TRIM COVER RETAINER AND METHOD OF USING SAME

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application Serial No.

61/108,098 filed on October 24, 2008, entitled "Seat Cover Retainer and Method of Using Same," the entire disclosure of the application being considered part of the disclosure of this application and hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The subject invention relates to a trim cover retainer assembly for securing a trim cover to a core, for example a seat core.

2. Description of the Prior Art

[0003] Vehicular components, for example, seats having an interior foam core and an exterior trim covering have become ever-present, especially in automotive applications. In this regard, the foam core is provided with a predetermined shape in terms of the seat, back, and head rest portions thereof, and is further typically provided with frame attachment provisions, such as for example an embedded metallic structure for being attached to a framework at the bottom of the seat. The trim cover provides an attractive, durable, protective and comfortable covering for the foam core. Typical materials include cloth, vinyl, and leather. In order for the trim cover to be pleasingly and functionally interconnected with the foam core, the trim cover must be tightly conformed to the contour of the foam core. Usually, grooves are provided in the foam core to provide an attractive appearance to the seat or other vehicular component and, sometimes, to provide a juncture for pieces of the core, wherein the trim cover must also conform to these grooves. [0004] In the prior art, there are several approaches taken to attach trim covers to foam cores. Such approaches include hog rings, clips, sewing, and adhesives. Such systems

are complex and require multiple components and thus increases manufacturing time and cost.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0005] The present invention provides for a trim cover retainer assembly to secure a trim cover to a core. The assembly includes first and second retainers that are attached to the first and second edges of the trim cover. The first retainer includes first and second legs that extend upwardly from a first retainer base to define a retainer cavity therebetween. At least one external barb extends outwardly from the first retainer to fixedly attach the first retainer to the core when the first retainer is inserted into a core cavity defined by the core. The first retainer further includes an internal barb that extends inwardly into the retainer cavity. The second retainer includes a retention barb that extends outwardly from the second retainer to engage the internal barb of the first retainer to fixedly secure the second retainer to the first retainer when the second retainer is inserted into the retainer cavity.

[0006] The subject invention further provides for a method to secure the trim cover to the core. To begin, the first edge of the trim cover material is attached to the first retainer and the second edge of the trim cover material is secured to the second retainer. The first retainer is then inserted into the core cavity that is defined by the core. The first retainer includes at least one external barb that extends outwardly from the first retainer to engage the core and fixedly secure the first retainer within the core cavity. Next, a retention barb that extends from the second retainer is mated with an internal barb that extends from the first retainer to secure the second retainer to the first retainer. In an alternative method, the second retainer may be secured to the first retainer prior to the first retainer being inserted into the core cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0008] Figure 1 is a perspective view of a vehicle incorporating a trim cover retainer assembly according to the subject invention;

[0009] Figure 2 is a perspective view of a seating assembly incorporating the trim cover retainer assembly according to the subject invention;

[0010] Figure 3 is a partial side sectional view of a trim cover retainer assembly according to the subject invention;

[0011] Figure 4 is perspective view of an exemplary head rest incorporating the trim cover retainer assembly according to the subject invention;

[0012] Figure 5 is a partial side sectional view of the trim cover retainer assembly prior to insertion into a core;

[0013] Figure 6 is a side view of a second retainer according to the subject invention;

[0014] Figure 7 is a side view of a first retainer according to the subject invention;

[0015] Figure 8 is a side view of a second retainer partially inserted into a first retainer according to the subject invention;

[0016] Figure 9 is a side sectional view of an exemplary method of using the trim cover retainer assembly according to the subject invention;

[0017] Figure 10 is a flow diagram showing an exemplary method according to the subject invention; and

[0018] Figure 11 is a flow diagram showing another exemplary method according to the subject invention.

DETAILED DESCRIPTION OF THE INVENTION

[0019] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a trim cover retainer assembly 20 for securing a trim cover 22 to a core 24 is generally shown.

[0020] Referring generally to the figures and in particular Figure 1, a vehicle is shown. The vehicle includes one or more vehicle seats provided for an occupant of the vehicle. While a vehicle is shown with reference to seat assemblies used in a vehicle, it should be understood that the present invention may be used in any other seats, or seat components, including, among others, office, airline and entertainment seating applications. In addition, while the present invention is shown with references to seat assemblies, it should be further understood that the present invention may be used with any other trim component, including but not limited to, any other interior vehicular component having a trim cover disposed over a core portion.

[0021] The seating assembly, as shown in Figure 2, includes a seat track and seating components including a seat base connected to a seatback and a head restraint. The head restraint component is shown here as disassembled from the seat back. The seatback includes a seat frame shown in phantom having a seat core 24 and a trim cover 22, such as a leather skin, attached to the seat core 24 for occupant comfort. It should be appreciated that the trim cover 22 can be any material known in the art, including but not limited to, vinyl and cloth. It should be understood that the seat core 24 may be made of any core material known in the art, such as a foam core, and may be made of any number of known materials including, but not limited to, polypropylene, polyurethane, expanded polypropylene, or polyethylene. [0022] A trim cover retainer assembly 20, as shown in Figure 3, is used to join at least two edges 26, 28 of the trim cover 22 to the core 24. The trim cover retainer assembly 20 runs longitudinally along any point in the vehicular component requiring the mating of the

trim cover 22 to the core 24. It should be appreciated that the trim cover retainer assembly 20 may be used in connection with any portion of the seating assembly or seating components including, for example, the head restraint, seat base or seatback. By way of example, Figure 4 shows a head restraint with the trim cover 22 fixed to the seat core 24 with the trim cover retainer assembly 20.

[0023] The trim cover retainer assembly 20 includes a first retainer 30 and a second retainer 32. The first retainer 30 is attached to a first edge 26 of the trim cover 22 and the second retainer 32 is attached to a second edge 28 of the trim cover 22. In this embodiment, retainers 30, 32 are sewn onto the trim cover 22 but it should be appreciated that many other methods may be used to attach the retainers 30, 32 to the trim covers 22, including but not limited to, glue, adhesives, tapes, and material welding.

[0024] As shown in Figure 3, the first retainer 30 is partially U-shaped and includes at least one external barb 34 and at least one internal barb 36 to fixedly attach first retainer 30 to core 24. The first retainer 30 may include a plurality of external barbs 34. In the exemplary embodiment, the first retainer 30 includes two external barbs 34 that extend in opposite directions to engage the core 24. Second retainer 32 includes at least one retention barb 38 interfacing with internal barb 36 of first retainer 30 to position and fix second retainer 32 inside of first retainer 30 after complete insertion and installation of second retainer 32 into first retainer 30. Retainers 30, 32 may be made of any material including for example, extruded polypropylene.

[0025] As shown in Figure 5, the core 24 is provided with a core cavity 40 for receiving the trim cover retainer assembly 20. It should be appreciated that core cavity 40 may be formed in many ways including, without limitation, by molding the core cavity 40 into the core 24 when the core 24 is formed. The core cavity 40 may be many different sizes and shapes so long as a portion of the core cavity 40 is narrower than the overall width of

first retainer 30. As shown in Figure 3, after insertion of the trim cover retainer assembly 20, the core cavity 40 shape is deformed around at least a portion of first retainer 30. [0026] Second retainer 32, as shown in Figure 6, includes a first end 42 for attaching to the trim cover 22, a second end 44 having a retention barb 38 formed thereon and a second indicator 46 formed between the first and second ends 42, 44. Second indicator 46 is provided as a visual locator when attaching the trim cover 22 to the second retainer 32. In other words, when the trim cover 22 is positioned for attachment to second retainer 32, the second edge 28 of the trim cover 22 is aligned with reference to second indicator 46 to ensure the appropriate amount of material is used in connecting the trim cover 22 to second retainer 32. In the exemplary embodiment, the second indicator 46 is a ridge extending outwardly from an internal surface of the second retainer 32. It should be appreciated that second indicator 46 can be provided in many other shapes or sizes so long as the trim cover 22 can be appropriately positioned and attached to second retainer 32. Retention barb 38 is shown extending in a direction toward first end 42 of second retainer 32 such as in the form of a partial arrow, however, it should be appreciated that other shapes may be used for retention barb 38 so long as retention barb 38 interfaces with internal barb 36 of first retainer 30 to provide the desired retention of second retainer 32 to first retainer 30. [0027] First retainer 30, as shown in Figure 7, is partially U-shaped including a first retainer base 48 for attaching to the core 24, a first leg 50 extending in a direction toward the trim cover 22 and a second leg 52 extending in a direction toward the trim cover 22. First leg 50 and second leg 52 define a retainer cavity 54 for receiving second retainer 32 when inserted into first retainer 30. As shown in Figure 6, first leg 50 is shorter than the length of second leg 52 to provide for ease of insertion of second retainer 32 into retainer cavity 54. It should be appreciated that the amount of difference in the length of the first leg 50 to the second leg 52 depends on many design factors including, among others, the amount of trim

cover 22 material attached to each of the retainers 30, 32, and the amount of interface between the retention barb 38 and the internal barb 36.

[0028] The first retainer base 48 of the first retainer 30 is shaped for reduced resistance when inserted into the core cavity 40 of the core 24 and, in this embodiment, is shown shaped like the head of an arrow as shown in Figures 7 and 8. The first retainer base 48 includes the at least one external barb 34. In the exemplary embodiment, two external barbs 34 are disposed on the first end 42. The external barbs 34 are disposed on opposite ends of the first retainer base 48 and extend outwardly from the first retainer base 48 of the first retainer 30 toward the trim cover 22.

[0029] The second leg 52 of first retainer 30 includes the internal barb 36 that extends in a lateral direction toward the first leg 50, and a first indicator 56. The location of internal barb 36 on the second leg 52 is important since it has been found that second retainer 32 may try to pivot out of first retainer 30, however, the placement of internal barb 36 on the second leg 52 helps to prevent or limit second retainer 32 from pivoting out of first retainer 30. Both first indicator 56 and internal barb 36 extend along the length of first retainer 30. Like second indicator 46 of second retainer 32, first indicator 56 is provided as a visual locator when attaching the trim cover 22 to first retainer 30. In other words, when the trim cover 22 is positioned for attachment to first retainer 30, the first edge 26 of the trim cover 22 is aligned with reference to first indicator 56 to ensure the appropriate amount of material is used in connecting the trim cover 22 to first retainer 30. hi the exemplary embodiment, the first indicator 56 is a groove extending inwardly into the second leg 52 of the first retainer 30. It should be appreciated that, like second indicator 46 of second retainer 32, first indicator 56 can be provided in many other shapes or sizes so long as the trim cover 22 can be appropriately positioned and attached to first retainer 30.

[0030] As shown best in Figure 8, the spacing of retainer cavity 54 of first retainer 30 at a tip of internal barb 36 is less than a maximum width of second retainer 32 at a tip of retention barb 38. This dimensional relationship has been found to provide an appropriate retention/interlocking force between retainers 30, 32. Further, since the width of retention barb 38 is greater than the spacing in retainer cavity 54 at internal barb 36, an audible or snap-like feel is received by the assembler thereby providing some assurance during assembly that the appropriate assembly step was completed.

[0031] Figures 9 and 10 are used to detail a first method of using the trim cover retainer assembly 20. First, the first edge 26 of the trim cover 22 material is aligned with a visual indicator formed on first retainer 30, such as first indicator 56 shown in Figure 7. After such alignment, the trim cover 22 is attached to first retainer 30. A second edge 28 of the trim cover 22 material is aligned with a visual indicator formed on second retainer 32, such as second indicator 46 shown in Figure 6. After such alignment, the trim cover 22 is attached to second retainer 32. First retainer 30, with the trim cover 22 attached thereto, is then inserted into the core cavity 40 formed in the core 24 such that upon complete insertion the external barbs 34 deform the core 24 to fixedly attach first retainer 30 to such core 24. Second retainer 32, with the trim cover 22 attached thereto, is then inserted into the core cavity 40 formed in the core 24. Second retainer 32 is further inserted into the retainer cavity 54 of first retainer 30 such that second retainer 32 is fixedly attached to first retainer 30 by the interface between retention barb 38 and internal barb 36.

[0032] Figure 11 is used to detail a second method of using the trim cover retainer assembly 20. First, the first edge 26 of the trim cover 22 material is aligned with a visual indicator formed on first retainer 30, such as first indicator 56 shown in Figure 7. After such alignment, the trim cover 22 is attached to first retainer 30. A second edge 28 of the trim cover 22 material is aligned with a visual indicator formed on second retainer 32 such as

second indicator 46 shown in Figure 6. After such alignment, the trim cover 22 is attached to second retainer 32. Second retainer 32 is inserted into the retainer cavity 54 of first retainer 30, such that second retainer 32 is fixedly attached to first retainer 30 by the interface between retention barb 38 and internal barb 36. The entire trim cover retainer assembly 20 with first retainer 30 and second retainer 32, with the trim cover 22 attached thereto, is then inserted into the core cavity 40 formed in the core 24 such that upon complete insertion the external barbs 34 deform the core 24 to fixedly attach the trim cover retainer assembly 20 to such core 24.

[0033] The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.