Securing seat trim covers to foam cushions

#This specification generally relates to securing seat trim covers to foam cushions.

#Seats for cars and light trucks have been formed by molding a foam bun that will serve as the seat cushion, and then attaching a pre-stitched fabric cover to the foam bun. Often, when the fabric cover is to be held securely to the foam bun along a bun contour, discrete fastenings, such as hog rings, are employed to connect a fabric flange, extending from the inner surface of the cover, to a wire retainer embedded at the bottom of a corresponding trench in the foam bun surface. Tension in the cover flange holds the cover against the bun in the contour. Other fastening methods involve fastening a clip, secured in the trench, to a bead along the flange edge.

#Some fastening methods can be very labor-intensive, and can require significant manual dexterity. Some also require pneumatic tools for repetitive installations, due to the force required.

#FIG. 1A is a partial cutaway view of a portion of a covered foam seat cushion having an embedded retainer.

#FIG. 1B is a partial cutaway view of a portion of a covered foam seat cushion having a molded bead retainer.

#FIG. 2A is perspective view of an edge of a flexible web of a seat trim cover, showing a first clip configuration.

#Many of the features are exaggerated to better show the features, process steps, and results. Like reference numbers and designations in the various drawings indicate like elements.

#Referring first to FIG. 1A, a covered foam cushion 10a includes a foam bun 12a and a cover 14 extending over a contoured outer surface of the foam bun. The bun surface features an elongated trench 16 at which the cover 14 is held in place by a retainer 18a. In this example, retainer 18a is a metal wire embedded in the body of foam bun 12a beneath trench 16. Trench 16 is defined by two opposing side walls 20 and a floor 22 spanning the distance between the side walls. In this example, the opposing trench side walls are parallel with each other and perpendicular to the trench floor. However, other trench geometries are also envisioned and compatible with the concepts discussed herein. The trench is positioned with respect to the bun contour such that holding the cover tight against the bun at the trench helps to hold the cover tight against the rest of the contour of the foam bun. In this example, the foam cushion is designed for an automotive seat. However, the concepts described in the present disclosure are not so limited, and are suitable for various other applications.

#Retainer 18a is exposed to the open area of trench 16 along a series of spaced-apart openings 24 along the trench floor 22. A series of discrete clips 26 cooperate with retainer 18a to secure cover 14 to foam bun 12a. Clips 26 are secured to a flexible web (or “flange”) 28 of cover 14 extending down into trench 16. Clips 26 extend beyond a distal edge of the flange and are aligned with openings 24, through which the clips extend to clip onto retainer 18a. As described below, the clips feature an opposing set of one or more latch elements located on either side of the cover flange. The opposing sets of latch elements are positioned offset from one another along a length of the distal edge of the flange.