Seat assembly having improved trim appearance and method and tool for making the same

Patent metadata

Field	Value
Publication number	US-11155191-B2
Application number	US-201816192168-A
Country	US
Kind code	B2
Filing date	Nov 15, 2018
Priority date	May 7, 2012
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

A seat assembly having improved trim appearance is provided as well as a method and mold tool for making the seat assembly. In certain embodiments, the seat assembly has at least one narrow trench having a substantially constant width of up to 5 mm, which provides for better tolerances when installing a trim cover on the cushion and provides improved appearance and comfort. In certain embodiments, the mold tool has at least one tool insert that is configured to create the at least one narrow trench with a substantially constant width in the cushion.

First claim

What is claimed:

1. A mold tool comprising:
a first mold half and a second mold half, the first and second mold halves forming a mold cavity when closed;
at least one elongated tool insert attached to one of the first mold half and the second mold half, the at least one tool insert having a base and a protruding portion extending from the base, the protruding portion having a first side wall, a second side wall and a tip;
wherein the protruding portion has a substantially constant width between the first and second side wall of up to about 5 mm along substantially an entire length of the elongated tool insert and is configured to form a trench in a molded part having a substantially constant width of up to about 5 mm.

2. The mold tool of claim 1 , wherein the protruding portion has a width from about 2 mm to about 4 mm.

3. The mold tool of claim 1 , wherein the protruding portion has a width of about 3 mm.

4. The mold tool of claim 1 , wherein the insert is a separate component from the first and second mold halves and the protruding portion is configured to receive at least one trim clip female attachment portion having at least a first arm and a second arm.

5. The mold tool of claim 4 , wherein the protruding portion has at least one notch defined in at least one of the first and second side walls configured to accept a protrusion of an arm of the female attachment portion, thereby providing a locating feature for attaching the female attachment portion.

6. The mold tool of claim 4 , wherein the protruding portion has at least one pair of notches defined in the first and second side walls, the pair of notches being juxtaposed on each of the first and second side walls to accept a protrusion of an arm of the female attachment portion, thereby providing a locating feature for attaching the female attachment portion.

7. The mold tool of claim 5 , wherein the at least one notch is rectangular in shape and has a depth of 0.1 mm to 0.3 mm.

8. The mold tool of claim 1 , wherein the base is wider than the protruding portion.

9. The mold tool of claim 1 , wherein the protruding portion has a locating feature for receiving a portion of a female attachment portion.

10. The mold tool of claim 9 , wherein the locating feature comprises a slot extending through the protruding portion.

11. The mold tool of claim 1 , further comprising a plurality of elongated tools, each of the plurality of elongated tools having a base and a protruding portion extending from the base to a tip;
wherein each of the protruding portions have a substantially constant width of up to about 5 mm along substantially an entire length of the elongated tool and is configured to form a trench in a molded part having a substantially constant width of up to about 5 mm.

12. A mold tool comprising:
a first mold half and a second mold half cooperable to form a mold cavity; and
an elongated tool on one of the first mold half and the second mold half, the elongated tool having a base and a protruding portion extending from the base to a tip;
wherein the protruding portion has a substantially constant width of up to about 5 mm along substantially an entire length of the elongated tool and is configured to form a trench in a molded part having a substantially constant width of up to about 5 mm.

13. The mold tool of claim 12 , wherein the protruding portion has a width from about 2 mm to about 4 mm.

14. The mold tool of claim 12 , wherein the protruding portion is configured to receive at least one trim clip female attachment portion having at least a first arm and a second arm.

15. The mold tool of claim 14 , wherein the protruding portion has a first side wall, a second side wall and a pair of notches defined in the first and second side walls, the pair of notches being juxtaposed on each of the first and second side walls to accept a protrusion of an arm of the female attachment portion, thereby providing a locating feature for attaching the female attachment portion.

16. The mold tool of claim 15 , wherein each of the notches have a depth of 0.1 mm to 0.3 mm.

17. The mold tool of claim 12 , wherein the base is wider than the protruding portion.

18. The mold tool of claim 12 , wherein the at least one elongated tool is integral with one of the first mold half and the second mold half.

19. The mold tool of claim 12 , further comprising a plurality of elongated tools, each of the plurality of elongated tools having a base and a protruding portion extending from the base to a tip;
wherein each of the protruding portions have a substantially constant width of up to about 5 mm along substantially an entire length of the elongated tool and is configured to form a trench in a molded part having a substantially constant width of up to about 5 mm.

20. A cushion assembly comprising:
a cushion having a top surface and a bottom surface, the top surface being configured to receive a trim cover and having defined therein at least one trench having first and second opposing side walls and a bottom wall, the first and second side walls having a substantially constant width therebetween of up to about 5 mm;
at least two clips spaced apart in the substantially constant width trench and at least partially embedded in the bottom wall of the trench, each of the clips having a trim cover attachment member projecting into the trench to be engagable with an attachment member of the trim cover;
at least one slit defined in the bottom wall of the trench adjacent to each of the at least two clips, the slit extending from the bottom wall of the trench through to the bottom surface; and
at least one tapered access hole defined in the bottom surface of the cushion juxtaposed with the slit to allow a tool to have access to the slit, the access hole having a diameter that increases in a direction from the slit towards the bottom surface.

Assignees

• Lear Corp

Inventors

• Galbreath Ashford A
• Ali Asad S
• Lymburner Gregory Alan
• Severinski Paul S
• Rock Gary
• Clauser James B
• Patterson Louella Ann
• Welch Thomas A

Classifications

• B60N2/64

  Back-rests {or cushions (B60N2/2222 takes precedence)} · CPC title

• B60N2/5825 Primary

  by hooks, staples, clips, snap fasteners or the like · CPC title

• B29C44/02

  for articles of definite length, i.e. discrete articles · CPC title

• B60N2/5891

  characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for · CPC title

• B29L2031/3002

  Superstructures characterized by combining metal and plastics, i.e. hybrid parts · CPC title