Panel assembly with molded foam backing

Abstract

A seat trim cover for a motor vehicle seat having a three-dimensional shape is formed by pre-cutting a laminate blank (210) into a pre-defined shape having a pre-defined trim (410) extending around an outer periphery of the laminate blank; vacuum forming the laminate blank in a three-dimensional mold to form a three-dimensional laminate blank; and forming a molded foam backing (420) on the three-dimensional shaped laminate blank to form the seat trim cover. The molded foam backing has an outer periphery that is spaced apart from the pre-defined trim such that the pre-defined trim is free of foam.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and all rights to U.S. Provisional Application No. 62 / 910,705, filed October 4, 2019, and is also a continuation-in-part of International Application No. PCT / US2019 / 035244, filed June 3, 2019, which claims priority to U.S. Provisional Application No. 62 / 679,053, filed June 1, 2018, and U.S. Provisional Application No. 62 / 845,928, filed May 10, 2019, all of which are incorporated herein by reference in their entirety. Background of the Invention 1. Technical Field

[0004] This invention relates to a process for molding cover materials and cover materials formed using the molding process. More specifically, this invention relates to a process for forming three-dimensional cover materials and automotive seat trim covers formed by the molding process. 2. Background Technology

[0006] Motor vehicles typically include one or more seat assemblies for supporting passengers above the vehicle floor, said seat assemblies having seat cushions and seat backs. Typically, each of the seat cushions and seat backs includes a foam padding supported by a frame. A cover is assembled with the foam padding to provide a final surface. Each of the seat cushions and seat backs typically has one or more contoured surfaces and usually requires a contour cover. A contour cover typically includes a seat surface portion fastened and / or stitched to one or more side members (this seat surface portion is hereinafter referred to as a trim cover panel or trim cover).

[0007] Various processes for forming three-dimensional automotive seat upholstery covers are known in the art. One commonly known method for forming a contoured upholstery cover involves cutting pieces of cover material into desired shapes and sewing multiple pieces together along the edges to form the upholstery cover. Depending on the desired contour level in the upholstery cover, this cutting and sewing process can be relatively expensive, time-consuming, and difficult. As the required contour level increases, additional material pieces are needed. Furthermore, additional seams and stitching lines may be required in the upholstery cover to achieve the desired styling appearance. There are practical limitations on the amount of detail and contour level that can be produced using cutting and sewing up the upholstery cover.

[0008] Other known methods for forming contoured trim covers include various molding processes. Molded seat surfaces are ideal for automotive applications because they offer reduced material and labor costs compared to conventional cut-and-stitched trim covers. Furthermore, the molding process allows for additional shaping and deeper contours that are difficult to achieve using cut-and-stitched constructions. Finally, molded seat surfaces generally offer improved processability and cleaner operation compared to cut-and-stitched constructions due to the fewer seams.

[0009] U.S. Patent No. 4,722,760 discloses a known method generally described as Uni-Trim TM (integrated decoration) TM The method of molding decorative covers. Uni-Trim TM The method typically includes the following steps: forming a plurality of spaced-apart recesses on the surface of the foam backing; placing cover material on a lower mold having protrusions corresponding to the recesses in the surface of the foam backing; molding the cover material into the contour of the lower mold; applying adhesive to the formed cover material; applying the grooved foam backing to the formed cover material; and bonding the formed cover material to the foam backing. This known process may generate more manufacturing waste than conventional cutting and sewing methods because mis-bonded covers cannot be recycled or reused. Additionally, the process may require cover material with high fiber elongation, which increases the cost of the cover material and limits the selection of suitable materials. Furthermore, because the cover material cannot be removed from the foam backing, warranty costs are higher than with other manufacturing methods, and therefore the entire cover and backing assembly must be replaced in case of damage.

[0010] Another known method called SureBond is disclosed in U.S. Patent No. 4,692,199. TM A method for assembling decorative covers. SureBond TM The method typically involves applying a thermoplastic adhesive film and a cover material to the formed porous foam liner, and applying superheated steam to diffuse the adhesive layer and permanently bond the cover material to the foam liner. The cover material can be recycled if defects occur during the bonding process. However, the porous foam liner is generally not recycled. Using steam to diffuse the adhesive can cause the cover material to warp and the porous foam liner to change shape. Superheated steam can also warp the fibers in the fabric cover material during the bonding process. When the cover material and the porous foam liner are not fully bonded, the unbonded adhesive film can produce an annoying wrinkled "squeak" in the final car seat. Compared to other known methods, SureBond... TM The warranty cost for the cover is high because if there is any problem with the porous foam padding or the cover material, the entire decorative cover and foam padding must be replaced.

[0011] Another known method for incorporating a decorative cover into a foam pad is disclosed in U.S. Patent No. 5,231,746, and this method is commonly referred to as PureFit. TM (complete match) TM The PureFit TM The process typically includes the following steps: sewing the front and back fabric panels together with their facing outer surfaces to form a bag-like structure; sliding the bag-like structure onto a tongue-shaped mold; placing an airtight barrier film on the inner surface of the front panel and applying a vacuum to form a front panel surrounding the tongue-shaped mold; bringing the front panel into contact with the mold surface of the tongue-shaped mold; forming a bulk of foam material on the inner surface of the front panel; and flipping the bag-like structure so that the foam material is located within the bag-like structure. This known PureFit... TM The method has high processing costs. Furthermore, improperly formed seatback covers cannot be reused, and the entire molded cover / foam assembly is scrapped. Additionally, molded seatback covers are not breathable because a barrier membrane is required during the vacuum forming process. Airflow through the foam is restricted by the barrier membrane, which can lead to moisture buildup between the car seat and the occupant.

[0012] U.S. Patent No. 8,794,708 discloses a commonly known technology called Cover Carving Technology. TM (Cover carving technique) TM A method for forming seat trim panels (CCT) is described. The CCT method typically includes the following steps: spraying porous foam onto a polypropylene substrate to form a coated substrate; attaching the coated substrate to the opposite side of a textile material in a press including a die and a punch; and actuating the press to impart a visible shape within the foam bonded to the textile material while the foam is in a viscous state. Because the porous foam is sprayed onto a polypropylene sheet, the resulting seat trim panels typically have little or no airflow through the sheet.

[0013] Another known compression molding process developed by Actex, Inc. is disclosed in U.S. Patent No. 4,867,826. The Actex method generally includes the following steps: applying a heat-curable polyurethane adhesive to one surface of a compressible polyurethane foam layer; bringing the adhesive-coated surface of the foam layer into direct contact with a cover material layer to form a double layer; placing the double layer on a pressure plate; bringing the cover material layer of the double layer into contact with at least one heated protrusion of a molding tool at a temperature of about 300°F to about 480°F (about 150°C to about 250°C); compressing a region of the foam layer adjacent to the heated protrusion; using the heat of the protrusion to melt and collapse the compressed region of the foam layer for a period of about 30 seconds to about 90 seconds to form a permanent protrusion in the double layer; and removing the protrusion from the double layer and curing the melted and collapsed region of the foam layer. As generally described, the laminated foam article is compressed and molded against a flat lower surface, i.e., the profile is molded into the foam layer by heated protrusions pressed into the upper surface of the foam layer. While the relatively high molding temperature of approximately 300°F to approximately 480°F allows for processing times of approximately 30 seconds to approximately 90 seconds and for curing the urethane adhesive, this molding temperature range limits the choice of suitable fabrics. Additionally, because the foam product is compressed and molded while maintaining the generally flat lower surface of the foam layer (often described as a two-dimensional molding process), the foam product must be bent to achieve the desired shape for assembly into the car seat, which can result in cracks and wrinkles in the final seat. Warranty costs for Actex foam products are also similarly high compared to other known methods because if any problem occurs with either the foam layer or the cover material, the entire trim cover and foam layer must be replaced.

[0014] Therefore, it is desirable to form a car seat cover having a three-dimensional shape with a partial profile of up to approximately 4 inches along the seat surface. Furthermore, it is desirable to have a seat cover that can be releasably attached to the seat foam padding. Additionally, it is desirable to minimize the amount of bending required for the cover when it is assembled to the car seat. Furthermore, it is desirable to have a seat cover with a smooth, seamless styling surface, wherein fasteners are concealed. It is also desirable to have a predefined, foam-free edging extending around the outer periphery of the seat cover. Furthermore, it is desirable to form seat covers with increased contours and / or detailed shapes to provide a styling appearance that is not typically achievable with conventional cut-and-stitch designs. Additionally, it is desirable to integrally incorporate secondary features, such as electronic sensors and / or seat heaters, into the seat cover as part of the molding process. Similarly, it is desirable to mold other types of surface covers for automotive interiors and household products. Finally, it is desirable to provide seat covers that offer improved breathability compared to other molding techniques and provide thermal comfort comparable to conventional cut-and-stitch covers. Summary of the Invention

[0015] A seat cover with a three-dimensional shape for a motor vehicle seat is formed by the following steps: pre-cutting a laminated preform into a predetermined shape having a predetermined edging extending around an outer periphery of the laminated preform; vacuum forming the laminated preform in a three-dimensional mold to form a three-dimensional laminated preform; and forming a molded foam backing on the three-dimensional laminated preform to form the seat cover. The molded foam backing has an outer periphery spaced apart from the predetermined edging such that the predetermined edging is foam-free. Attached Figure Description

[0016] The advantages of the present invention will be readily apparent, as they become more readily understood by referring to the following detailed description taken in conjunction with the accompanying drawings, in which:

[0017] Figure 1 The illustration shows a front perspective view of a vehicle seat having a molded seat back cover and a molded seat cushion cover according to an embodiment of the present invention.

[0018] Figure 2 The illustration shows a decorative cover with a molded backrest panel according to an embodiment of the present invention. Figure 1 A rear-view 3D view of the vehicle seats;

[0019] Figure 3 The illustration shows an embodiment of the present invention. Figure 1 An exploded view of the vehicle seats;

[0020] Figure 4 The illustration shows an embodiment of the present invention. Figure 1 Front view of the molded seat back trim cover;

[0021] Figure 5 The illustration shows an embodiment of the present invention. Figure 2 Rear view of the molded backrest panel decorative cover;

[0022] Figure 6 The illustration shows the path along the embodiment of the present invention. Figure 4 The section line shown in Figure 6-6 is the cut. Figure 4 A cross-sectional view of the molded seat back decorative cover;

[0023] Figure 7 The illustration shows the path along the embodiment of the present invention. Figure 5 The section line shown in 7-7 is the cut. Figure 5 A cross-sectional view of the molded backrest panel decorative cover;

[0024] Figure 8 The illustration shows a perspective view of a vehicle seat in the prior art;

[0025] Figure 9A The diagram illustrates the following: along Figure 8 The section line 9A-9A shown is the cut. Figure 8 A cross-sectional view of a portion of the existing decorative cover;

[0026] Figure 9B The diagram illustrates the following: along Figure 8 The section line shown is 9B-9B. Figure 8 A cross-sectional view of a portion of the existing decorative cover;

[0027] Figure 10 illustrates a typical seat cover hook fastener embedded in a prior art base foam liner;

[0028] Figure 11 illustrates a prior art seat cover ring fastener for stitching to a cut and stitched decorative cover;

[0029] Figure 12 illustrates a partial exploded perspective view of a portion of a prior art seat with an integrated seat heater;

[0030] Figure 13 An enlarged view of a molded three-layer structure according to an embodiment of the present invention is shown;

[0031] Figure 14 The illustration shows a top view of a cover material blank, a moldable foam interlayer blank, and a nonwoven roving backing blank according to an embodiment of the present invention.

[0032] Figure 15 The illustration shows an embodiment of the present invention. Figure 13 A perspective view of a portion of a three-layer laminated assembly (laminated preform) consisting of a cover material layer, a moldable foam intermediate layer, and a nonwoven roving backing layer;

[0033] Figure 16A and Figure 16B This is a schematic diagram of a first embodiment of a laminated preform having a heating element according to an embodiment of the present invention;

[0034] Figure 16C This is a perspective view of a molded seat back decorative cover having an integrally integrated seat heater according to another embodiment of the present invention.

[0035] Figure 17A and Figure 17B This is a schematic diagram of a second embodiment of a laminated preform having a heating element according to an embodiment of the present invention;

[0036] Figure 17C and Figure 17D This is a perspective view of a molded seat back decorative cover with an integrally integrated heater according to another embodiment of the present invention.

[0037] Figure 18 The illustration shows a perspective view of the lower molding tool surface and the upper molding tool surface according to an embodiment of the present invention;

[0038] Figure 19 The illustration shows an embedding according to an embodiment of the present invention. Figure 18 The lower molding tool surface and the upper molding tool surface Figure 15 A three-dimensional view of the triple-laminated component;

[0039] Figure 20 The illustration shows the process after the molding process according to an embodiment of the present invention. Figure 15 Trilaminated components and Figure 19 A three-dimensional view of the molding tools;

[0040] Figure 21A , Figure 21B and Figure 21C A perspective view of an alternative molding process according to another embodiment of the present invention is shown;

[0041] Figure 22 The illustration shows a top view of a base foam pad with hook fasteners according to an embodiment of the present invention;

[0042] Figure 23 The illustration shows a bottom view of a molded seat cover with partially attached ring fasteners according to an embodiment of the present invention.

[0043] Figure 24 The illustration shows a bottom view of a molded seat cover according to an embodiment of the present invention;

[0044] Figure 25 The illustration shows a top view of a molded seat cover according to an embodiment of the present invention;

[0045] Figure 26 The illustration depicts an object exposed to environmental aging according to an embodiment of the present invention. Figure 25 A top view of the molded seat cover;

[0046] Figure 27A The illustration shows a rear view of a molded seat back panel with a seam between two materials prior to the molding process, according to another embodiment of the invention.

[0047] Figure 27B The illustration shows another embodiment of the invention. Figure 27A A partial rear view of the molded seat back panel;

[0048] Figure 28 The illustration shows a rear view of a molded seat back panel with an integrally integrated pocket according to another embodiment of the present invention.

[0049] Figure 29 The illustration shows a rear view of a molded seat back panel with a full-width pocket according to another embodiment of the present invention;

[0050] Figures 30A to 30E The illustration shows a front view of a vehicle seat according to an embodiment of the present invention;

[0051] Figure 31A The illustration shows a top view of a vehicle seat with a molded buckle pocket according to another embodiment of the present invention;

[0052] Figure 31B and Figure 31C The illustration shows another embodiment of the invention. Figure 31A A partial top view of a molded buckle pocket;

[0053] Figure 32 The illustration shows a view of a molded seat back panel with a predefined edge that is free of foam, according to another embodiment of the invention.

[0054] Figure 33 A view of a pre-cut laminated blank with positioning features according to another embodiment of the present invention is shown;

[0055] Figure 34 The illustration shows a three-dimensional molded cover and a molded base according to another embodiment of the present invention;

[0056] Figure 35 The diagram shows Figure 34An enlarged perspective view of a portion of the molded base, showing the molding positioning features and vacuum holes;

[0057] Figure 36 The diagram shows Figure 33 The pre-cut blank is inserted into Figure 34 A three-dimensional view showing the alignment of the positioning features of the laminated blank with the positioning features of the molded cover and the molded base;

[0058] Figure 37 The diagram shows Figure 33 The laminated preform is inserted into Figure 34 A three-dimensional view inside the molded base, wherein the molding positioning features of the molded base pass through the corresponding positioning features of the laminated blank;

[0059] Figure 38 The illustration shows the process after vacuum forming the laminated preform into a three-dimensional shape. Figure 34 The molded base Figure 33 A three-dimensional view of the laminated preform;

[0060] Figure 39 The illustration shows the vacuum forming process after the laminated preform is pressed against the molding base. Figure 34 Molded caps and molded bases and Figure 33 A cross-sectional view of the laminated preform assembly is shown, and the liquid component is also illustrated by being injected through a port in the molded cap into the cavity between the vacuum-formed laminated preform and the molded cap.

[0061] Figure 40 The illustration shows the process after a molded foam backing is formed within the cavity between the vacuum-formed laminated preform and the molded cap. Figure 39 Cross-sectional views of the molded cap, molded base, and vacuum-formed laminated preform;

[0062] Figure 41 As shown Figure 40 The image shows a perspective view of a molded seat back panel located within a molded base after a molded foam backing has been formed on a vacuum-formed laminated preform.

[0063] Figure 42 A front view of a molded seat back panel according to another embodiment of the invention is shown, illustrating the vacuum-formed surface profile and the predefined foam-free edging.

[0064] Figure 43 It shows Figure 42 A rear view of a molded seat back panel, illustrating a molded foam backing adhered to a vacuum-formed laminated blank, and illustrating a foam-free, predefined edging extending around the outer periphery of the molded seat back panel.

[0065] Figure 44 It shows Figure 43 A magnified view of part 44, which illustrates the pre-defined edging without foam;

[0066] Figure 45 It shows Figure 42 An enlarged perspective side view of the seat back panel and side layer assembly, illustrating the stitching seam connecting the foam-free, pre-defined trim of the seat back panel to the edge of the side layer; and

[0067] Figure 46 It shows Figure 45 An enlarged perspective top view of a portion of the decorative cover assembly, illustrating the stitching seam formed within a predefined, foam-free edging of the seat back panel. Detailed Implementation

[0068] Figures 1 to 7 as well as Figures 13 to 46 The illustrations depict molded vehicle seat covers and / or trim components according to embodiments described herein, a vehicle seat having the molded covers and / or trim components, and a process for manufacturing the seat covers and / or trim components. Directional designations used or shown in the specification, drawings, or claims, such as top, bottom, upper, lower, upward, downward, longitudinal, lateral, left, right, etc., are relative terms used for ease of description and are not intended to limit the scope of the invention in any way. Furthermore, the drawings are not necessarily shown to scale. Referring to the drawings, similar numbers indicate similar or corresponding parts throughout several views.

[0069] Figure 1 and Figure 2 An embodiment of the FreeForm is shown according to the present invention. TM (freeform) TM A perspective view of the vehicle seat assembly 10 with the molded trim cover 12. The trim cover 12 and other components assembled and compressed using the process disclosed herein are optionally described as FreeForm. TM Components. As is commonly known in the art, the vehicle seat assembly 10 has a seat back 14 rotatably connected to a seat cushion 16 and a headrest 18 coupled to the seat back 14. The seat cushion 16 extends between a front end 20 and an opposite rear end 22 adjacent to the seat back 14. The seat cushion 16 includes a base foam pad 24 and other optional components. The seat back 14 extends between a top end 26 and an opposite bottom end 28 adjacent to the rear end 22 of the seat cushion 16. The seat back 14 includes a front surface 30 and a rear surface 32. The seat back 14 includes a base foam pad 40 and other optional components. Figure 3As shown, each of the seat cushion 16 and seat back 14 includes frames 34 and 36 for supporting molded base foam pads 24 and 40. The front surface 30 and rear surface 32 of the seat cushion 16 and seat back 14 are enclosed in molded trim covers 12 and other optional trim components. Each trim cover 12 includes a molded trim component 45, which may optionally be stitched or assembled with one or more side components 46 to form a trim cover assembly 48. The seat cushion trim cover 50 is assembled with the base foam pads 24 to form the seat cushion 16. Figure 3 As shown, the seat back cover 52 and seat back panel 54 are assembled together with the base foam padding 40 to form the seat back 14.

[0070] This invention relates to a molded trim cover for a vehicle seat 10. More specifically, compared to conventional molded trim covers, the disclosed molded seat trim cover 12 has an improved appearance, reduces the number of required seams, and has improved breathability.

[0071] FreeForm TM Molded seat back cover 52 and FreeForm TM The molded seat back panels 54 are respectively in Figure 4 and Figure 5 The diagram shows the molding feature 70, the molding line 72 with a stitched seam appearance, the surface concave portion 74, and the three-dimensional shape. Cross-sectional views of the seat back trim cover 52 and the seat back panel 54 are shown in [the diagram / illustration]. Figure 6 and Figure 7 As shown in the diagram. Both the seat back cover 52 and the seat back panel 54 include at least a cover material layer 78 adhered to a moldable foam interlayer 80. Optionally, a woven or nonwoven fabric backing layer 82 is adhered to the underside 84 of the foam interlayer 80. The cover material layer 78 includes one or more of fabric, vinyl material, and / or leather. Optionally, although not shown in the diagram... Figure 6 As explicitly stated, each seat back cover 52 may have additional layers, such as adhesives, spacer materials, and / or functional elements, such as embedded electronics and / or seat heaters. It will be understood that various materials may be incorporated into the seat back cover 52 prior to molding, as intended or desired for the application. It will also be understood that the layered construction choice for the seat back cover 52 and the seat back panel 54 also applies to the seat cushion cover 50.

[0072] The molded decorative covers 50, 52 and the backrest panel 54 may optionally have portions with steeply curved inclined surfaces 86 and / or gently sloping facets 88 in their surface profiles. As generally... Figure 6 and Figure 7As shown, the local variations in amount and slope in the upper surface 90 of the molded decorative covers 50, 52 and backrest panel 54 result in the appearance of deep “strong” molding lines 92, shallow “weak” molding lines 94, surface concavity, and / or local curvature, thereby providing a three-dimensional shape. During the molding process described below, the molded decorative covers 50, 52 and backrest panel 54 are molded into shapes typically formed in their ejection from the molding tool 96 ( Figure 18 The final shape retained after removal (as shown in the diagram). This three-dimensional shape is mainly achieved by using the upper molding tool 98 and the lower molding tool 100 in three dimensions. Figure 18 The foam interlayer 80 is produced by compression molding between the layers (shown in the diagram). The molding tool 96 is heated to a range of about 150°F to about 320°F to create a temperature gradient on the foam interlayer 80. The foam interlayer 80 can be molded in a temperature range of about 220°F to about 260°F. The overall shape of the molded trim covers 50, 52 and backrest panel 54 is maintained even when they are bent; that is, the molded trim covers 50, 52 and backrest panel 54 generally return to their molded shape when they are not constrained.

[0073] In contrast, commonly known methods of constructing decorative covers include known molding techniques and traditional cutting and stitching construction. Figure 8 The illustration shows a car seat 108 with exemplary decorative covers 110, 112, which have a commonly known compression-molded seam 114 and a commonly known cut and stitched seam 116. Figure 8 and Figure 9A The commonly known compression-molded seam 114 shown is obtained by applying a cover material 118 and an adhesive (not shown) to a foam layer 120 to form a cover / foam assembly 122, which is compression-molded at a high temperature of about 300°F to about 480°F (about 150°C to about 250°C) to form the appearance of a seam in the exemplary decorative cover 110. Figure 9A A partial cross-sectional view of an exemplary seat cover 110 is shown, illustrating the appearance of the molded seam 114. The resulting molded seam 114 is generally uniform in appearance, with a minimal profile in the resulting upper surface 124 of the cover 110. Furthermore, the resulting cover 110 is generally rigid and has little or no breathability. Exemplary known covers 110 are typically formed using two-dimensional tools and bent into a three-dimensional shape, which may result in wrinkles in the cover 110. Finally, the choice of cover material is limited because compression molding is performed at high temperatures ranging from about 300°F to about 480°F.

[0074] Figure 9BA partial cross-sectional view of an exemplary seat cover 112 is shown, illustrating the appearance of the cut and stitched seam 116. The resulting cut and stitched seam 116 is generally uniform in appearance, with a minimal profile on the resulting upper surface 130 of the cover 112. Conventional cut and stitched covers 112 require cutting material pieces 132, 134 into a certain shape and stitching the edges 136, 138 of the cut pieces 132, 134 together, resulting in, for example... Figure 8 and Figure 9B The illustrated complete cut and stitched decorative cover 112. The cut and stitched decorative cover 112 is expensive because multiple material pieces 132, 134 must be cut and stitched together. Furthermore, the cost and complexity of the cut and stitched decorative cover 112 increase when additional design details, such as surface contours and / or seams 116, are added.

[0075] Referring to Figures 10 and 11, the seat cover 142 is typically attached to a base foam pad 144 using fasteners 146. The base foam pad 144 shown in Figure 10 includes a plurality of hook fasteners 148. As illustrated in Figure 11, the seat cover 142 has a plurality of ring fasteners 150 attached to the lower surfaces 152, 154 of the cover 142. During assembly, the ring fasteners 150 on the lower surface 154 align and engage with the hook fasteners 148 on the base foam pad 144. Typically, the number of fasteners 146 needs to increase as the desired profile of the cover 142 increases. One known method to minimize fasteners is to permanently adhere the cover 142 to the base foam pad 144. Another known method is to form the cover 142 and the base foam pad 144 as a single unit. However, it is desirable to have a removable cover 142 so that the cover 142 can be replaced if needed.

[0076] Seat heaters 162 are typically installed in automotive seat cushions and / or seat backs. Figure 12 illustrates a partial exploded view of a typical automotive seat cushion assembly 164. A typical seat cushion assembly 164 includes a seat heater 162, a base porous foam padding 168, and a seat cover assembly 170. The seat cover assembly 170 includes a cover 172 having multiple cover pieces 174, 176. Adjacent cover pieces 174, 176 are stitched together along their edges 178, 180 to form a seam 182. Cover pieces 174, 176 include a cover material layer 186 and a padding layer 188. The seat heater 162 is typically located below the cover 172 and is adhesively bonded to the base foam padding 168. Also shown are hook fasteners 192 for attaching the decorative cover 172 to the base foam pad 168 and ring fasteners 194 for attaching the decorative cover 172 to the base foam pad 168.

[0077] Seat heaters 162 are typically evaluated based on the seat occupant's first-time perception of heat and the power consumption designed for the seat heater 162. The most common seat heaters 162 have a first-time perception of approximately 30 to 60 seconds and a power consumption of approximately 60 to 90 watts. The first-time perception is typically influenced by the thickness of the cover 172, the density of the foam and textiles within the cover 172, and the power density / consumption designed for the seat heater 162.

[0078] A thick, plush seat cover 172 is ideal for occupant comfort. The initial softness of the cover material layer 186 provides positive comfort to the occupant. Initial softness is a function of the stiffness and thickness of the cover 172. Typically, seat designs with a high degree of softness / plusiness will be relatively thick. Plusiness can also be achieved by softening the material of the cover 172. Because the seat heater 162 is adhered to the base foam padding 168 under the cover 172, the thicker cover 172 provides poorer heat transfer and a longer initial perceived comfort to the occupant compared to a thinner cover 172.

[0079] Making the trim cover 172 softer will allow the occupant's weight to sink deeper into the seat cushion assembly 164 and bring the body closer to the heating element 200 of the seat heater 162. However, an overly soft trim cover 172 will cause wrinkles on the cover material layer 186 over time and will deteriorate the workmanship and appearance of the seat cushion assembly 164.

[0080] As an alternative to making the trim cover 172 softer to improve first-time perception, the power density of the heating element 200 of the seat heater 162 could be increased to output more heat to overcome the thickness of the trim cover 172. However, there are practical limitations on the amount of power that the seat heater 162 can safely consume. A typical seat heater 162 consumes approximately 60 watts of energy, while a high-performance seat heater 162 consumes approximately 90 watts. It is generally desirable to limit the power consumption of the seat heater 162 to 90 watts or less. Some automotive seat cushion assemblies 164 require that the power usage of the seat heater 162 be limited to 90 watts or less.

[0081] By thinning the trim cover 172, the seat heater 162 can be moved closer to the occupant, which improves the performance of the seat heater 162. However, a thinner trim cover 172 may not be as comfortable and less plush as an occupant might expect. Therefore, plushness and occupant comfort directly conflict with the performance and first-time perception of the seat heater 162. A better alternative, which will be described below, is to integrate the seat heater 162 integrally into the trim cover 12, rather than attaching the seat heater 162 to the base foam padding 168.

[0082] The disclosed FreeForm is manufactured using the following process. TM The decorative cover 12 and its components overcome some of the limitations of known seat covers. These are described below and... Figures 13 to 2 Figure 1 illustrates FreeForm according to an embodiment of the present disclosure. TM Decorative covers 12 and the process for forming these decorative covers 12.

[0083] exist Figures 13 to 2 Figure 1 illustrates a method for molding FreeForm from a preformed laminated blank 210 according to an embodiment of the present invention. TM The process of creating the decorative cover 12 typically includes the following steps: 1) assembling the laminated preform 210; 2) placing the laminated preform 210 in a three-dimensional compression molding tool 96; 3) molding the laminated preform 210 at a molding tool temperature of about 150°F to about 320°F and a molding tool pressure of about 150 psi to about 250 psi to form the molded decorative cover 12 of a three-dimensional shape; and 4) removing the decorative cover 12 from the molding tool 96. It will be understood that the disclosed process may include more or fewer processing steps and different sequence of steps depending on the specific intended application or manufacturing process requirements.

[0084] Reference Figure 13 The laminated preform 210 comprises a cover material layer 78, a first adhesive layer 214, a moldable foam interlayer 80, a second adhesive layer 218, and a woven fabric backing layer 82. When cut into... Figure 14 When the desired blank shape 222 is illustrated, the cover material layer 78, the moldable foam intermediate layer 80, and the woven fabric backing layer 82 can be described as cover material blank 212, foam intermediate layer blank 216, and woven fabric backing blank 220, respectively.

[0085] Figure 15A perspective view of the assembled laminate blank 210 is shown. Generally, the descriptions of cover material layer 78 and cover material blank 212 are used interchangeably. Similarly, the descriptions of moldable foam interlayer 80 and roving backing layer 82 are used interchangeably as foam interlayer blank 216 and roving backing blank 220, respectively. It will be understood that, for the purposes of this disclosure, the phrases "cover material layer" 78 and "cover material blank" 212 are used interchangeably. Similarly, the phrases "foam interlayer" 80 and "roving backing layer" 82 can be used interchangeably with "foam interlayer blank" 216 and "roving backing blank" 220, respectively. Furthermore, it will be understood that cover material blank 212, moldable foam interlayer blank 216, and roving backing blank 220 can be pre-cut into desired blank shapes 222 prior to assembly into laminate blank 210. Alternatively, the cover material layer 212, the moldable foam interlayer 216, and optionally the woven fabric backing layer 220 can be assembled and adhered into a laminated assembly prior to cutting the laminated preform 210. Two or more layers of the laminated preform 210 can be assembled into a sheet form and cut into the desired preform shape 222 after pre-bonding or pre-attaching two or more layers. Gerber cutting is an exemplary process of pre-cutting layers into preform shape 222 and / or cutting the shape of the laminated preform 210 from two or more assembled layers.

[0086] It will be understood that, depending on the needs of a particular application, the laminated preform 210 may include more or fewer layers. Furthermore, it will be understood that additional layers, such as seat heaters or additional foam layers of different densities, may be added to the laminated preform 210 to form a four-layer or multi-layer laminate. Similarly, when the woven fabric backing layer 220 is omitted, the laminated preform 210 of the cover material layer 212 and the moldable foam intermediate layer 216 can be described as a “two-layer laminated preform.” Alternatively, the laminated preform 210 of the cover material layer 212, the foam intermediate layer 216, and the woven fabric backing layer 220 can be referred to as a “three-layer laminated preform.” The term “laminated preform” 210 describes two or more materials laminated together and cut into the desired preform shape 222. Therefore, it will be understood that the laminated preform 210 may include more than [a certain number of layers]. Figure 13 and Figure 15 The illustration shows more or fewer layers.

[0087] Typically, the laminated preform 210 has a two-dimensional shape, meaning that the laminated preform 210 is generally flat when laid unconstrained on a flat surface. Preferably, the shape and size of the laminated preform 210 are configured such that minimal trimming or no trimming is required after molding the decorative cover 12 and before assembly with other components. The upper surface 224 of the cover material layer 212 and the lower surface 226 of the woven fabric backing layer 220, which are oriented and assembled into the laminated preform 210, are generally referred to as the "A surface" and "B surface" of the molded decorative cover 12, respectively.

[0088] like Figure 13 and Figure 15 As illustrated, one or more adhesive layers 214, 218 secure the cover material layer 212 and an optional woven fabric backing layer 220 to a moldable foam interlayer 216. The choice of adhesive and / or adhesive method is based in part on the selection of materials used for the cover material layer 212 and the woven fabric backing layer 220. Various known adhesives—such as thermoplastic adhesives and one-piece or two-piece polyurethane adhesives (referred to as “1K” and “2K” adhesives)—are suitable for bonding certain cover material layers 212 and woven fabric backing layers 220 to the foam interlayer 216. The adhesive can be applied by spraying, or alternatively, by a film or mesh structure. Thermoplastic adhesives can be roller-applied to one or more surfaces to be bonded. Thermoplastic adhesives can be remelted at elevated temperatures to separate the cover material layer 212 from the foam interlayer 216, and then the cover material layer 212 can be reassembled to the foam interlayer 216 to correct defects at any time during the lifespan of the decorative cover 12. Both 1K and 2K type adhesives have a delayed curing reaction and act like thermoplastic adhesives for the first 4 hours, allowing for rebonding if needed. Both 1K and 2K adhesives cure into a permanent bond within 24 hours. Both 1K and 2K adhesive systems eventually become thermosetting materials, thus the bond between layers becomes irreversible.

[0089] As an alternative to adhesives, the cover material layer 212 and / or the woven fabric backing layer 220 can be flame-laminated to the foam interlayer 216. Flame lamination is a commonly known process of bonding one or more layers of material to a foam layer after passing it through a flame to melt the surface of the foam. Flame lamination creates a permanent bond between the foam interlayer 216, the cover material layer 212, and / or the woven fabric backing layer 220. One or more adhesive layers 214, 218 can optionally be replaced by flame lamination. The cover material layer 212, the moldable foam interlayer 216, the optional woven fabric backing layer 220, and / or other material layers can be bonded to each other using flame lamination as needed, thus eliminating one or more adhesive layers 214, 218 between the individual layers 212, 216, 220.

[0090] Additionally, where necessary, two or more layers 212, 216, 220 may be flame-laminated before or after the adhesion of one or more additional layers 212, 216, 220 using an adhesive. It will be understood that the choice of adhesive type (e.g., 1K or 2K polyurethane adhesive) and / or flame lamination is based in part on the selected cover material layer 212 and the desired process method. As is well known to those skilled in the art, certain materials are suitable for adhesion using flame lamination. Other materials may be more suited to adhesion with 1K or 2K polyurethane adhesive or other known adhesives. For example, certain leathers may not be suitable for flame lamination adhesion to the moldable foam interlayer 216.

[0091] Furthermore, when the laminated preform 210 comprises more than three layers, additional adhesive layers may be used. Additionally, each layer may be adhered to an adjacent layer before or after the individual layers are cut into preform shape 222. For example, the woven fabric backing layer 220 and the foam interlayer 216 may be bonded together using flame lamination or adhesive, and then cut into a foam / woven fabric preform (not shown). This foam / woven fabric preform may be adhered to a pre-cut cover material preform 212 using adhesive or flame lamination. It will be understood that any combination of adhesives, flame lamination, pre-cutting and post-cutting, as well as material selection and the number of layers, may be selected based on the desired final decorative cover 12 for a given application and / or preferred manufacturing method.

[0092] Suitable cover material layer 212 includes a variety of textiles, vinyl materials, and leather. Exemplary textiles include polyester, polyester blends, acrylic blends, rayon, nylon, and similar fabrics. The selection of the textile for the desired application depends on the combination of the amount of elongation required during the molding process in both the longitudinal and transverse directions of the textile with the amount of forming. Generally, cover material layer 212 with an elongation of about 10% to about 25% in both the longitudinal and transverse directions has been found to be ideal. However, depending on the desired three-dimensional molding shape and the amount of concavity in the mold, cover material layer 212 with more or less elongation may be suitable. The fabric may have a flat surface, a raised construction, and / or be woven or nonwoven, depending on the desired appearance of the molded decorative cover 12. Alternatively, the fabric may be laminated with a foam material or spacer fabric to produce the desired appearance of the molded decorative cover 12.

[0093] The wide selection of cover material layer 212 is suitable for use with the disclosed molding process because the temperature range of the molding tool 96, from about 150°F to about 320°F, is below the deformation temperature of various fabrics. Molding the decorative cover 12 by applying heat in the temperature range of about 150°F to about 320°F allows for an expanded selection of cover material layer 212, including various fabrics, vinyl materials, and leather. Some fabrics are not suitable for use in known prior art molding processes with molding temperatures in the range of about 300°F to about 480°F because these fabrics may deform or be damaged due to higher levels of heat. Reducing the temperature of the molding tool 96 to the range of about 150°F to about 320°F reduces and / or prevents fabric deformation during the molding process. Furthermore, the lower molding temperature used in the disclosed process allows for an increase in the achievable profile of the three-dimensional shape of the molded decorative cover 12 without distorting or damaging the cover material layer 212. As described below, additional materials and / or laminates can be molded into three-dimensional shapes by optionally adding vacuum assistance and a movable barrier membrane during the molding process.

[0094] like Figure 14 and Figure 15 As shown, the moldable foam interlayer 216 beneath the cover material layer 212 is used to achieve the desired final molded shape and provide a soft and comfortable feel within the molded trim cover 12. The strength, density, and thickness of the moldable foam interlayer 216 are selected to achieve the desired look or feel of the vehicle seat assembly 10. Depending on the needs of the intended application, the moldable foam interlayer 216 is an open-cell polyurethane (PU) foam designed to be molded at temperatures between approximately 220°F and approximately 260°F.

[0095] As is generally known in the field of polyurethane foam manufacturing, the glass transition temperature (Tg) of polyurethane foam is related to the upper limit of the service temperature of PU foam and the temperature at which PU foam can be molded. Furthermore, it is well known in the art that the Tg of PU foam is affected by foam chemistry, and particularly by the amount of crosslinking in the PU foam. Adding grafted polyols and adjusting the diol content are methods for adjusting the Tg of PU foam. The Tg of PU foam can be controlled such that selected moldable PU foam can be molded at temperatures between 220°F and approximately 260°F while still maintaining occupant support and passing all applicable test requirements, including life cycle, durability, and thermal aging.

[0096] Typical PU foam formulations used in vehicle seat applications are generally capable of being molded at temperatures above approximately 320°F. These foam formulations were previously selected to ensure acceptable performance of the vehicle seat assembly 10 throughout the vehicle's lifespan and to allow for shorter manufacturing cycle times. However, PU foams with higher Tg values ​​are difficult to mold and require expensive and / or complex molding methods. Furthermore, the high molding temperature limits the choice of cover material layer 212, as some materials are not suitable for molding at temperatures above approximately 320°F. Additionally, some processes in these known molding processes result in reduced breathability of the trim cover 110.

[0097] It has been found that, as disclosed in this invention, satisfactory results can be obtained by molding the decorative cover 12 at a foam molding temperature of about 220°F to about 260°F by lowering the Tg in the moldable PU foam. Furthermore, since the foam molding temperature is about 260°F or lower, the cost and complexity of the molding tool 96 are reduced, and the range of suitable cover material layers 212 is increased.

[0098] Figure 14 The figure illustrates an optional roving backing blank 220. As shown, the roving backing layer 82 has been pre-cut into the roving backing blank 220 before being assembled into the laminate blank 210. The roving backing layer 82 improves the handling of the molded decorative cover 12 when sewn to other components in the assembled decorative cover 12. However, it will be understood that the roving backing layer 220 can be omitted if necessary.

[0099] Although the roving backing layer 82 can be a woven or nonwoven fabric, the elongation of the fibers in the roving backing layer 82 affects the formability of the laminate preform 210 during the molding process. When molding a highly contoured molded decorative cover 12, fabrics with greater elongation in the fibers are preferred over fabrics with less elongation in the fibers. Furthermore, cover material layers 78 and roving backing layer 82 with similar elongation in the fibers are selected. Some common nonwoven roving backing layers 82 have suitable properties for elongation and loop attachment behavior. Nonwoven roving backing layers 82 are inexpensive and meet typical warranty, assembly, and disassembly standards.

[0100] The embodiments of the present invention are as follows: Figures 16A to 16B The diagram in the middle shows, Figures 16A to 16BA laminated preform 252 with a seat heater 254 is shown, the seat heater 254 being positioned adjacent to a surface cover material layer 256. The seat heater 254 is ideal for automotive seats. The molded trim cover 12 can offer improved comfort compared to conventional cut-and-stitched cover designs. Furthermore, when the seat heater 254 is integrally integrated into the molded trim cover 12, it can be positioned closer to the occupant compared to when the seat heater 254 is placed below the trim cover 12. The seat heater 254 is included in the laminated preform before the laminated preform 252 is compressed and molded into the molded trim cover 12.

[0101] exist Figure 16A The diagram shows a schematic representation of the construction of a laminated preform 252 with an integrally integrated seat heater 254. The laminated preform 252 is assembled by adhering the upper surface 258 of the seat heater 254 to the lower side 260 of the A-surface cover material layer 256. Depending on the specific application, the adhesive layer 264 can be applied as a complete surface cover to one or both of the upper surface 258 of the seat heater 254 and / or the lower surface 260 of the A-surface cover material layer 256, or applied to a localized area. The lower surface 266 of the seat heater 254 is adhered to the upper surface 268 of the moldable foam intermediate layer 270 by applying an adhesive layer 272 to one or both of the lower surface 266 of the seat heater 254 and / or the upper surface of the moldable foam intermediate layer 270, as needed, through localized application or complete coverage of the adhesive. A nonwoven woven fabric backing layer 274 is adhered to the lower surface 276 of the moldable foam intermediate layer 270 using the adhesive layer 278. Figure 16B The illustration shows that in Figure 16A The diagram shows a laminated blank 252 with an integrally integrated seat heater 254 after the layers are adhered together.

[0102] What will be understood is... Figure 16AThe various layers shown can be assembled in any order suitable for the intended application and the required manufacturing process. Furthermore, it will be understood that any suitable adhesive can be selected based on the required manufacturing process and the composition of the A-surface cover material layer 256. Additionally, it will be understood that the adhesive layer 278 can be replaced by flame lamination, as is commonly known in the art. For example, a nonwoven roving backing layer 274 can be adhered to the moldable foam interlayer 270 using an adhesive or flame lamination. Alternatively, the nonwoven roving backing layer 274 can be pre-bonded to the moldable foam interlayer 270 via an adhesive or flame lamination, optionally cut into the desired blank shape 222 before or after bonding, and provided as a sub-assembly S for adhesion to the seat heater 254 and the A-surface cover material layer 256. Therefore, the laminated blank 252 can be assembled from one or more pre-cut blanks (A surface cover material layer 256, seat heater 254, moldable foam interlayer 270, woven fabric backing layer 274, etc.), and / or from pre-cut blanks comprising sub-assemblies including a single layer or at least two layers, and / or assembled as a laminated assembly and cut into the final laminated blank shape after the layers are combined together. It will also be understood that additional layers can be incorporated into the laminated blank 252, and certain layers, such as the woven fabric backing layer 274, can be optionally omitted as needed.

[0103] Attaching the seat heater 254 directly to the lower side 260 of the surface cover material layer 256 helps minimize the initial perception by the seat occupant. However, as Figure 16C As shown, there is a risk that the seat heater 254 may be seen through certain A surface cover material layers 256. Figure 16C A molded seat back cover 280 is shown, which has an integrally integrated seat heater 254, which is formed during compression molding. Figure 16B The laminated preform 252 shown is then adhered to the lower side 260 of the surface cover material layer 256. Seat heater wires 282 extend from the edge 283 of the molded seat back trim cover 280. (As shown...) Figure 16C As indicated by 284, the seat heater 254 is slightly visible through the A-surface cover material layer 256. For some thin A-surface cover material layers 256, the shape and texture of the seat heater 254 may be clearly visible and / or the seat heater 254 may reduce occupant comfort. However, the design and construction of the trim cover 12 can be adjusted to minimize the visual impression of the seat heater 254. For example, the placement of the molding line 72 and the molding surface recesses 74 may make the seat heater 254 imperceptible to the occupant.

[0104] exist Figure 17A and Figure 17BAn alternative embodiment is shown in which a laminated blank 286 structure incorporating a seat heater 254 is constructed, which reduces the visible appearance of the seat heater 254 on the surface of the molded decorative cover 12. Figure 17A and Figure 17B The illustration shows schematic diagrams of the layers before and after they are assembled into the laminate preform 286. The laminate preform 286 is constructed similarly to... Figure 16A and Figure 16B In the illustrated embodiment, an additional layer of foam liner 288 is pre-laminated to the underside 260 of surface cover material layer 256. The pre-laminated foam liner 288 can be adhered to surface cover material layer 256 using adhesive or flame lamination, depending on the need and suitability for the surface cover material layer 256. Furthermore, a moldable foam interlayer 270 can be adhered to an optional woven fabric backing layer 274 prior to assembling the laminated blank 286. The pre-laminated foam interlayer 270 / woven fabric backing layer 274 and the pre-laminated surface cover material layer 256 / foam liner 288 are adhesively bonded to the respective sides of the seat heater 254, as shown. Figure 17A and Figure 17B As shown in the diagram. Figure 17C and Figure 17D The image shows a molded seat back cover 289 with an integrated seat heater 254. (See image for reference.) Figure 17C As illustrated, the foam lining 288 pre-laminated to the A surface cover material layer 256 reduces and / or eliminates the permeability of the seat heater 254 through the A surface cover material layer 256. The seat heater wires 282 extend from the edge 290 of the molded seat back trim cover 289. Figure 17D yes Figure 17C The diagram shows a top perspective view of the molded seat back cover 289, illustrating the pile of the cover 289 after the compression molding process. The inclusion of a foam lining 288 between the seat heater 254 and the surface cover material layer 256 increases the surface pile of the cover 289 to some extent.

[0105] As in Figure 16A and Figure 16BIn the previous embodiments shown, the choice of adhesive layer 278 or flame lamination, and the desired coverage of adhesive layers 264, 272, are based on the intended application and preferred manufacturing method. Similarly, each layer can be adhered to the assembly before the laminated preform 286 is cut from the adhered layers. Alternatively, each layer can be pre-cut into the desired preform shape 222 prior to assembly. It will be understood that any combination and sequence of cutting, assembly, and adhesion required for the intended application can be selected. For example, a surface cover material layer 256 can be pre-laminated to the foam liner 288 using adhesive or flame lamination. Similarly, a moldable foam interlayer 270 can be pre-laminated to the woven fabric backing layer 274 using adhesive or flame lamination.

[0106] Furthermore, it will be understood that more or fewer layers may be incorporated into the laminated preform 286 compared to those shown in the figures. It will be understood that one or more sensors, circuits, and / or alternative materials, such as fiber wadding, other than the foam lining 288, may be incorporated into the laminated preform 286 if needed. Additionally, although not specifically shown in the figures, the A-surface cover material layer 256 may include one or more material pieces fastened together and / or laminated together along the seams if needed. For example, a pocket may be pre-stitched to the A-surface cover material layer 256 and / or two or more materials sewn together along the seams to create a desired shape, as will be described below relative to... Figures 27A to 30E Further description.

[0107] Figures 18 to 20 The figure illustrates a tool for molding a decorative cover 12 from a preformed laminated preform 210 according to one embodiment of the invention. Typically, the molding process includes the following steps: 1) assembling the laminated preform 210; 2) placing the laminated preform 210 in a three-dimensional compression molding tool 96; 3) molding the laminated preform 210 at a molding tool temperature of about 150°F to about 320°F and a molding tool pressure of about 150 psi to about 250 psi to form a three-dimensional molded decorative cover 12; and 4) removing the decorative cover 12 from the molding tool 96. It will be understood that the disclosed process may include more or fewer process steps and different sequence of steps depending on the specific intended application or manufacturing process requirements.

[0108] Figure 18An exemplary upper molding tool 98 and lower molding tool 100 are shown. The upper molding tool 98 and lower molding tool 100 include molding surfaces 300, 302 having three-dimensional shapes, optionally one or more protrusions 304, and optionally one or more recessed areas 306. The upper molding tool 98 and lower molding tool 100 can have different surface temperatures, thereby being more compatible with various constructions of the cover material layer 212 and the foam intermediate layer 216. The three-dimensional shape is formed in the decorative cover 12 in the following manner: Figure 19 The process generally involves placing a laminated preform 210 between a molding tool 98 of an upper three-dimensional shape and a molding tool 100 of a lower three-dimensional shape; compressing the laminated preform 210 between the upper molding tool 98 and the lower molding tool 100 at approximately 150 psi to approximately 250 psi; and applying heat in a temperature range of approximately 150°F to approximately 320°F to form and compress a moldable foam interlayer 216, and removing it from the molded decorative cover 12 after a processing time of approximately 90 seconds to approximately 10 minutes. Figure 20 (As shown) Remove the upper molding tool 98. The amount of local compression and the resulting induced surface tilt result in a three-dimensional decorative cover 12 that typically retains the desired three-dimensional shape after molding.

[0109] It will be understood that, for certain selected materials, the thickness of the laminated blank 210, and the contours in the upper molding surface 300 and the lower molding surface 302, the compression molding process can be combined with vacuum assistance as needed. Although not shown in the figures, the combination of vacuum assistance, as well as overall heating and / or spot heating, into the upper molding tool 98 and the lower molding tool 100 is generally known to those skilled in the art of molding tool making.

[0110] like Figure 21A , Figure 21B and Figure 21C As illustrated, an alternative implementation of the disclosed process includes a vacuum-assisted step prior to the compression molding step. Alternatively, the vacuum-assisted step may be performed during the compression molding step if necessary. Improved appearance, increased three-dimensional depth, and improved molding details can be achieved by using materials such as leather and / or thicker materials, or certain materials of the laminated preform 210 having more than three layers, to partially or completely preform the laminated preform 210 against the lower molding surface 100 by adding vacuum assistance during the molding process.

[0111] Reference Figure 21A The laminated preform 210 is placed (arrow 311) on the lower molding tool 100, and the barrier film 312 is placed (arrow 313) on top of the laminated preform 210. Figure 21BAs shown, a vacuum 314 is applied through the lower molding tool 100 to partially or completely shape the laminated preform 210. The upper molding tool 98 is compressed 316 against the barrier film 312 and the laminated preform 210, while the upper molding tool 98 and / or the lower molding tool 100 are heated to a temperature of approximately 150°F to approximately 320°F to shape and compress the moldable foam interlayer 216. Depending on the intended application and the required construction of the laminated preform 210, the molding tools 98, 100 may optionally be heated uniformly or include localized areas with elevated heating temperatures.

[0112] like Figure 21C As shown, the upper molding tool 98 removes the barrier film 312 and the molded decorative cover 12 (arrow 317). The barrier film 312 is removed from the molded decorative cover 12 (arrow 318), and the molded decorative cover 12 is removed from the lower molding tool 100. Optionally, the barrier film 312 may be removed from the laminated preform 210 in vacuum form before it is compressed by the upper molding tool 98 and heated to a temperature of approximately 150°F to approximately 320°F. Since the barrier film 312 is used only during the vacuum forming process 314 and optionally during the compression molding process 316, and is removed from the molded decorative cover 12 before the molded decorative cover is assembled into the final assembly, the permeability of the molded decorative cover 12 is generally maintained. It will be understood that the disclosed process may include more or fewer processing steps and different sequence of steps depending on the specific application or manufacturing process required.

[0113] The selection of the molding temperature range and the location of the heated areas in the mold are based in part on the selected cover material layer 212, the number of layers in the laminated preform 210, the selected mold design, and the amount of concavity formed in the molded decorative cover 12 and the molding details. Typically, a molding temperature range of about 150°F to about 320°F is desired. This allows the foam intermediate layer 216 to be molded in a temperature range of about 220°F to about 260°F, thereby producing an acceptable molded decorative cover 12 with a machine cycle time of about 90 seconds to about 10 minutes, depending on the aggression of the molding and the thickness of the laminated preform 210.

[0114] Compression molding pressures of approximately 150 psi to approximately 250 psi are generally sufficient to produce satisfactory results. It will be understood that more or less molding pressure may be desired depending on the specific application, the construction of the laminated preform 210, the machine construction, and other factors such as machine cycle time. Pneumatic cylinder presses are generally sufficient to provide the required amount of compression force during the molding process. Aluminum molding tools are generally suitable for the disclosed molding process because the required molding temperature range is generally equal to or less than approximately 320°F, and the molding pressure is generally equal to or less than approximately 250 psi. The disclosed molding process does not require steel molds and / or hydraulic presses, and therefore, the disclosed molding process can use molding tools and machines that are less expensive than previously known molding methods for decorative covers 12. Furthermore, molding tools 98, 100 may have independent heating systems (not shown) and may be adapted to have zone heating as needed to facilitate more or less aggressive contouring and shaping lines. Vacuum assistance may be integrally incorporated into the mold when required for a specific application and / or the construction of the laminated preform 210.

[0115] Because the requirements for tools and the manufacturing process are typically moderate (aluminum tools are independently heated in a temperature range of approximately 150°F to approximately 320°F, compression pressures of approximately 150 psi to approximately 250 psi, and cycle times of approximately 90 seconds to approximately 10 minutes), an exemplary manufacturing process may include approximately three compression molding machines, loaded and unloaded by one operator. The operator can load the laminated blanks 210 into each molding machine by assembling and cutting them prior to the molding process, and remove the molded decorative cover 12 after the molding process is complete. It is desirable to cut the laminated blanks 210 to a certain size and shape prior to molding such that the molded decorative cover 12 requires minimal trimming and / or no trimming before being assembled into the final decorative cover assembly. By pre-bonding or pre-attaching layers of the laminated blanks 210, the operator loads the laminated blanks 210 into the compression molding machines without having to load multiple pieces.

[0116] However, it will be understood that, where required by a particular application, more than one blank 210 may be loaded into the lower molding tool 100 before the compression molding process begins. An example process typically includes the following steps: 1) placing the cover material blank 212 and the barrier film 312 on the lower molding tool 100; 2) vacuum forming the cover material blank 212 to generally outline the lower molding tool 100; 3) removing the barrier film 312 and placing the seat heater 254 on the pre-formed cover material blank 212; 4) placing the foam interlayer blank 216 on top of the seat heater 254; 5) compressing and molding the cover material blank 212, the seat heater 254, and the foam interlayer blank 216 to form the molded decorative cover 12; and 6) removing the molded decorative cover 12 from the molding tool 96. Another example process typically includes the following steps: 1) loading the laminated blank 210 onto the lower molding tool 100; 2) placing the pre-stitched pocket blank on top of the laminated blank 210; 3) compressing the laminated blank 210 and the pocket blank to form a decorative cover 12 with pockets; and 4) removing the decorative cover 12 with pockets from the compression molding tool 96.

[0117] Compared to a known two-dimensional molded cover 110, the cover 12 requires minimal bending when assembled into the cover assembly 48 and when the cover assembly 48 is applied to the vehicle seat 10. The reduction in necessary bending or folding of the three-dimensional molded cover 12 compared to the two-dimensional molded cover 110 results in fewer wrinkles. Although less bending is required when the cover 12 is assembled to the vehicle seat 10, the cover 12 can be bent and twisted during assembly with additional seat cover components without permanently deforming the molded cover 12. When unconstrained, the cover 12 tends to substantially return to its molded shape.

[0118] Before being assembled and / or sewn together with other seat cover components to form the final decorative cover assembly 48, the edges of the molded decorative cover 12 are optionally trimmed and / or ground.

[0119] The molded trim cover 12 can be permanently or releasably attached to the base foam padding 24 during assembly of the vehicle seat 10 to form a padded assembly. A simplified "hook and loop" attachment system can be integrated with the molded trim cover 12 and the base foam padding 24 so that it is not felt by the occupants of the vehicle seat 10. Figure 22 As shown, the base foam pad 24 includes hook fasteners 344 of a "hook and loop" attachment system, which are embedded in the upper surface 346 of the base foam pad 24. Figure 23As shown, the ring fastener 348 of the "hook and loop" attachment system is embedded in the "B surface" of the molded trim cover 12. Alternatively, the ring fastener 348 can be assembled with the lower surface of the laminated preform 210 before it is molded into the trim cover 12, such that the ring fastener 348 is permanently adhered to the lower surface of the trim cover 12 during compression molding. Furthermore, the ring fastener 348 can be adhered to the trim cover 12 before it is assembled with the base foam padding 24. After the ring fastener 348 on the molded trim cover 12 is attached to the hook fastener 344 on the base foam padding 24, the molded trim cover 12 can be releasably coupled to the base foam padding 24 of the vehicle seat 10. Alternatively, some commonly used nonwoven woven fabric backing layers 82 are used as the "ring" fastener 348 of the "hook and loop" attachment system for attaching the trim cover 12 to the base foam padding 24, such as... Figure 24 As shown in the diagram. It will be understood that other fastening methods may be suitable for the intended application, including using an adhesive to directly adhere the decorative cover 12 to the base foam pad 24. In some applications, the number and type of fasteners are reduced compared to some known decorative covers because the disclosed molded decorative cover 12 has a three-dimensional shape without additional fasteners and generally maintains the molded profile.

[0120] After the decorative cover 12 (by adding side parts and optional fasteners if necessary) is assembled into the final seat cover assembly 48, the seat cover assembly 48 is placed on the base foam padding 24 and forms the seat cushion 16 or seat back 14 of the vehicle seat 10, as... Figure 3 As illustrated in the diagram, the base foam pad 24 provides the primary support surface for the seat system and offers stability to maintain the overall contours of the seat design. The base foam pad 24 requires no design features when forming desired design features and styling lines within the molded "A-surface" trim cover 12. Therefore, the standardized base foam pad 24 can be used with many vehicle seat 10 designs when combined with various trim cover 12 designs. Using the standardized base foam pad 24 reduces the complexity of foam manufacturing equipment and the seat assembly process. By combining design features included in the removable trim cover 12 with the simplified base foam pad 24, waste and rework during the manufacturing process are reduced.

[0121] Figure 25 and Figure 26The molded trim cover 12 is shown before and after undergoing GMW 14124Cycle Q environmental aging. GMW 14124Cycle Q—General Motors' global standard testing protocol—exposes samples to 176°F and 75% humidity for 400 hours to evaluate the trim cover 12's durability and suitability for the automotive interior environment. During testing, the trim cover 12 must exhibit no delamination, no color distortion, and no deformation of the foam interlayer 80. Figure 26 As shown in the illustration, the decorative cover 12 was proven to have no delamination, no color distortion, and no deformation of the foam interlayer 80 after undergoing the GMW 14124 Cycle Q environmental test.

[0122] Although not shown in the figures, the volatile organic compound (VOC) emissions of the decorative cover 12 were assessed using the Ford WSS-M99P2222-F1 test method by testing the decorative cover 12 at 149°F for 120 minutes and recording key emissions from the decorative cover 12. The first decorative cover 12 with a fabric cover material layer 78 and a first foam interlayer 80, and the second decorative cover 12 with a vinyl cover material layer 78 and a second foam interlayer 80 were evaluated. Both test samples showed acceptable test results.

[0123] Furthermore, the air permeability of various decorative covers 12 was evaluated by measuring the airflow rate through the decorative cover 12. The air permeability of the decorative cover 12 was measured by placing a sample of the decorative cover 12 in a Gurley densitometer and measuring the time it took for 300 ml of air to pass through the decorative cover 12 according to ASTM D-726-58 and ASTM D-202-77 test methods. The air permeability was also evaluated using conventional cutting and sewing methods and PureFit. TM Method, Cover Carving Technology TM The air permeability of samples of decorative covers manufactured using (CCT) and the publicly disclosed molding process was measured. The airflow rate through the cut and sewn decorative cover samples was approximately 150 ml / sec. Airflow through CCT decorative cover samples and PureFit samples was also measured. TM The airflow rates of the decorative cover samples were approximately 15 ml / sec and 10 ml / sec, respectively. In contrast, the decorative cover 12 sample prepared by the disclosed molding process had an airflow rate of approximately 100 ml / sec. Therefore, when compared with samples prepared using the CCT method or PureFit... TMCompared to a decorative cover manufactured by the method, a decorative cover 12 prepared by the disclosed molding process allows approximately 6 to 10 times more airflow through the decorative cover 12. Although the airflow through the decorative cover 12 prepared using the disclosed molding process is less than the airflow through a conventional cut-and-stitched decorative cover, the thermal comfort of the occupants of the assembled vehicle seat 10 can be comparable to that of a cut-and-stitched decorative cover.

[0124] Figures 27A to 29 An alternative embodiment of the seat back panel 54 construction is shown. If needed, two or more pieces 350, 352 of the cover material 78 can be used as follows: Figure 27A and Figure 27B The seams are stitched together along seam 354 as shown. The stitched cover material 78 can be included in the laminated preform 210 as an A-surface cover material layer 78. The stitched seam 354 is sealed and molded flush during the molding process. By combining one or more materials into the A-surface cover material layer 78 of the laminated preform 210 prior to molding, the resulting molded seat back panel 54 can include additional shaping and design details.

[0125] Although not specifically shown in the accompanying drawings, some complex seat cover 12s can be formed by stitching / adhering one or more pre-formed segments of the cover 12 together along the seams to form a more complex shape of the final cover 12. Furthermore, secondary processes such as stitching and / or adhering pockets and other design details can be completed after the cover 12 is molded. It will be understood that for any cover component 12, such as seat cushion cover 50, seat back cover 52, seat back panel 54, and any other similar cover 12, the cover material 78 with the stitched seams 354 can be incorporated into the laminated blank 210.

[0126] In addition, such as Figure 28 and Figure 29 As illustrated, for example, the secondary features of pocket 356 can be integrally incorporated into the laminated blank 210 before the molded decorative cover 12. Figure 28 Pocket 356 is shown sewn into seam 354 of the A-surface cover material layer before being integrally incorporated into the laminated preform 210. When the laminated preform 210 is compression molded, the sewn seam 354 is closed and molded flush. The molded seat back panel 54 with fully overlapping pockets 358 is shown. Figure 29As shown in the diagram. The pocket 358 may be sewn or adhered to the A surface cover material layer 78 before being integrally incorporated into the laminated preform 210. Alternatively, if desired, the pocket 358 may be placed on top of the laminated preform 210 after the laminated preform 210 has been placed on the lower molding tool 100. Furthermore, the pocket 358 may be molded into a three-dimensional shape and then sewn or adhered along its edges to the molded decorative cover 12. It will be understood that the disclosed process may include more or fewer processing steps, and different sequences of steps, depending on the specific intended application, the materials selected, and / or the requirements of the desired manufacturing process.

[0127] Figures 30A to 30E The illustration shows a non-limiting example of a vehicle seat 10 with various decorative cover 12 designs according to embodiments of the present disclosure. Seat 10A ( Figure 30A The diagram shows a single A-surface cover material layer 78, wherein the decorative cover 12A has a strongly defined molding line 364 and minute molding lines 366, which extend on the seat cushion 16A, seat back 14A, and headrest 18A, and gradually disappear at the ends 368 of the molding lines 366 to become flush with the local surface. Seat 10B ( Figure 30B The illustration shows a seat back decorative cover 52B with two cover materials 350, 352 stitched along seam 354 before assembling the laminated blank 210 and the molded decorative cover 12B. Figure 30B The image also shows surface protrusions 372 formed in the decorative cover 12B during the molding process. (See image for details.) Figure 30C As shown, the seat 10C exhibits a stylized protrusion 374 and a molded line 364 that defines the contour, as well as an integrated headrest 18C. Figure 30D The following variation is shown, in which two materials 350, 352 are stitched together along seam 354 to form a stitched cover material 78 before assembling the laminated blank 210 and the molded decorative cover 12D. The seat 10D is also illustrated with a first material 350 having short pile fabric and a second material 352 being perforated leather, and shows strong sculpted contour design features 376 and subtle surface contours 378.

[0128] A profile with a concavity greater than approximately 4 inches can optionally be formed by connecting smaller molded decorative cover segments 382, ​​384, and 386, such as... Figure 30E As shown. Alternatively, for certain laminated constructions and / or surface cover material layers 78, decorative covers 12E with an overall concavity substantially greater than about 4 inches can be molded using the disclosed process. Typically, local concavities up to about 4 inches are desired. Sharp bends 390 and gentle transitions 392 in the surface profile 394 can increase the overall concavity to well beyond the recommended local concavity. Therefore, depending on the construction of the laminated preform 210, Figure 30E The seat back cover 52 of the seat 10E shown can be formed as a single molded seat back cover 52, or formed by connecting smaller molded cover segments 382, ​​384, 386 together as needed.

[0129] exist Figures 31A to 31C The illustration depicts another embodiment in which a portion of the seat cushion cover 50 includes molded seatbelt pockets 396, 398. Some known vehicle seat covers have highly contoured sections formed by cutting and sewing together multiple small pieces of material. An example is a seatbelt pocket for a rear seat cushion. Typically, multiple pieces of material are cut and sewn together along seams to form the generally complex contour required for the seatbelt pocket. Cutting and sewing multiple small pieces is expensive and labor-intensive. These multi-piece sewn seatbelt pockets can be replaced by molded seatbelt pockets 396, 398, compressed and molded from a laminated preform 210 using the disclosed process. Figure 31A and Figure 31B The seat pocket 396 shown illustrates a molded, intricate pocket shape sewn to the seat cushion trim cover 50. In contrast, seat pocket 398 shows a narrow U-shaped pocket with a sharp bend at the base 400 of the U-shape (in... Figure 31A and Figure 31C (As shown in the image).

[0130] It will be understood that any combination of materials, fabrics, and the number of parts can be used to produce the desired shape of the trim cover 12 and similar components. Although not specifically shown in the figures, molding the trim cover 12 is suitable for any interior component of a vehicle, including armrests or door panels. While the above disclosure primarily relates to vehicle seat trim covers 12, the process can be used to form any cover for automotive interiors or household products. Complex shapes can be molded from the laminated preform 210, thereby eliminating the need for stitching together multiple pieces to form complex shapes.

[0131] Figure 32 An alternative embodiment of the seat back panel 54' is shown, illustrating a predefined, foam-free edging 410' extending around the outer periphery 283' of the seat back panel 54'. Figures 33 to 41 The diagram illustrates the process of forming Figure 32 One embodiment of the manufacturing process for the seat back panel 54'. Both seat back panels 54, 54' include molded cover material 78, 78' having molding features 70, 70' and molding lines 72, 72'. Furthermore, as... Figures 18 to 20 and Figures 34 to 41As illustrated, both embodiments of the seat back panels 54 and 54' are produced using the following manufacturing process: wherein laminated blanks 210 and 210' are shaped to produce seat back panels 54 and 54'.

[0132] In back-to-back applications, such as in seat back panels 54, 54', the foam interlayer 80, 420 is preferably formed of relatively dense foam, so that the seat back panels 54, 54' have a smooth appearance while maintaining the desired shape. Figures 18 to 20 In the embodiment shown, the foam interlayer 80 is integrated within the laminated preform 210 prior to vacuum forming and / or compression molding of the laminated preform 210. Figures 34 to 41 In the embodiment shown, the foam intermediate layer 80 is composed of a molded foam backing 420 ( Figure 43 As shown, instead of the molded foam backing 420, it is formed on the laminated preform 210' after being vacuum-formed into a three-dimensional shape. Thus, Figure 32 The seat back panel 54' illustrates the vacuum forming line 72' and the vacuum forming feature 70', and is described below. Figure 43 Additional molding features 70C, 72B, and 70B are illustrated in the seat back panel 54". Certain molding features 70' and molding lines 72' may optionally have curved surface profiles, raised appearances, and / or appearances with stitched seams. Although seat back panels 54' and 54' are illustrated, alternative embodiments include decorative covers that include seat back decorative covers, seat cushion decorative covers, and other decorative cover components, such as side layers.

[0133] Figure 32 The molded seat back panel 54' includes a predefined border 410' without foam 420 extending around the outer periphery 283' of the seat back panel 54'. In contrast, Figure 5 The seat back panel 54 is formed from a laminated preform 210 having a foam interlayer 80 extending over the entire width and length of the laminated preform 210, such as Figure 15 As shown. Figure 5 As illustrated, the foam interlayer 80 is compressed near the outer periphery 283 of the seat back panel 54 during the molding process to provide a compressed molded trim 410 extending around the outer periphery 283. The trims 410, 410' can be used to attach the outer peripheries 283, 283' of the seat back panels 54, 54' to one or more other trim pieces to form trim cover assemblies 416, 416', which, for example, are... Figure 3 The seat back panel decorative cover assembly 416 shown in the figure is illustrated below and referenced. Figure 45 and Figure 46Further description. The compression molding of the relatively dense foams 80, 216 to form a compression molding trim 410 results in a relatively rigid trim 410, which, in conjunction with... Figure 32 The foam-free edging 410' shown is more difficult to sew. Seat back panels 54, 54' with improved sewing capabilities are desired. Figure 32 , Figure 42 and Figure 43 The seat back panels 54', 54" shown have foam-free trim 410', 410" compared to Figure 5 The embodiment shown has improved stitching capability because the stiffness of the foam-free edging 410', 410" is less than that of the compression-molded edging 410.

[0134] In some implementations... Figure 32 , Figure 42 and Figure 43 The foam-free edging of the seat back panels 54', 54" shown is superior to that of the 410', 410" panels. Figure 5 The compression-molded trim 410 of the seat back panel 54 shown is different because the foam-free trim 410', 410" includes fewer layers in the seams 418, 418' compared to the compression-molded trim 410. Furthermore, the foam-free trim 410', 410" is more flexible than the compression-molded trim 410 because it lacks the relatively rigid foams 80, 216, 420.

[0135] Reference Figure 33 The seat back panel 54' is formed from a laminated blank 210' comprising at least a cover material 78'. For example... Figure 32 As illustrated, the first surface 210A of the laminated preform 210' forms the A surface 210A of the seat back panel 54'. Figure 33 The image shows the opposite second surface 210B of the laminated blank 210'. The laminated blank 210' is pre-cut into a predefined shape with an outer perimeter 283'. A plurality of positioning holes 422 are punched through the laminated blank 210' near the outer perimeter 283'. Depending on the specific embodiment, the laminated blank 210' may include any number, shape, size, and location of pre-punched positioning holes 422. The positioning holes 422 may be punched before, during, or after the laminated blank 210' is cut from the cover material 78'. Preferably, each positioning hole 422 passes through a predefined edging 410' of the laminated blank 210'. Figure 33 As shown, a predefined border 410' extends between a predefined boundary 410C of the laminated blank 210' and an outer periphery 283'.

[0136] Despite Figure 33The illustration shows a single-layer laminated blank 210' including cover material 78'. However, depending on the specific implementation, any number of additional layers may be included within the laminated blank 210'. These additional layers include, but are not limited to, one or more foam layers, a woven fabric backing, pre-stitched sections of material forming a single layer within the laminated blank 210', and partial layers, such as pre-stitched pockets. Furthermore, other components such as heating elements, seat heaters, electrical sensors, attachment devices, fasteners, etc., may be integrated into and / or assembled with the laminated blank 210' during the manufacturing process.

[0137] Preferably, the laminated blank 210' includes pre-punched positioning holes 422. As a non-limiting example, in some embodiments, the laminated blank 210' may include alternative positioning features, such as slots, slits, protrusions, etc. Furthermore, in some embodiments, the positioning holes 422 may be omitted if they are not required to position the laminated blank 210' within the molding tools 98', 100'.

[0138] Figure 34 An embodiment of molding tools 98', 100' suitable for forming a seat back panel 54' is shown. Exemplary molding tools 98', 100' include a molding cover 98' and a molding base 100'. The molding base 100' includes a three-dimensional molded bowl-shaped portion 102' having a desired molding shape for the seat back panel 54'. The outer periphery 424 of the three-dimensional molded bowl-shaped portion 102' includes a plurality of spaced-apart locating pins 426. The number and position of the locating pins 426 are selected in part based on the size and shape of the outer periphery 424 of the three-dimensional molded bowl-shaped portion 102'.

[0139] Figure 35 It shows Figure 34 An enlarged view of portion 35 of the molded base 100', illustrating the locating pin 426 positioned around the outer periphery 424 of the three-dimensional molded bowl-shaped portion 102'. Also... Figure 35 As shown, the three-dimensional molded bowl-shaped portion 102' includes a plurality of vacuum holes 430 distributed on the lower surface 436 of the molded bowl-shaped portion 102'. In one embodiment, the vacuum holes 430 have an outer diameter of about 0.003”; however, larger and / or smaller diameter vacuum holes 430 may be used if required based on the specific requirements of the embodiment.

[0140] like Figure 34As shown, the molded cap 98' includes a plurality of cap holes 426B configured to engage with locating pins 426 around the outer periphery 424 of the molded bowl-shaped portion 102'. More specifically, the locating pins 426 and cap holes 426B are configured such that when the molded cap 98' is placed in a closed position in friction engagement with the molded base 100', the upper end 426A of each locating pin 426 fits into a corresponding cap hole in the cap hole 426B.

[0141] Figures 36 to 41 The diagram illustrates the process of forming Figure 32 An exemplary manufacturing process for the seat back panel 54'. (Refer to...) Figure 36 The laminated preform 210' is inserted between the molding cap 98' and the molding base 100'. More specifically, the laminated preform 210' is assembled with the three-dimensional molded bowl-shaped portion 102' by aligning the positioning holes 422 in the laminated preform 210' with the positioning pins 426 extending vertically from the molding base 100'. Figure 37 As illustrated, the laminated preform 210' is positioned against the molding base 100' such that the locating pin 426 extends through the locating hole 422 in the laminated preform 210'. Before the molding cap 98' is securely attached to the molding base 100', the upper molding surface 440 of the molding cap 98' is preferably coated with a release agent. The upper molding surface 440 of the molding cap 98' has a three-dimensional molding surface 440 for forming the B surface 488 of the molding foam backing 420.

[0142] like Figure 38 As illustrated, the laminated preform 210' is vacuum-formed to conform to the contour of the three-dimensional molded bowl-shaped portion 102'. During the vacuum forming process, air is extracted through vacuum holes 430 in the lower surface 436 of the three-dimensional molded bowl-shaped portion 102'. The vacuum forming process can be performed before or after the molding cap 98' is placed against the molding base 100'. Locating holes 422 in the laminated preform 210', which are assembled with locating pins 426, hold the outer periphery 283' of the laminated preform 210' in the desired position during the vacuum forming process. Molding features 70' and molding lines 72' are formed in the laminated preform 210' during the vacuum forming process, such as... Figure 38 As shown in the image.

[0143] Figure 39A cross-sectional view is shown showing a molded cover 98' fixedly attached to a molded base 100'. A vacuum-formed laminated preform 210' is positioned abutting against a three-dimensional molded bowl-shaped portion 102', wherein the outer periphery 283' of the laminated preform 210' is held by locating pins 426 passing through locating holes 422 in the laminated preform 210'. The upper end 426A of each locating pin 426 is inserted into a corresponding mating cover hole 426B in the molded cover 98'. The outer periphery 283' of the laminated preform 210' is sandwiched between the molded cover 98' and the molded base 100', thereby forming a seal around the outer periphery 424 of the three-dimensional molded bowl-shaped portion 102'. In other embodiments, the laminated preform 210' may be completely contained within the three-dimensional molded bowl-shaped portion 102', such that the outer periphery 283' of the laminated preform 210' is spaced apart from the molded cover 98'. In one embodiment, the molding base 100' and the molding cap 98' are configured to provide a parting line gap of about 0.5 mm to accommodate the outer periphery 283' of the laminated blank 210'.

[0144] Figure 39 The diagram also shows that each vacuum hole 430 in the three-dimensional molded bowl-shaped portion 102' is fluidly connected to a corresponding vacuum air channel 430A. During the vacuum process, vacuum pressure is applied to the vacuum air channel 430A to draw the laminated preform 210' into abutment against the lower surface 436 of the three-dimensional molded bowl-shaped portion 102'. Vacuum forming the laminated preform 210' into abutment against the lower surface 436 of the three-dimensional molded bowl-shaped portion 102' forms a cavity 452 between the laminated preform 210' and the molding cap 98', as shown. Figure 39 As shown in the diagram. Preferably, the molding base 100' and / or the molding cap 98' are heated to a temperature between approximately 140°F and approximately 150°F. However, in other embodiments, other molding temperatures may be selected depending on the needs of a particular manufacturing process.

[0145] Reference Figure 34 and Figure 39 The molded cap 98' includes an inlet port 460 for injecting liquid into the cavity 452. The inlet port 460 is fluidly connected to an inlet channel 460A passing through the molded cap 98', such as... Figure 39As illustrated in the diagram, inlet channel 460A is fluidly connected to at least one first filler line 466 and a second filler line 472. The first filler line 466 and the second filler line 472 are configured to provide a first liquid 466A and a second liquid 472A to inlet channel 460A, respectively. In other embodiments, inlet channel 460A is fluidly connected to a plurality of filler lines 466, 472, wherein each filler line 466, 472 is configured to provide a liquid additive 466A, 472A to inlet channel 460A. The first liquid 466A and the second liquid 472A are mixed within inlet channel 460A to form a mixed liquid 460B, which is injected through inlet port 460 and into cavity 452. As a non-limiting example, the first liquid 466A and the second liquid 472A, and possibly other selected components based on the specific needs of a selected seat back panel 54', may partially comprise a mixture of polyol 466A and isocyanate (ISO) 472A. The mixed polyol 466A and isocyanate 472A are injected and / or poured into the inlet channel 460A via the first filling line 466 and the second filling line 472, respectively. The mixed polyol 466A and isocyanate 472A are mixed and injected into cavities 452 within molds 98' and 100', causing the mixed polyol 466A and isocyanate 472A to react within cavities 452 and form a molded polyurethane foam backing 420. The molded foam backing 420 adheres to the laminated preform 210' during the reaction process. The assembly of the molded foam backing 420 and the laminated preform 210' is then completed. Figure 32 The seat back panel 54' shown is illustrated. In some embodiments of the seat back panel 54', the molded foam backing 420 has a density of about 425 kg / m³, a thickness of about 3 mm, and a curing time of about 2 minutes.

[0146] Reference Figure 41 Once the foam reaction process is complete, the molding cap 98' is removed from the molding base 100'. Figure 41As shown, the outer periphery 283' of the laminated preform 210' is foam-free. The molded foam backing 420 has an outer periphery 420A that is spaced apart from the outer periphery 283' of the laminated preform 210' to form a foam-free edging 410' extending around the outer periphery 283' of the seat back panel 54'. The predefined edging 410' of the laminated preform 210' that forms a gasket between the molded cover 98' and the molded base 100' is spaced apart from the molded foam backing 420 formed by the reaction of a mixture of polyol 466A and isocyanate 472A within the cavity 452. After the molded cover 98' is removed from the molded base 100', the seat back panel 54' can be removed from the three-dimensional molded bowl-shaped portion 102'. Optionally, the seat back panel 54' is placed in a cooling fixture after being removed from the molded base 100', thereby allowing the molded foam backing 420 to cool.

[0147] Figure 42 and Figure 43 It shows the use of Figures 34 to 41 Another embodiment of the seat back panel 54” produced by the manufacturing process illustrated. Figure 42 and Figure 43 Surface A 486 and surface B 488 of the seat back panel 54” are shown respectively. Figure 3 As further illustrated, surface A 486 of the seat back panel 54” faces outward relative to the vehicle seat 10, while surface B 488 faces inward relative to the vehicle seat 10.

[0148] and Figure 32 The seat back panel 54' shown is the same. Figure 42 The seat back panel 54” includes a laminated blank 210”, which includes a cover material 78” forming a surface 486 of the seat back panel 54”. Figure 42 In the embodiment shown, the cover material 78” comprises a vinyl textile; however, the vinyl textile can be replaced by other materials, such as fabric and / or leather. Additionally, if required by the specific embodiment, the laminated preform 210” forming the A surface 486 of the seat back panel 54” may include multiple layers, including but not limited to a pre-stitched pocket layer, a foam interlayer, a woven fabric backing layer, etc. Furthermore, although the A surface 486 of the laminated preform 210” is... Figure 42 The diagram shows a single-piece cover material 78”, but other embodiments of surface 486 of the laminated blank 210” may include, for example, Figure 27A The multiple pre-stitched pieces 350, 352 and / or, for example, shown in the figure Figure 28 The pre-stitched pocket 356 is illustrated in the figure. Alternatively, the laminated preform 210 may include a second A surface 358, such as... Figure 29The pre-stitched pocket layer 358 is illustrated in the seat back panel 54 shown.

[0149] Figure 42 The A surface 486 of the seat back panel 54” shown includes reference Figure 38 The molding features 70” and molding lines 72” formed during the described vacuum forming steps. Depending on the specific application, various embodiments may include any number and profile of molding features 70” and molding lines 72”, as well as combinations of molding features 70” and molding lines 72”.

[0150] In addition, such as Figure 32 and Figure 42 As illustrated, the width of the 410' and 410" unfoamed edging can be varied according to the specific application requirements. For example, in Figure 32 In the embodiment shown, the seat back panel 54' has a foam-free trim 410', which has a generally uniform width of about 8 mm and extends around the outer periphery 283' of the seat back panel 54'. In contrast, in Figure 42 In the illustrated embodiment, the seat back panel 54” has a foam-free trim 410”, which includes a segment 410A having a width of approximately 8 mm and a segment 410B having a width greater than approximately 8 mm. Although foam-free trims 410’, 410” with a width of approximately 8 mm are preferred, the selected width of the foam-free trims 410’, 410” may be greater than and / or less than approximately 8 mm depending on the needs of different embodiments. For example, a wider foam-free trim 410’, 410” may be ideal, partly depending on the selected manufacturing process, the complexity of the design of the vehicle seat cover 12, etc.

[0151] exist Figure 43 In the embodiment of the seat back panel 54 shown, the molded foam backing 420 on surface B 488 has a... Figure 42 The outer perimeter 420A corresponds to the molding line 72A on surface A 486 shown. Furthermore, Figure 43 The molded foam backing 420 of the seat back panel 54" shown includes... Figure 42The corresponding molding lines 72B” and molding features 70B”, 70C” are visible on surface A 486 shown. Each molding feature 70C on surface B 488 of seat back panel 54” includes a foam-free orifice 70D. Laminated blank 210” extends across orifice 70D. Orifice 70D may optionally be penetrated during an additional manufacturing process to provide a passageway 70D for fasteners through seat back panel 54”. Additional molding features 492, 495 are visible on surface B 488 of seat back panel 54”, such as a foam gate 492 formed by an inlet port 460 in molding cap 98’ and an automatic venting mark 495 formed by a venting channel within molding cap 98’. Figures 34 to 41 In various embodiments of the seat back panel 54', 54" formed by the manufacturing process described above, features such as molding features 70B, 70C, molding line 72B, molding orifice 70D, foam gate 492, and automatic ventilation mark 495 will vary in position, size, number, etc. In some embodiments, certain features may be omitted entirely.

[0152] Figure 44 It shows Figure 43 An enlarged view of portion 44 of surface 488 of the seat back panel 54”, further illustrating a foam-free trim 410” extending between the outer periphery 420A of the molded foam backing 420 and the outer periphery 283” of the laminated blank 210”. The foam-free trim 410” comprises both a generally uniform narrow segment 410A with a generally wide width of approximately 8 mm and a wider segment 410B. The specific width of the foam-free trim 410”, including the foam-free segment such as 410B, is selected based on the needs of the specific embodiment. The foam-free trim 410” is formed by sandwiching the outer periphery 283” of the laminated blank 210” between the molding cover 98’ and the molding base 100’, thereby preventing the molded foam backing 420 from adhering to these areas. Figure 44 The diagram also shows a positioning hole 422 extending around the outer periphery 283” of the laminated preform 210”.

[0153] Figure 45 and Figure 46 The illustration shows a perspective view of the seam 418 between the foam-free edging 410” of the seat back panel 54” and the side layer 540. Figure 45 and Figure 46In the illustrated embodiment, the side layer 540 comprises a layered assembly of a woven fabric backing layer 540A, a foam intermediate layer 540B, and a fabric A surface layer 540C. However, the side layer 540 may include any number of layers 540A, 540B, and 540C, including a single A surface layer 540C. The seat back panel 54” is assembled with the side layer 540 and other trim pieces (not shown) to form a seat back panel trim cover assembly 416'. The A surface 486 of the seat back panel 54” and the A surface 540C of the side layer 540 are assembled facing each other, wherein the outer peripheral edge 283” of the seat back panel 54” is aligned with the outer peripheral edge of the side layer 540. Once the seat back panel 54” is assembled with the side layer 540, the stitching seam 418” is stitched through layers 540A, 540B, 540C of the side layer 540 and the foam-free trim 410” of the seat back panel 54” to form the seat back panel trim cover assembly 416’. The foam-free trim 410” of the seat back panel 54” minimizes the thickness of the stitching seam 418’ because the outer periphery 420A of the molded foam backing 420 is spaced from the stitching seam 418’.

[0154] Compared to other known methods for manufacturing decorative covers, the disclosed FreeForm method... TM Decorative masks and using FreeForm TM Other components manufactured using the process offer numerous advantages. One such advantage is FreeForm. TM The decorative cover offers similar breathability to traditional cut and stitched decorative covers while eliminating most or all seams. A second advantage is that the amount of styling detail, contour, and complexity in the decorative cover can be increased compared to the practicality of traditional cut and stitched covers. A third advantage is the low processing cost, which further allows for rapid updates to styling variations by replacing less expensive molding tools. A fourth advantage is that seat heaters and other components are directly and integrally bonded to the decorative cover during the preparation of the laminated blank. A fifth advantage is the seamless styling surface and concealed fasteners of the seat decorative cover. A sixth advantage is the formation of a foam-free, pre-defined edging extending around the outer perimeter of the seat decorative cover. FreeForm TM Another advantage of the process is its applicability to manufacturing other contour covers and similar parts for a variety of automotive and domestic applications.

[0155] The invention has been described in an illustrative manner, and it should be understood that the terminology used is intended to be descriptive rather than restrictive. In view of the foregoing teachings, many modifications and variations of the invention are possible. Therefore, it should be understood that the invention can be practiced in ways other than those specifically described within the scope of the appended claims.

Claims

1. A seat cover for a vehicle seat, the seat cover comprising: A laminated preform, comprising at least a cover material and having a first surface and an opposite second surface, the laminated preform being pre-cut into a predefined shape having a predefined edging extending around the outer periphery of the laminated preform. The laminated preform is vacuum-formed into a three-dimensional shape; Wherein, after the laminated preform is vacuum-formed into the three-dimensional shape, a molded foam backing is formed on the second surface of the laminated preform, the molded foam backing being spaced apart from the predefined edging extending around the outer periphery of the laminated preform; The cover material includes one or more of vinyl materials, fabrics, and leather; The predefined edging includes multiple positioning features configured to fix at least a portion of the outer periphery of the laminated preform in place when the laminated preform is vacuum-formed into the three-dimensional shape; and Each of the plurality of positioning features is a positioning hole that passes through the predefined edging of the laminated blank.

2. The seat cover according to claim 1, wherein: The first surface of the vacuum-formed laminated preform forms surface A of the seat trim cover; and The A surface includes at least one vacuum-formed feature that has the appearance of a stitched seam.

3. The seat cover according to claim 1, wherein: The first surface of the vacuum-formed laminated preform forms surface A of the seat trim cover; and The A surface includes at least one vacuum-formed feature having a curved surface profile.

4. The seat cover according to claim 1, wherein: The first surface of the vacuum-formed laminated preform forms surface A of the seat trim cover; and The surface A includes at least one vacuum-formed feature with a raised appearance.

5. The seat cover according to claim 1, wherein: The seat cover is either a seat cushion cover or a seat back cover.

6. The seat cover according to claim 1, wherein: Before the laminated preform is vacuum-formed, at least one or more of the seat heater, sensor, circuit, fastener, woven fabric backing layer, and foam lining are assembled as part of the laminated preform.

7. The seat cover according to claim 1, wherein: Before the laminated preform is vacuum-formed into the three-dimensional shape, the second material is assembled with the cover material to form a pocket between the second material and the cover material; and The second material is one or more of vinyl materials, fabrics, and leather.

8. The seat cover according to claim 7, wherein: The second material forming the pocket extends from one edge of the cover material to the opposite edge of the cover material; and The second material is fixedly attached to the cover material before the laminated preform is vacuum-formed into the three-dimensional shape.

9. The seat cover according to claim 1, wherein: The cover material includes a first cover member having a first edge and a second cover member having a second edge; and The first edge and the second edge are adjacent to each other by a stitched seam to form a stitched cover material having at least one stitched seam.

10. The seat cover according to claim 9, wherein: The cover material of the laminated preform includes the stitched cover material; and When the molded foam backing is formed, at least a portion of the first edge and the second edge of the at least one seam of the stitched cover material is enclosed within the molded foam backing.

11. The seat cover according to claim 10, wherein: The cover material includes a third cover element having a third edge; The third cover is assembled with the first cover and the second cover to form a pocket between the third cover and the first cover; and The third edge is adjacent to the first edge and the second edge within the stitched seam between the first cover and the second cover.

12. The seat cover according to claim 1, wherein: The molded foam backing is formed from at least a mixture of polyols and isocyanates.

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