Cushion assembly

Inventors: David Hale (Southfield, MI); Wu Pan Zagorski (Clawson, MI); Samuel Blair (Troy, MI); Joshua Hallock (Warren, MI)

Assignee: LEAR CORPORATION

B60N2/5866 B68G7/05

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Quick Facts

Patent No.: US 12703279
App. No.: 18/087,857
Granted: Aug 11, 2026
Kind: B2

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Abstract

An assembly is provided with a unitary mesh of expanded thermoplastic resin strands with a cavity formed therein. A trim component or a support member is oriented at least partially within the cavity. A weld is formed at least partially along the mesh adjacent to the cavity to retain the trim component or the support member within the cavity.

Claims (21)

1 . A seat cushion assembly, comprising:

a unitary mesh of thermoplastic strands with a cavity formed therein, the cavity formed by compressing at least a portion of each of at least two regions of the unitary mesh, such that the at least two regions are folded to overlap;

a trim component oriented partially within the cavity and extend through the unitary mesh, wherein the trim component comprises a tab that is adapted to engage with a frame of a seat; and

a weld comprising a depth, the weld formed at least partially along mating surfaces of the at least two regions, adjacent to the cavity and along a lateral side of the trim component, wherein the weld is outside the cavity.

2 . An assembly, comprising:

a unitary mesh of expanded thermoplastic resin strands comprises at least two regions that are folded to overlap, such that a cavity is formed between the at least two regions;

a trim component or a support member oriented at least partially within the cavity, wherein the trim component or the support member is adapted to engage with a seat frame; and

a weld formed at least partially along mating surfaces of the at least two regions of the unitary mesh, adjacent to the cavity to retain the trim component or the support member within the cavity, such that the weld is formed outside the cavity.

3 . The assembly of claim 2 , wherein the cavity is formed by compressed regions in the mating surfaces of the unitary mesh.

4 . The assembly of claim 2 , wherein the trim component or the support member extend through the mesh.

5 . The assembly of claim 4 , wherein the weld is formed along a lateral side of the trim component or the support member.

6 . The assembly of claim 2 , wherein the trim component is oriented partially in the cavity.

7 . The assembly of claim 6 , wherein the trim component further comprises a tab adapted to engage with a structural member.

8 . The assembly of claim 2 , wherein the support member is oriented partially in the cavity.

9 . The assembly of claim 8 , wherein the support member further comprises a suspension wire.

10 . The assembly of claim 2 , wherein the mesh is welded without adhesive.

11 . The assembly of claim 2 , wherein a quantity of strands throughout the weld is consistent.

12 . A seat cushion assembly comprising the assembly of claim 2 .

13 . A seat assembly, comprising:

a seat frame; and

a cushion assembly according to claim 12 .