  12 , the elasticity of fabric  60 , and the configuration of anchor members  18 , among other considerations known to those skilled in the art. Fabric  60  can be sized such that as each aperture  62  is secured near the base of anchor member  18 , the tension in fabric  60  is increased. Central portion  64  of fabric  60  can be large enough to completely overlay first side  14  of speaker grille  12 . Fabric  60  can be grille cloth, audio fabric, single-knit polyester, or any suitable material known to those of skill in the art. Fabric  60  can be elastic (i.e., capable of returning to its natural length after being stretched), such that central portion  64  is in tension when anchor members  18  are inserted through apertures  62 . 
         [0022]    Apertures  62  can be disposed near the perimeter of fabric  60 , defining central portion  64  of fabric  60 . The size, spacing, and number of apertures  62  can correspond with the size, spacing, and number of anchor members  18 . Apertures  62  can be slits, ovals, rectangles, squares, or other shapes known by those in the art. Apertures  62  can be sized such that they must be stretched to fit over anchor members  18 . Alternatively, apertures  62  can be sized such that they freely fit over anchor members  18  so long as fabric  60  is in tension when at least one anchor member  18  is inserted through aperture  62 . Apertures  62  can be manufactured into fabric  60  before anchor members  18  are inserted through apertures  62 , or anchor members  18  can have tips that are sharp enough to pierce fabric  60  to create apertures  62  when anchor members  18  are pressured against taut fabric  60 . Additionally, a combination of the two methods for creating apertures  62  may be used, such as manufacturing apertures  62  along one half of fabric  60  and creating the other half of apertures  62  by piercing fabric  60  with anchor members  18 . 
         [0023]    Anchor members  18  are projections from second side  16  of speaker grille  12  that include retention members  22  to secure fabric  60  to speaker grille  12 . Anchor members  18  can have round or polygonal cross-sections. The cross-sectional area of anchor member  18  can remain constant or decrease as anchor member  18  extends away from speaker grille  12  until anchor member  18  joins an optionally included clip  24  or forms a sharp geometry to pierce fabric  60  as described above. Anchor members  18  can be distributed substantially evenly around the perimeter of speaker grille  12 . The distance of anchor members  18  from the perimeter of speaker grille  12  can be based on the height of anchor members  18  and the elasticity of fabric  60 , such that fabric  60  is taut across first side  14  of speaker grille  12  yet still capable of being stretched over anchor members  18 . The number of anchor members  18  can depend on the number of mating receptacles  82  in speaker housing  80 . The number of anchor members  18  can also be changed to achieve the desired tautness of fabric  60  if fabric  60  must be stretched to fit over each anchor member  18 . 
         [0024]    A single speaker grille  12  can include one or multiple types of anchor members  18 . As an example,  FIG. 3  illustrates speaker grille  12  having several anchor members  18  formed as clip towers  19  and standoffs  26 . Anchor members  18  in the form of barbs  32  can be molded on the second side  16  of speaker grille  12  where anchor members  18  are desired to secure fabric  60 , but speaker housing cannot accommodate clip towers  19  or standoffs  26 . Additionally, barbs  32  can be formed in other areas along second side  16  of speaker grille  12 , between other anchor members  18  for example, to achieve a desired tautness of fabric  60 . 
         [0025]    Anchor members  18  formed as clip towers  19  are elongate projections which include a clip  24  at the distal end for attachment to the speaker housing  80 . Clips  24  can be molded integrally with the clip tower  19  as in  FIGS. 3 and 4 , or separately formed and attached to the clip tower  19  (not shown). Retention members  22  are formed near the bases of the clip towers  19 . As fabric  60  is applied to the speaker grille  12  as described above, the distal end of the clip tower  19  is passed through aperture  62 , and the fabric  60  is pushed past the clip  24  and the retention member  22  until the retention member  22  secures fabric  60  to speaker grille  12 . Alternatively, a separately formed clip (not shown) can be attached to the distal end of the clip tower  19  after fabric  60  is secured by retention member  22 . 
         [0026]    The shape of clip  24  on the distal end of a clip tower  19  can be substantially equal to the shape of a mating receptacle  82  in speaker housing  80 , such that a friction fit secures clip  24  in the mating receptacle  82 . For example, the clip  24  on clip tower  19  in  FIG. 5  can feature a first ramp surface  25  on one side that can be pressed into mating receptacle  82  and deflected for installation into mating receptacle  82  and a second ramp surface  27  on its opposite side that can be deflected for removal from mating receptacle  82 . Clips  24  can be shaped like single-sided triangular bosses as depicted in  FIG. 4 , double-sided triangular bosses (not shown), a plurality of serrations (not shown), or any other suitable configuration known to those skilled in the art. Each clip tower  19  can also include a larger cross-sectional area near its base that functions as a standoff member by contacting the speaker housing  80  on the surface of the speaker housing facing speaker grille  12 . 
         [0027]      FIG. 3  also shows anchor members  18  formed as standoffs  26 . Standoffs  26  are projections extending substantially perpendicular to the second side  16  of the speaker grille  12 , and standoffs  26  are of sufficient length to contact the speaker housing  80  to maintain the speaker grill  12  at a predetermined distance from the speaker housing  80 . Standoffs  26  maintain the fit and finish of speaker grille  12  in relation to surrounding components and surfaces, as well as maintain a tight fit between the clips  24  and the mating receptacles  82  to reduce undesired noise and vibrations. Retention members  22 , such as double-sided triangular boss  30  in  FIG. 5 , are formed near the bases of the standoffs  26 . As fabric  60  is applied to the speaker grille  12 , the distal end of the standoff  26  is passed through aperture  62 , and the fabric  60  is pushed past the retention member  22  until the retention member  22  secures fabric  60  to speaker grille  12 . 
         [0028]    Standoffs  26  can provide support to hold speaker grille  12  distal from housing  80 . Each standoff  26  can include a retention member  22  disposed along standoff  26  and near its base. Retention members  22  can be separately formed pieces affixed to standoffs  26  (e.g., double-sided triangular boss  30  in  FIG. 5 ) or integral with standoffs  26  (e.g., plurality of serrations  136  in  FIG. 7 ). If retention members  22  are separately formed pieces, they can include apertures of substantially the same or slightly smaller size than standoffs  26  such that standoffs  26  can be inserted through the apertures to secure retention members  22  as shown in the exploded view portion of  FIG. 3 . As an additional example, retention members  22  can include C-clips (not shown) to secure themselves to standoffs  26 . 
         [0029]    In another example, anchor members  18  are formed as barbs  32 , as shown in  FIG. 6 . Barbs  32  are projections extending toward the center of the speaker grille. Barb  32  includes a center facing surface  34  which forms an acute angle with second surface  16  of the speaker grille  12  as shown in  FIG. 6 , or a concave surface (not shown) which forms the retention member  22 . As fabric  60  is applied to the speaker grille  12  as described above, the distal end of the barb  32  is passed through aperture  62  and the fabric  60  is pushed toward the base of the barb until the retention member  22  secures the fabric  60  to speaker grille  12 . 
         [0030]    Anchor members  18  can also be elongated flanges  20  as shown in  FIG. 8 . Elongated flanges  20  can include retention members  22  and clips  24 , both of which are depicted as single-sided triangular bosses in  FIG. 8 . Apertures  62  in fabric  60  can be elongated slits  66  when anchor members  18  are elongated flanges  20  to ensure compatibility between the two elongated elements. 
         [0031]    As previously stated, each anchor member  18  includes a retention member  22  disposed along anchor member  18  near the base of anchor member  18 . Retention members  22  are devices that secure fabric  60  to speaker grille  12 . The blow-up illustration in  FIG. 2  shows anchor member  18 , retention member  22 , and clip  24 . Retention member  22  can be placed along anchor member  18  such that the distance between second side  16  of speaker grille  12  and retention member  22  substantially equals or exceeds the thickness of fabric  60 . Each retention member  22  can be sized such that a combined cross-sectional area of anchor member  18  and retention member  22  is greater than the size of a corresponding aperture  62  in fabric  60  if fabric  60  is elastic, or substantially equal to the size of a corresponding aperture  62  in fabric  60  if fabric  60  is not elastic, such that aperture  62  can be forced along anchor member  18  toward speaker grille  12  and past retention member  22 . The relative cross-sectional area of aperture  62  compared to the combined cross-sectional area of anchor member  18  and retention member  22 , in addition to or independent of the tension in fabric  60 , can prevent aperture  62  from unintentionally becoming detached from retention member  22 , thereby ensuring fabric  60  stays lodged between retention member  22  and speaker grille  12 . 
         [0032]    Retention members  22  can take a variety of forms.  FIG. 4  shows a cross-section of one example of clip tower  19  that could be located along line A-A in  FIG. 1 . In this example, retention member  22  is a single-sided triangular boss  28 . Boss  28  protrudes from the side of clip tower  19 , and boss  28  can increase in size as it approaches speaker grille  12 . Single-sided triangular boss  28  is disposed near the base of clip tower  19  on the side of clip tower  19  facing the center of speaker grille  12 . Fabric  60  is shown secured between boss  28  and speaker grille  12 . Boss  28  prevents fabric  60  from unintentionally traveling toward the distal end of clip tower  19  by ensuring fabric  60  is lodged between boss  28  and speaker grille  12 . 
         [0033]      FIG. 5  shows a cross-section of a second example of anchor member  18  that could be located along line A-A in  FIG. 1 . In this example, the anchor member  18  is standoff  26 . A double-sided triangular boss  30  is shown connected to standoff  26  near the base of standoff  26 . Boss  30  protrudes from two opposing sides of standoff  26 , and boss  30  can increase in width as it approaches speaker grille  12 . While double-sided triangular boss  30  is shown as a separate element that has been attached to standoff  26 , double-sided triangular boss  30  and standoff  26  could also be formed integrally. Fabric  60  is secured between both sides of boss  30  and speaker grille  12 . Boss  30  prevents fabric  60  from unintentionally traveling toward the distal end of standoff  26  on the side of standoff  26  facing the center of speaker grille  12  and also from hanging away from second side  16  of speaker grille  12  on the opposite side of standoff  26 . 
         [0034]      FIG. 6  shows a cross-section of a third example of anchor member  18  that could be located along line A-A in  FIG. 1 . In this example, anchor member  18  is a barb  32 . Barb  32  also performs the function of retention member  22 . Barb  32  projects from speaker grille  12  at an acute angle from speaker grille  12  such that barb  32  has a retaining surface  34  facing toward the center of speaker grille  12 . In other words, the base end of barb  32  is closer to the edge of speaker grille  12  than the distal end of barb  32 . As a result, fabric  60  is stretched to a greater extent when at the distal end of barb  32  than when at the base end. 
         [0035]      FIG. 7  shows a cross-section of an example of anchor member  18  that could be located along line A-A in  FIG. 1 . Anchor member  18  is shown as a standoff  26 , while retention member  22  is shown as a plurality of serrations  136 . Plurality of serrations  136  are disposed near the base of standoff  26  and can be integral with standoff  26 . Serrations  136  could be on one side, multiple sides, or circumscribing standoff  26 . Serrations  136  can extent to the distal end of standoff  26  or end part-way along standoff  26 . The benefits of using serrations  136  as retention members  22  will be discussed in greater detail below in reference to another example. 
         [0036]      FIG. 8  shows an example of speaker grille  12  in which anchor members  18  are elongated flanges  20 . To correspond with elongated flanges  20 , apertures  62  take the form of elongated slits  66 . Elongated flange  20  can create tension in fabric  60  over the entire length of flange  20  to keep fabric  60  wrinkle-free along flange  20 . 
         [0037]    Although only four embodiments of retention members  22  are illustrated above, retention members  22  can take a variety of other additional forms. For example, a retention member  22  can also be a spring-actuated clip, a two-piece anchor member with a snap-fit connecting the two pieces, a hook, an anchor member  18  that has at least one diameter greater than the resting length of the major diameter of a corresponding aperture  62  in fabric  60 , or any other suitable connecting device known by those skilled in the art. 
         [0038]    To assemble speaker grille assembly  10 , fabric  60  is affixed to speaker grille  12  by inserting anchor member  18  through aperture  62 , sliding fabric  60  along anchor member  18  toward second side  16  of speaker grille  12 , engaging fabric  60  with retention member  22 , and repeating for each remaining aperture  62  and anchor member  18  pair. Engaging fabric  60  with retention member  22  is accomplished by lodging fabric between speaker grille  12  and retention member  22 . Once assembled, speaker grille assembly  10  can be installed on vehicular housing  80  by inserting anchor members  18  into mating receptacles  82 . 
         [0039]    Retention members  22  secure fabric  60  to speaker grille  12 , so staples and/or glue are unnecessary, saving components and assembly time. Whereas a large number of staples have been necessary, perhaps  50  to secure audio fabric to a 5 inch by 8 inch speaker grille, they can be replaced by a small number of retention members  22 , preferably 6-8 for the same 5 inch by 8 inch speaker grille. Additionally, retention members  22  do not have sharp tips that require careful handling. In the event fabric  60  becomes unsecured from retention member  22 , a consumer or mechanic could easily lodge fabric  60  back between retention member  22  and speaker grille  12 . Integrally molding speaker grille  12 , anchor members  18 , and retention members  22  can result in a speaker grille assembly  10  that does not squeak or rattle when subject to vibrations. Moreover, retention members  22  can secure fabric  60  to speaker grille  12  without changing the properties of fabric  60 , thereby ensuring the transmissiveness of fabric  60  and maintaining sound quality. 
         [0040]      FIGS. 9 and 10  illustrate another example, specifically seat cushion assembly  110  for use in a vehicle including seat cushion substrate  112  wrapped in upholstery  160 . Seat cushion substrate  112  includes a first side  114  and a second side  116 . Anchor members  18 , shown as circular clip towers  19 , project from second side  116  of seat cushion substrate  112 . Upholstery  160  includes apertures  162  disposed about a central portion  164 . Upholstery  160  can be any upholstering material such as leather, cloth, vinyl, suede, carpet, or any other material known to those of skill in the art. Clip towers  19  are inserted through apertures  162  in upholstery  160 , and upholstery  160  is secured to seat cushion substrate  112  by retention member  22 , here represented by serrations  136 . Upholstery  160  is secured between seat cushion substrate  112  and the serration  136  closest to seat cushion substrate  112 . Serrations  136  are adept at securing thick upholstery  160 , e.g., carpet, because multiple serrations  136  can engage thick upholstery at the same time. Serrations  136  are also adept at securing multiple layers of upholstery  160  and upholstery  160  of various thicknesses. A vehicle seat  180  includes mating receptacles  182  about an opening  184 . Seat cushion assembly  110  is installed over opening  184  of vehicle seat  180  by inserting clip towers  19  into mating receptacles  182 . 
         [0041]    Finally, the above-described embodiments have been described in order to allow easy understanding of the present invention and do not limit the present invention. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structure as is permitted under the law.