Automobile seat composite cover and forming method

Abstract

The present invention relates to a composite cover for automobile seats and a molding method, wherein a semi-finished PVC / PU film is formed by winding and vacuum molding, and then impregnated into a resin mixture according to the impregnation area and bonded with a non-woven fabric / foam. The present invention is based on the ergonomics of the driver and passenger. The composite cover has the advantages of being soft and comfortable at a small deformation rate and having high tensile strength at a large deformation rate. It can not only ensure the tensile and fatigue strength at a large deformation rate, but also reduce the thickness and strength of the resin coating, thereby ensuring the softness of the PVC film and the bending fiber. The molded cover has good softness, ensuring the softness and comfort required by the driver and passenger when touching or sitting down, or the mid-front thigh support or shoulder support required by the driver and passenger when driving. The balance between softness and comfort at a small deformation rate and high tensile strength at a large deformation rate is adjusted by adjusting the number of fiber windings and the impregnation area, thereby meeting the customer's requirements for the performance of the seat cover.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile seats, and in particular relates to a composite cover for an automobile seat and a molding method thereof. Background Art

[0002] Currently, research on automotive seat covers primarily focuses on breathability, aesthetically pleasing seams, and different fabric assembly methods, with limited research examining their impact on ride comfort. In most cases, domestic OEMs only require seat covers to meet tensile and fatigue resistance requirements. However, while conventional seat cover molding processes meet the tensile strength requirements during driving, their softness is no longer sufficient for the comfort required during seating and driving.

[0003] The prior art discloses a cover structure for a car seat, comprising: a plurality of cut pieces, each of which includes a surface layer, a bottom layer arranged opposite to the surface layer, and a cushioning layer sandwiched between the surface layer and the bottom layer, wherein the side portions of the bottom layer and the surface layer both protrude from the corresponding side portions of the cushioning layer and are sewn together to form an extension portion; two adjacent cut pieces are sewn together through the extension portion to form a cover structure.

[0004] However, existing research on automotive seat trims, focusing on the softness and hardness requirements of the driver's seat, is scarce. Research on trims that simultaneously meet the requirements of softness and comfort at low deformation rates, as well as tensile and fatigue resistance at high deformation rates, is almost nonexistent. Advances in fiber and composite molding processes have made it possible to develop trims that balance softness and comfort with both tensile and fatigue resistance. Consequently, there is an urgent need to develop a composite automotive seat trim and molding method that combines softness and comfort at low deformation rates with high tensile strength at high deformation rates. Summary of the Invention

[0005] The purpose of the present invention is to address the deficiencies of the above-mentioned prior art and provide a composite cover for automobile seats that is soft and comfortable at a small deformation rate and has high tensile strength at a large deformation rate. A molding method for the above-mentioned composite cover for automobile seats is also provided to solve the problem of simultaneously satisfying the softness, comfort and fatigue resistance of the cover.

[0006] The purpose of the present invention is achieved through the following technical solutions:

[0007] A composite seat cover for an automobile, characterized in that it comprises a seat cover, wherein the seat cover is made by gluing and curing a sandwich structure formed by a semi-finished PVC / PU film, curved fibers, and non-woven fabric / foam;

[0008] Wherein, the seat cover surface A is made of PVC / PU film; the seat cover surface B is made of non-woven fabric / foam; and the curved fiber is arranged between the seat cover surface A and B.

[0009] Furthermore, the curved fibers are divided into two types: single fiber bundle and radial and weft braided.

[0010] Furthermore, the curved fibers are curved fiber bundles or fiber films woven from curved fibers.

[0011] Furthermore, the seat cover is wound with curved fibers below the waist and buttocks and at the shoulders and front end of the thighs, and the density of the curved fibers at the waist and buttocks is greater than that at the shoulders and front end of the thighs.

[0012] A method for forming a composite cover for an automobile seat, characterized by comprising the following steps:

[0013] A. Semi-wet curved fiber winding of PVC / PU film semi-finished products:

[0014] The semi-finished PVC / PU film is mounted on the core mold of the filament winding machine for semi-wet bending filament winding;

[0015] B. The formed curved fibers are subjected to semi-wet curved fiber treatment:

[0016] Then, the formed curved fiber is impregnated into the resin mixture according to the impregnation area;

[0017] C. After the bending fiber winding is completed, the non-woven fabric / foam is wound onto the preformed core mold;

[0018] D. After semi-curing, disassemble the preformed core mold and place it in a vacuum forming bag. After complete curing, remove the vacuum bag and core mold.

[0019] Furthermore, in step A, the winding is carried out according to the designed fiber orientation and laying method.

[0020] Furthermore, in step B, the impregnated fiber areas are impregnated at an angle of less than or equal to 45 degrees with intervals of 5 to 20 mm.

[0021] Furthermore, in step B, the curved fibers are divided into two types: single fiber bundles and radial and weft braided fibers.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] Based on the comfort perception of the driver and passenger's biomechanics, this invention has developed a composite face cover that is soft and comfortable at low deformation rates and highly tensile at high deformation rates, as well as a molding process. The process utilizes winding vacuum molding and regional fiber impregnation to ensure tensile and fatigue strength at high deformation rates while reducing the thickness and strength of the resin coating, thereby ensuring the softness of the PVC / PU film and curved fibers.

[0024] The molded seat cover has good softness, which ensures the softness and comfort that the driver and passenger can feel when touching or sitting down, or the softness and comfort required for the front middle thigh or shoulder support during driving; by adjusting the number of fiber windings and the impregnation area, the balance between softness and comfort at small deformation rates and high tensile strength at large deformation rates can be adjusted to meet customer requirements for seat cover performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 Schematic diagram of the winding method of curved fibers on the PVC / PU film semi-finished product before vacuum forming;

[0027] Figure 2 Schematic diagram of the impregnated and non-impregnated areas of a bent fiber bundle or film and their impregnation method;

[0028] Figure 3a-3c Schematic diagram of the bent fiber bundle and the woven fiber film;

[0029] Figure 4 Schematic diagram of the cross-section of the sandwich structure formed by winding;

[0030] Figure 5 Schematic diagram of the evolution of the bending fiber state under small and large deformation rates of the cover when carrying the driver and passengers during driving;

[0031] Figure 6 Schematic diagram of the requirements of different parts of the driver and passenger for the softness, comfort and fatigue resistance of the face mask. DETAILED DESCRIPTION

[0032] The present invention will be further described below in conjunction with embodiment:

[0033] The present invention will be further described in detail below with reference to the accompanying drawings and examples. It will be understood that the specific embodiments described herein are intended only to illustrate the present invention and are not intended to limit the present invention. It should also be noted that, for ease of description, the accompanying drawings only illustrate portions relevant to the present invention, not all structures.

[0034] It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings. At the same time, in the description of the present invention, the terms "first", "second", etc. are used only to distinguish the description and should not be understood as indicating or implying relative importance.

[0035] The composite cover for the automobile seat of the present invention is formed by winding vacuum and is made by pasting and curing a sandwich structure formed by a semi-finished PVC / PU film, curved fibers and non-woven fabric / foam.

[0036] The method for forming a composite cover for an automobile seat of the present invention comprises the following steps:

[0037] 1. Semi-wet bending fiber winding on PVC / PU film semi-finished products:

[0038] The semi-finished PVC / PU film is mounted on the core mold of the filament winding machine and the machine is started to perform semi-wet curved filament winding. During winding, the fiber direction and laying method are followed.

[0039] 2. The formed curved fibers are subjected to semi-wet curved fiber treatment:

[0040] The formed curved fibers are impregnated into a resin mixture along the designed impregnation area. The impregnated resin mixture has adhesive properties and is an adhesive for bonding PVC / PU films and non-woven fabrics / foams. The impregnated fiber area is impregnated at an angle of 45° or less and at intervals of 5 to 20 mm.

[0041] The regional fiber impregnation method is to impregnate the wrapped fiber bundle at an angle of less than or equal to 45 degrees, with an interval of 5 to 20 mm between the impregnation areas. This can not only ensure the tensile and fatigue strength under large deformation rates but also reduce the thickness and strength of the resin coating, thereby ensuring the softness of the PVC film and the curved fiber.

[0042] 3. After the bending fiber winding is completed, the non-woven fabric / foam is wound onto the pre-formed core mold.

[0043] 4. After semi-curing, remove the preformed core mold and place it in the vacuum forming mold cavity. After complete curing, remove the core mold.

[0044] The curved fiber forms are divided into two types: single fiber bundle and radial weft braiding.

[0045] The present invention achieves the softness of the mask for different parts of the human body by studying the bent fiber bundles, the woven fiber films and the impregnation method. When the deformation rate is large, the fatigue tensile performance can be increased after the bent fibers inside are straightened.

[0046] By using curved fiber bundles or curved fiber braids, the fibers remain bent and unstretched at low deformation rates. The fiber layer does not contribute to the stretchability, preserving the elasticity of the PVC / PU film and ensuring the softness of the face cover. This ensures the softness and comfort required by the driver and passenger when touching or sitting down, as well as the mid-thigh and shoulder support required during driving.

[0047] By using bent fiber bundles or bent fiber woven layers, when the seat cover has a large deformation rate, the bent fiber state is in an extended state. The fiber layer increases the stretching, and works together with the PVC / PU film to present the tensile strength of the seat cover. By adjusting the number of fiber windings and the impregnation area, the balance between softness and comfort at a small deformation rate and high tensile strength at a large deformation rate can be adjusted to meet customers' requirements for seat cover performance.

[0048] like Figure 1 As shown, when the curved fibers before vacuum forming are wound on the PVC / PU film semi-finished product, the wound fibers may be curved fiber bundles or a fiber film woven with curved fibers.

[0049] like Figure 2 As shown, according to the tensile strength requirements of the cover, the fiber quantity and impregnation area are designed to meet the needs of softness, comfort and fatigue tensile strength.

[0050] like Figure 5 As shown, during use, the face cover after vacuum wrapping is affected by the weight of the occupant and the bumps during driving. The face cover has a higher deformation rate at the waist and below the hips. At this time, some of the curved fibers in the face cover are in a straightened state. Compared with the case with a small deformation rate, the tensile strength is significantly increased, supporting the occupant and ensuring muscle deformation is within a comfortable tension range. In contrast, during driving, the shoulders and the front and middle thigh areas often require the face cover to be soft and comfortable. At this time, at a small deformation rate, the curved fibers are not straightened, and most of the load-bearing capacity comes from the PVC / PU film, ensuring the face cover's softness and comfort at a small deformation rate. In the present invention, designers can choose to wrap a higher density of curved fibers at the waist and below the hips, and a lower density of curved fibers at the shoulders and the front and middle thighs, according to their needs, more flexibly meeting the needs of different parts of the body for the face cover's softness and comfort.

[0051] like Figure 6 As shown, the shoulders and the front end of the thighs require greater face mask softness, that is, the shoulders and the front end of the thighs require better softness. In contrast, the waist and the lower part of the hips can be harder.

[0052] The present invention utilizes a vacuum winding method to produce a seat cover that meets the comfort requirements of different human body parts. Specifically, the seat cover will have different properties corresponding to different body parts, with softness levels 1-3. For example, the seat cover corresponding to the mid-front section of the shoulders and thighs needs to be relatively soft, corresponding to softness level 1, while the waist and hips can be less soft, corresponding to softness level 2. For another example, the shoulders, waist, hips, and mid-front section of the thighs all have the same softness, except that the waist and hips experience a greater deformation rate. This is when the curved fibers straighten, and the curved fibers and PVC film together create tensile strength.

[0053] Note that the above are only preferred embodiments of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments, and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments and may include many other equivalent embodiments without departing from the concept of the present invention. The scope of the present invention is determined by the scope of the appended claims.

Claims

1. A composite cover for a car seat, characterized by: The seat cover is made of a sandwich structure formed by gluing and curing a PVC / PU film semi-finished product, curved fibers, and non-woven fabric / foam; Wherein, the seat cover surface A is made of PVC / PU film; the seat cover surface B is made of non-woven fabric / foam; the curved fiber is arranged between the seat cover surface A and B; The curved fibers are divided into two types: single fiber bundles and radial and weft braided fibers; the curved fibers are curved fiber bundles or fiber films woven from curved fibers; The seat cover is wound with curved fibers at the waist and below the buttocks and at the shoulders and front end of the thighs, and the density of the curved fibers at the waist and buttocks is greater than that at the shoulders and front end of the thighs. A method for forming a composite cover for an automobile seat comprises the following steps: A. Semi-wet curved fiber winding of PVC / PU film semi-finished products: When winding, follow the designed fiber direction and laying method; The semi-finished PVC / PU film is mounted on the core mold of the filament winding machine for semi-wet bending filament winding; B. The formed curved fibers are subjected to semi-wet curved fiber treatment: the impregnated fiber area is impregnated at an angle of less than or equal to 45 degrees with intervals of 5 to 20 mm; the curved fibers are divided into two types: single fiber bundles and radial and weft braids; Then, the formed curved fiber is impregnated into the resin mixture according to the impregnation area; C. After the bending fiber winding is completed, the non-woven fabric / foam is wound onto the preformed core mold; D. After semi-curing, disassemble the preformed core mold and place it in a vacuum forming bag. After complete curing, remove the vacuum bag and core mold.

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