Molded trim cover assembly with improved recoverability and air permeability

Abstract

A trim cover for an automobile seat assembly includes a seat cover and a polyester batt fixedly coupled to the seat cover. The polyester cotton fibers are formed by polyester fibers.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 394,987, filed on August 4, 2022, the entire disclosure of which is hereby incorporated by reference. Technical Field

[0003] The present invention relates to seat assemblies for use in automotive vehicles. More particularly, the present invention relates to trim covers for use in automotive seat assemblies. Background Art

[0004] Motor vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above the vehicle floor. It is generally known that certain seat assemblies include a decorative cover covering portions of the seat cushion or seat back. Certain known decorative covers include a cover material forming a seating surface and a foam pad including a polyurethane foam adhered to a side opposite the cover material. Commonly used polyurethane pads typically have a thickness of about 3 mm to about 12 mm. In addition, it is generally known that the foam pad is laminated to the cover material using an adhesive or flame lamination, which permanently adheres the foam pad to the cover material. Certain commonly used cover materials are formed from polyester cloth.

[0005] However, when the trim cover includes a polyurethane foam pad adhered to the cover material, the trim cover is not recyclable because the polyurethane foam is not easily separated from the cover material.

[0006] In addition, some seat assemblies include a heating and ventilation system integrated into the seat assembly. Spacer fabric is usually inserted between the heating and ventilation system and the trim cover to maintain air permeability and airflow.

[0007] However, spacer fabrics require additional labor for installation within the seat assembly and involve material costs.

[0008] It is desirable to form the trim cover from commonly recycled materials so that the trim cover can be recycled. It is also desirable to form a trim cover with an attached spacer fabric for use with a seat assembly having a heating and ventilation system. Summary of the invention

[0009] According to one embodiment, a trim cover for an automotive seat assembly is provided. The trim cover includes a seat cover having a lower surface and a polyester batting fixedly coupled to the lower surface of the seat cover.

[0010] According to another embodiment, a method for forming a trim cover for a seat assembly is provided. The method includes the steps of providing a cover material having a lower surface; providing a polyester batting including polyester fibers; adhering the polyester batting to the lower surface of the cover material to form a laminated sheet; and cutting the laminated sheet to form the trim cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Advantages of the present invention will be readily appreciated as they become better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0012] Figure 1 is a perspective view of a seat assembly according to one embodiment of the present invention, the seat assembly including a seat cushion, a seat back, and a trim cover assembly covering the seat cushion and the seat back;

[0013] Figure 2 yes Figure 1 An exploded perspective view of a seat assembly;

[0014] Figure 3 is a perspective view of a trim cover assembly according to one embodiment of the present invention;

[0015] Figure 4 According to one embodiment of the present invention, Figure 1 A cross-sectional view of the trim cover assembly and the base pad within the seat cushion taken at section 4-4 in FIG.

[0016] Figure 5 is taken along section 4-4 according to another embodiment of the present invention Figure 1 a cross-sectional view of a trim cover assembly and a base pad within a seat cushion showing the seat cushion including a heating and ventilation system;

[0017] Figure 6 yes Figure 4 an enlarged view of portion 6 of FIG. 1 showing a trim cover including polyester batting and a seat cover;

[0018] Figure 7 yes Figure 5 an enlarged view of portion 7 in which a trim cover including polyester batting and a seat cover is shown;

[0019] Fig. 8A shows a cross-sectional view of a monofilament polyester fiber according to another embodiment of the present invention;

[0020] Figure 8B shows a cross-sectional view of a bicomponent polyester fiber having side-by-side cross-sections according to another embodiment of the present invention;

[0021] Figure 8Cshows a cross-sectional view of a bicomponent polyester fiber having a core-sheath cross-section according to another embodiment of the present invention;

[0022] Fig.8D shows a cross-sectional view of a bicomponent polyester fiber having a hybrid fiber cross-section according to another embodiment of the present invention;

[0023] Fig. 9 is a flow chart of a process for forming a trim cover assembly according to one embodiment of the present invention;

[0024] Fig.10 is taken along section line 4-4 according to another embodiment of the present invention Figure 1 a cross-sectional view of a trim cover assembly and a base pad within a seat cushion showing the seat cushion including a heating and ventilation system;

[0025] Fig.11 is a cross-sectional view of the trim cover assembly and the base pad within the seat cushion of FIG. 1 taken along section line 4-4 according to another embodiment of the present invention;

[0026] Fig.12 yes Fig.10 an enlarged view of a portion 12 in FIG.

[0027] Fig.13 yes Fig.11 an enlarged view of a portion 13 in FIG.

[0028] Fig.14 is a flow chart of a process for forming a trim cover assembly according to another embodiment of the present invention;

[0029] Fig.15 is a perspective view of a laminated barrier according to another embodiment of the present invention;

[0030] Fig.16 is a schematic diagram of a molding process for forming a molded trim cover according to another embodiment of the present invention;

[0031] Fig.17 is a front view of a decorative cover according to another embodiment of the present invention;

[0032] 18 is a cross-sectional view of a known assembly of a base pad of a seat cushion and a trim cover assembly having a polyurethane foam pad; and

[0033] 19 is a cross-sectional view of another known assembly of a trim cover, spacer fabric, and base pad of a seat cushion having a heating and ventilation system. DETAILED DESCRIPTION

[0034] Figures 1 to 17Components of a trim cover assembly 10 for use in a motor vehicle seat assembly 12 are illustrated according to the embodiments described herein. Directional references such as top, bottom, upper, lower, upward, downward, longitudinal, lateral, left, right, etc., used or shown in the specification, drawings, or claims are relative terms used for convenience of description and are not intended to limit the scope of the present invention in any aspect. Referring to the drawings, like reference numerals indicate like or corresponding parts throughout the several views.

[0035] exist Figure 1 and Figure 2 , the seat assembly 12 includes a seat cushion 14 and a seat back 16 pivotally coupled to the seat cushion 14. The seat cushion 14 and the seat back 16 typically include a base pad 18 that forms a support layer within the seat assembly 12. In addition, the seat cushion 14 and the seat back 16 may include a support pad 20 that provides additional support to an occupant of the seat assembly 12. The seat assembly 12 optionally includes a heating and ventilation system 22 for occupant comfort and temperature control. The heating and ventilation system 22 includes one or more airflow channels 24 that pass through the base pad 18. The seat assembly 12 also includes a trim cover assembly 10 that is assembled on one or more exterior surfaces of the seat assembly 12 and covers the base pad 18 and other components in the seat assembly 12 to provide a seating surface for an occupant of the motor vehicle.

[0036] Figure 3 1 and 2. An exemplary trim cover assembly 10 for a seat back 16 is shown in FIG. The exemplary trim cover assembly 10 includes a trim cover panel 26 (hereinafter "trim cover"), opposing bolster panels 28, one or more side panels 30, a back panel 32, an auxiliary panel 34, and a bottom panel 36. The trim cover 26 includes opposing lateral edges 38 sewn to the inner edges 40 of the respective bolster panels 28 to form a sewn seam 42. Additionally, the trim cover 26 includes an upper edge 44 sewn to one of the side panels 30 and a lower edge 46 sewn to one edge 48 of the auxiliary panel 34. The additional side panel 30 has a front edge 50 sewn to an outer edge 52 of the respective bolster panel 28. The side panel 30 includes a rear edge 54 attached to an adjacent edge 56 of the back panel 32. As a non-limiting example, the exemplary trim cover assembly 10 may also include fasteners 58, zippers 60, etc. fixedly coupled to one or more components within the trim cover assembly 10. It will be appreciated that the trim cover assembly 10 may include additional components or fewer components than described above.It will also be appreciated that the bolster panel 28, side panels 30, back panel 32, etc. may generally be described as "trim covers."

[0037] Reference Figure 4 and Figure 6, the decorative cover 26 includes a seat cover 62 and a polyester batting 64. The seat cover 62 has an upper surface 66 opposite to the lower surface 68 and is formed by a cover material 70 such as cloth, vinyl and / or leather. An exemplary cover material 70 is a polyester fabric. The upper surface 72 of the polyester batting 64 is fixedly connected to the lower surface 68 of the seat cover 62 to improve the appearance and comfort associated with the decorative cover 26. The polyester batting 64 is alternatively described as polyethylene terephthalate batting (hereinafter "PET batting"). In addition, as a non-limiting example, the PET batting 64 is adhesively laminated, powder laminated, stapled and sewn, etc. to the lower surface 68 of the seat cover 62. In addition, the PET batting 64 can be assembled with the seat cover 62 and compression molded to form the decorative cover 26, as further described below.

[0038] exist Figure 6 , the PET batting 64 is formed from a random web 74 of dispersed polyester fibers 76 and optional melt polyester fibers 78. As non-limiting examples, the dispersed polyester fibers 76 typically include one or more of virgin polyester fibers (PET), recycled polyester fibers (rPET), bio-based polyester fibers, natural polyester fibers, and the like.

[0039] Reference FIG. 8A to FIG. 8D The melt polyester fiber 78 may include a monofilament polyester fiber 80 and / or a bicomponent polyester fiber 82. The monofilament polyester fiber 80 generally has a melting temperature lower than the melting temperature of the dispersed polyester fiber 76. The monofilament polyester fiber 80 has a cross section including a single type of polyester fiber 84, such as Fig. 8A The melting temperature of the monofilament polyester fibers 80 and the ratio of the dispersed polyester fibers 76 to the monofilament polyester fibers 80 are selected based in part on the desired flexibility and structural stability of the PET batting 64 .

[0040] In addition, the bicomponent polyester fiber 82 includes a high temperature polyester fiber 86 and a low temperature polyester fiber 88, which are extruded simultaneously to combine the physical and aesthetic properties of two different polyester fibers 86, 88. The low temperature polyester fiber 88 is selected to have a melting temperature less than the melting temperature of the high temperature polyester fiber 86. The low temperature polyester fiber 88 preferably has a melting temperature greater than or equal to about 100°C and less than or equal to about 180°C. In another embodiment, the low temperature polyester fiber 88 has a melting temperature equal to or greater than about 100°C and less than or equal to about 130°C. In a preferred embodiment, the low temperature polyester fiber 88 has a melting temperature of about 120°C, and the high temperature polyester fiber 86 has a melting temperature of about 180°C or greater. The high temperature polyester fiber 86 provides additional structure and durability to the bicomponent polyester fiber 82.

[0041] The bicomponent polyester fiber 82 is formed by simultaneously extruding a high temperature polyester fiber 86 and a low temperature polyester fiber 88 using a generally known method to form various cross-sections 90A to 90C. FIG. 8B to FIG. 8D As non-limiting examples, the bicomponent polyester fiber 82 may have a side-by-side extrusion cross section 90A, a core-sheath extrusion cross section 90B, an extruded mixed fiber cross section 90C, etc. It will be appreciated that the cross sections 90A to 90C of the bicomponent polyester fiber 82 and the melting temperatures of the high temperature polyester fiber 86 and the low temperature polyester fiber 86 may vary, respectively, without changing the scope of the present invention. In addition, it will be appreciated that the melting temperature may be alternatively described as a molding temperature without changing the scope of the present invention.

[0042] Reference Figure 6 In one exemplary embodiment, the PET batting 64 includes about 95% to 100% dispersed polyester fibers 76 and may include up to about 5% dyes and other additives. In an alternative embodiment, the PET batting 64 may include up to about 40% melt polyester fibers 78, 80, 82, wherein the remainder of the PET batting 64 is formed from dispersed polyester fibers 76. It will be understood that the PET batting 64 may include up to about 5% dyes and other additives without changing the scope of the present invention. In addition, the PET batting 64 has a batting thickness 92 that is generally between about 3 mm and about 13 mm. It will be understood that the batting thickness 92 of the PET batting 64 may vary without changing the scope of the present invention.

[0043] PET batting 64 has a fiber denier (D) that is generally less than about 45D. The fiber denier of PET batting 64 is selected based in part on the specific application of the decorative cover 26. For example, PET batting 64 can have a fiber denier greater than or equal to about 1D and less than or equal to about 10D when used in applications that do not require air permeability. In applications where PET batting 64 replaces conventional polyurethane foam additional pads 94 (shown in Figure 18), a fiber denier greater than or equal to about 20D and less than or equal to about 25D can be selected. PET batting 64 can be selected to have a fiber denier greater than or equal to about 35D and less than or equal to about 45D in certain applications that require a minimum air permeability of about 100cfm to about 120cfm (cubic feet per minute). It will be understood that the fiber denier of PET batting 64 can vary without changing the scope of the present invention.

[0044] As a non-limiting example, the web 74 of dispersed polyester fibers 76 and optional melted polyester fibers 78, 80, 82 forming the PET batting 64 can be stabilized using various known methods generally described as multi-knitted batting, non-woven batting, hot melt batting, etc. The multi-knitted batting is formed by sewing the web 74 with longitudinal yarns (not shown) to combine and hold the web 74 in place. The non-woven batting is formed by needles passing through the web 74 to push the web 74 into a consistent and stable batting. The hot melt batting is formed by a web 74 including dispersed polyester fibers 76 and melted polyester fibers 78. In order to form the hot melt batting, the web 74 passes through a warmer (not shown), which melts at least a portion of the melted fibers 78 and combines with the remaining fibers 76, 78, 80, 82 in the web 74. It will be understood that the PET batting 64 can be stabilized by generally known processes to produce multi-knitted batting, non-woven batting, hot melt batting, etc. without changing the scope of the present invention.

[0045] It will be appreciated that the properties of the PET batting 64 can be tailored for various seating applications by varying the fiber denier, the ratio and properties of the dispersed polyester fibers 76 and the melted polyester fibers 78, 80, 82, the batting thickness 92, the addition of monofilament polyester fibers 80 and / or bicomponent polyester fibers 82, the selection of specific high temperature polyester fibers 86 and low temperature polyester fibers 88 within the bicomponent polyester fibers 82, the cross-sections 90A to 90C of the bicomponent polyester fibers 82, the addition of batting stabilization methods, etc., to obtain a desired balance of flexibility, structure, and breathability. In addition, the melting temperature of the polyester fibers 76, 80, 82, 86, 88 is selected based in part on the processing steps selected to prepare the trim cover 26, as further described below. In addition, a low percentage of melted fibers 78 (i.e., between 0% and about 10%) can be incorporated into the PET batting 64 for "soft" applications, such as a replacement for conventional polyurethane foam cushions 94 (FIG. 18). A high percentage of melt fibers 78 (i.e., greater than about 20% and less than about 40%) can be incorporated into the PET batting 64 for "hard" applications, such as for certain seat back panels 32. In addition, it will be understood that the polyester fibers 76, 80, 82, 86, 88 preferably include recycled polyester fibers (rPET), which are polyester fibers spun from chips prepared by fragmenting post-consumer PET plastic bottles. Preferably, the PET batting 64 includes at least about 60% or more recycled polyester fiber content and is capable of being recycled at the end of life using commonly known melt recycling processes.

[0046] 18, a conventional trim cover 96 includes a conventional polyurethane foam pad 94, generally described as an "additional pad," which is flame laminated to a lower surface 98 of a conventional seat cover 100. The conventional trim cover 96 cannot be recycled using a melt recycling process because the conventional polyurethane foam pad 94 is of a different material and is permanently attached to the conventional seat cover 100.

[0047] exist Figure 4 and Figure 6 In one embodiment of the present invention shown in FIG. 18 , the trim cover 26 includes PET batting 64 that provides similar functionality to conventional polyurethane foam pads 94 in conventional trim cover 96 ( FIG. 18 ). Replacing conventional polyurethane foam pads 94 with PET batting 64 allows the trim cover 26 to be melt recycled because the trim cover 26 has no polyurethane content. The PET batting 64 provides comparable elasticity and quality to conventional polyurethane foam pads 94 having a thickness of about 3 mm to about 12 mm. Referring to FIG. Figure 4 , the trim cover assembly 10 includes, in part, a trim cover 26 having lateral edges 38 sewn to respective inboard edges 40 of opposing bolster panels 28 to form sewn seams 42. The trim cover 26 includes a seat cover 62 formed of a cover material 70 and a PET batting 64 attached to a lower surface 68 of the seat cover 62. Additionally, the bolster panel 28 includes a bolster cover 102 formed of the cover material 70 and a PET batting 64 attached to a lower surface 104 of the bolster cover 102. It will be appreciated that the seat cover 62 and the bolster cover 102 may be formed of different cover materials 70 and / or different PET batting 64 without altering the scope of the present invention.

[0048] The PET batt 64 used as a substitute for conventional polyurethane foam pads 94 has a batt thickness 92 of about 3 mm to about 13 mm. In addition, the PET batt 64 has a fiber denier of about 20D to about 25D. In certain applications, the PET batt 64 preferably has a batt thickness 92 of about 6 mm and a fiber denier of 25D. In addition, the PET batt 64 is selected to include about 95% to about 100% of dispersed polyester fibers 76 and up to about 5% of dyes and other additives. In certain embodiments, the PET batt 64 includes about 95% to about 100% of dispersed recycled polyester fibers 76. In addition, the melt polyester fibers 78, 80, 82 can be omitted from the PET batt 64.

[0049] The PET batting 64 can be selected to include about 60% to about 90% recycled dispersed polyester fibers 76 and about 10% to about 40% bicomponent polyester fibers 82 to reduce the tendency of the PET batting 64 to break or stretch during the cutting and sewing operations. In one embodiment, the PET batting 64 includes about 85% dispersed polyester fibers 76 and about 15% melt fibers 78. When the PET batting 64 is still in sheet form (before cutting), the PET batting 64 containing the bicomponent polyester fibers 82 can be preheated or "tempered" to allow at least a portion of the bicomponent polyester fibers 82 to fuse together, which improves the structure and stability of the PET batting 64. After the PET batting 64 is preheated or tempered, the PET batting 64 is attached to the cover material 70.

[0050] Fig. 9 The process for forming the trim cover 26 and the finished trim cover assembly 10 is shown in FIG. Fig. 9 , the PET batting 64 and the cover material 70 are initially in sheet form (step 106). Next, it is determined whether the PET batting 64 in sheet form needs to be stabilized (step 108). If the PET batting 64 needs to be stabilized, the PET batting 64 passes through a warmer to preheat / temper the PET batting 64 so that at least a portion of the bicomponent polyester fibers 82 fuse to the remaining polyester fibers 76, 82 (step 110). After the PET batting 64 is stabilized if necessary (step 110) or if the PET batting 64 does not need to be stabilized, it is determined whether the PET batting 64 and the cover material 70 will be cut before attaching the PET batting 64 to the cover material 70 (step 112). If the PET batting 64 and cover material 70 are not to be cut before the PET batting 64 is attached to the cover material 70, then, as a non-limiting example, the PET batting 64 is adhesively laminated, powder laminated, stapled, etc., to the lower surface 68 of the cover material 70 to form a laminated sheet 114 (step 116). Alternatively, the PET batting 64 can be attached to the cover material 70 using a reactive hot melt, a web adhesive, etc. Next, the laminated sheet 114 is cut to form the trim cover 26 (step 118). If the PET batting 64 and cover material 70 are to be cut before the PET batting 64 is attached to the cover material 70 (step 112), the PET batting 64 and cover material 70 are cut into the desired shape (step 120), and then the cut PET batting 64 is fixedly coupled to the seat cover 62 to form the trim cover 26 (step 122). Next, the trim cover 26 prepared in step 118 or step 122 is processed through additional trimming and sewing operations to form the finished trim cover assembly 10 (step 124). It will be appreciated that additional components of the trim cover assembly 10, such as the support pad panel 28, can be formed using a similar process as used to form the trim cover 26.

[0051] When the cover material 70 used in the trim cover 26 is polyester and PET batting 64 is used instead of conventional polyurethane foam padding 94, the trim cover 26 can be recycled mechanically, chemically or by melting so that the polyester component can be re-spun into new recycled polyester fiber (rPET). Therefore, the trim cover 26 can be recycled instead of being disposed of in a landfill.

[0052] 19, a conventional seat assembly 126 is shown including a heating and ventilation system 128 having one or more airflow channels 130 through a base cushion 132. The conventional seat assembly 126 includes a conventional spacer fabric 134 and a conventional trim cover 136. The conventional spacer fabric 134 is positioned between the base cushion 132 and the conventional trim cover 136 to maintain airflow and permeability of the heating and ventilation system 128. However, the conventional spacer fabric 134 adds significant material cost and requires additional labor to install.

[0053] Figure 5 and Figure 7 A second embodiment of a trim cover assembly 10 ′ is shown in FIG. 2 , wherein like primed reference numerals indicate similar elements to those described above. Figure 5 and Figure 7 The second embodiment of the trim cover 26' shown in FIG. 1 includes a PET batting 64' configured to replace the conventional spacer fabric 134 typically included in a conventional seat assembly 126 having a heating and ventilation system 128. Only the significant differences between the two embodiments are reflected in the drawings and the following description.

[0054] Reference Figure 5 , the seat assembly 12' includes a heating and ventilation system 22' incorporated into the base cushion 18' for occupant comfort and temperature control. The heating and ventilation system 22' typically includes one or more airflow channels 24' through the base cushion 18'. A key performance metric for textiles used in a trim cover 26' for a seat assembly 12' having a heating and ventilation system 22' is air permeability, which is evaluated in accordance with ASTM D737. Preferably, the minimum permeation level required through the trim cover 26' (arrow 138) when the seat assembly 12' is not occupied is approximately 100 cfm to 120 cfm (cubic feet per minute) to ensure adequate performance of the heating and ventilation system 22'.

[0055] Reference Figure 7, in order to ensure sufficient airflow (arrow 138) through the decorative cover 26', the PET batting 64' is selected to have a fabric denier greater than or equal to about 35D and less than or equal to about 45D. In one embodiment, the PET batting 64' preferably has a fabric denier of about 40D. In addition, the PET batting 64' includes about 95% to about 100% recycled dispersed polyester fibers 76' and up to about 5% dyes and other additives. In addition, the PET batting 64' may lack molten polyester fibers 78', 80', 82'. However, it will be understood that the PET batting 64' may include molten polyester fibers 78', 80', 82', and the PET batting 64' can be preheated or temperature-adjusted when in sheet form to improve handling during cutting and sewing operations. In addition, the PET batting 64' is selected to have a batting thickness 92' greater than or equal to about 8mm and less than or equal to about 15mm. In one embodiment, the PET batt 64' preferably has an initial batt thickness 92' of about 10 mm. Preferably, the PET batt 64' includes at least about 60% or more recycled polyester fiber content and is capable of being recycled at end of life using commonly known melt recycling processes.

[0056] Reference Figure 5 and Figure 7 , the upper surface 72' of the PET batting 64' is fixedly coupled to the lower surface 68' of the seat cover 62' when the cover material 70' and the PET batting 64' are in sheet form or after the PET batting 64' and the cover material 70' are cut, as previously described with reference to Fig. 9 Cost savings and labor savings associated with the trim cover 26' are achieved by replacing the conventional spacer fabric 134 with the PET batting 64'. Additionally, the trim cover 26' can be sewn to the bolster panel 28 including the PET batting 64 and the bolster cover 102, as described above in the first embodiment.

[0057] Fig.10 and Fig.12 A third embodiment of a trim cover 26" is shown in FIG. 1 , wherein like double prime reference numerals indicate similar elements to those described above. Fig.10 The trim cover 26" of the third embodiment shown in the drawing includes PET batting 64", which is configured to replace the conventional spacer fabric 134 typically included in a conventional trim cover 136 for a conventional seat assembly 126 with a heating and ventilation system 128 (see Figure 19). The trim cover 26" can also include an integral support pad section 140 configured to cover the support pad 20", rather than sewing the trim cover 26', 26 to the support pad panel 28 as described in the previous embodiment. In addition, the trim cover 26" includes a laminated barrier 142 ( Fig.15) is compression molded to form a 3-dimensional shape of a 3-dimensional molded panel 26". The laminated barrier 142 includes a central section 144P spaced between opposing support pad sections 140P. Only the significant differences between the previous embodiments are reflected in the drawings and the following description.

[0058] Reference Fig.10 and Fig.12 The trim cover 26" includes a seat cover 62" and a PET batting 64". The upper surface 72" of the PET batting 64" is adhered to the lower surface 68" of the seat cover 62". The trim cover 26" includes a central section 144 and an opposing support pad section 140. Fig.12 , the support cushion section 140 has a batting thickness 92b that is less than the batting thickness 92c of the central section 144. The PET batting 64" in the central section 144 is configured to allow adequate airflow and permeability through the trim cover 26" for the heating and ventilation system 22". The PET batting 64" is compressed to a reduced batting thickness 92b in the support cushion section 140 during the compression molding process described below.

[0059] The trim cover 26" is a 3-dimensional molded panel 26" formed using a compression molding process. Incorporating PET batting 64" in place of conventional spacer fabric 134 allows the trim cover 26" to be compression molded to form contours and molded grooves 145 ( Fig.11 ). Conventional spacer fabrics 134 are generally not suitable for use in compression molding processes having tool temperatures in the range of about 65°C to about 160°C.

[0060] The PET batting 64" is selected to have a sufficient amount of air permeability while allowing the PET batting 64" to be compression molded. In more detail, the PET batting 64" is selected to have a fiber denier greater than or equal to about 35D and less than or equal to about 45D. Fig.12 , the PET batting 64" is selected to have an initial batting thickness 92i greater than or equal to about 8 mm and less than or equal to about 15 mm. In addition, the PET batting 64" is selected to have an initial batting thickness 92i that is generally about 2 mm thicker than the desired compression molded batting thickness 92c in the central section 144 of the decorative cover 26". In an exemplary embodiment, the PET batting 64" having an initial batting thickness 92i of about 10 mm and a fiber denier of about 40D provides sufficient air permeability to meet occupancy airflow requirements when incorporated into a finished decorative cover assembly 10".

[0061] In addition, the PET batting 64" is selected to include at least about 60% and less than about 90% dispersed polyester fibers 76", wherein the dispersed polyester fibers 76" preferably include recycled dispersed polyester fibers 76". The PET batting 64" also includes at least about 10% and less than about 40% molten polyester fibers 78", and the molten polyester fibers 78" preferably include bicomponent polyester fibers 82". The bicomponent polyester fibers 82" are selected to allow the PET batting 64" to be compression molded within a temperature range of at least about 100°C and less than about 130°C. In one embodiment, the PET batting 64" includes about 85% dispersed polyester fibers 76" and about 15% molten fibers 78". Preferably, the PET batting 64" includes at least about 60% or more recycled polyester fiber content and is capable of being recycled at the end of its life using commonly known melt recycling processes. In addition, the PET batting 64" is selected to be suitable for compression molding using a compression molding process such as that disclosed in WO / 2019 / 232538, the entire contents of which are incorporated herein by reference.

[0062] Fig.14 The process for forming the trim cover 26" and the finished trim cover assembly 10" is shown in FIG. Fig.14 , the PET batting 64" and the cover material 70" are initially in sheet form (step 146). Next, as a non-limiting example, the PET batting 64" in sheet form is adhesively laminated, powder laminated, stapled, etc. to the lower surface 68" of the cover material 70" to form a laminated sheet 114" (step 148). Next, the laminated sheet 114" is cut to form a laminated barrier 142 (step 150). The laminated barrier 142 is formed at Fig.15 Next, the laminated barrier 142 is placed between an upper mold 152 having a 3-dimensional contour molding surface 156 and a lower mold 154 having a 3-dimensional contour molding surface 158 and compression molded to form the trim cover 26" (step 160), as shown in FIG. Fig.16 The laminated barrier 142 is compression molded at a moderate tool pressure and a tool temperature of about 65°C or greater and about 160°C or less, so that the bicomponent polyester fibers 82" are at least partially melted at a temperature of about 100°C or greater and about 130°C or less to form a 3-dimensional molded panel as a trim cover 26", as shown in FIG. Fig.12 and Fig.17 It will be appreciated that the tool temperature and melt temperature may vary without changing the scope of the invention.

[0063] like Fig.12As illustrated in , the laminate barrier 142 can compress the initial batting thickness 92i of the PET batting 64" to different batting thicknesses 92b, 92c in certain portions of the trim cover 26", such as the support pad section 140 compared to the central section 144. In addition, the outer periphery 161 of the laminate barrier 142 can be compressed to a reduced batting thickness for improved ease of sewing.

[0064] Next, the trim cover 26" is processed through additional trimming and sewing operations to form the finished trim cover assembly 10" (step 162). It will be appreciated that additional components of the trim cover assembly 10" may be formed using a similar process as that used to form the trim cover 26". It will be appreciated that the molded trim cover 26" may be sewn to additional components including additional molded panels without changing the scope of the present invention. Additionally, the trim cover 26" may be formed to cover both the base liner 18" and the associated support pad 20", such as Fig.10 As shown in the figure.

[0065] Fig.11 and Fig.13 A fourth embodiment of a trim cover 26 - 1 is shown in FIG. 2 , wherein reference numerals denoted by “-1” denote elements similar to those described above. Fig.11 The fourth embodiment of the decorative cover 26-1 shown in FIG. 1 includes a PET batting 64-1 that is configured to replace the conventional polyurethane foam pad 94 that is typically included in certain conventional decorative covers 96 (see FIG. 18 ). The decorative cover 26-1 may also include an integral support pad section 140-1 configured to cover the support pad 20-1, rather than sewing the decorative cover 26', 26 to the support pad panel 28 as described in the previous embodiments. In addition, the decorative cover 26-1 is formed by laminating the laminated barrier 142-1 ( Fig.15 ) is formed by compression molding a 3D molded panel 26-1. Only the significant differences between the previous embodiments are reflected in the drawings and the following description.

[0066] Reference Fig.11 and Fig.13 , the trim cover 26-1 includes a seat cover 62-1 and a PET batting 64-1. The upper surface 72-1 of the PET batting 64-1 is adhered to the lower surface 68-1 of the seat cover 62-1 formed by the cover material 70-1. The trim cover 26-1 includes a central section 144-1 and an opposing support pad section 140-1. Fig.11, support pad segment 140-1 has a nominal batt thickness 92b-1 similar to nominal batt thickness 92c-1 of center segment 144-1. PET batt 64-1 may be compressed in localized areas during the compression molding process described below to form one or more mold grooves 145. Molded grooves 145 may have the overall appearance of a stitched seam.

[0067] The trim cover 26 - 1 is a 3-dimensional molded panel 26 - 1 formed using the compression molding process discussed above with reference to the third embodiment. The PET batting 64 - 1 allows the trim cover 26 - 1 to be compression molded to form contours and molded recesses 145 in the trim cover 26 - 1 .

[0068] In more detail, the PET batting 64-1 is selected to have a fiber denier greater than or equal to about 20D and less than or equal to about 25D. Fig.13 , the PET batting 64-1 is selected to have an initial batting thickness 92i-1 greater than or equal to about 3 mm and less than or equal to about 10 mm. In addition, the PET batting 64-1 is selected to have an initial batting thickness 92i-1 that is generally about 2 mm thicker than the desired compression molded batting thickness 92c-1 of the trim cover 26-1. In an exemplary embodiment, the PET batting 64-1 has an initial batting thickness 92i-c of about 6 mm and a fiber denier of about 25D.

[0069] In addition, the PET batt 64-1 is selected to include at least about 60% and less than or equal to about 90% of dispersed polyester fibers 76-1, wherein the dispersed polyester fibers 76-1 preferably include recycled dispersed polyester fibers 76-1. The PET batt 64-1 also includes at least about 10% and less than or equal to about 40% of molten polyester fibers 78-1, and the molten polyester fibers 78-1 preferably include bicomponent polyester fibers 82-1. The bicomponent polyester fibers 82-1 are selected to allow the PET batt 64-1 to be compression molded within a temperature range of at least about 100° C. and less than or equal to about 130° C. In one embodiment, the PET batt 64-1 includes about 85% of the dispersed polyester fibers 76-1 and about 15% of the molten fibers 78-1.

[0070] The process for forming the trim cover 26-1 is similar to that previously described in Fig.14 The process described in , wherein the PET batting 64-1 is used to replace the previous PET batting 64". In summary, the PET batting 64-1 is adhered to the cover material 70-1 to form the laminated sheet 114. Next, the laminated sheet 114 is cut in step 150 to form the laminated barrier 142-1 ( Fig.15The laminated barrier 142-1 is positioned between an upper mold 152 having a 3-dimensional contoured molding surface 156 and a lower mold 154 having a 3-dimensional contoured molding surface 158 and compression molded to form the trim cover 26-1 (step 160), as shown in FIG. Fig.16 The laminated barrier 142-1 is compression molded at a moderate tool pressure and a tool temperature of about 65°C or more and about 160°C or less, so that the bicomponent polyester fiber 82-1 is at least partially melted at a temperature of about 100°C or more and about 130°C or less to form a laminated barrier 142-1. Fig.17 3-D molded panel of the trim cover 26-1 shown in FIG. It will be appreciated that the tool temperature and melt temperature may vary without changing the scope of the invention. Next, the trim cover 26-1 is processed through additional trimming and sewing operations to form the finished trim cover assembly 10-1 (step 162).

[0071] As discussed above, the trim cover assembly 10, 10', 10", 10-1 of the present invention includes a trim cover 26, 26', 26", 26-1, which includes a PET cotton batting 64, 64', 64", 64-1 adhered to the lower surface 68, 68', 68", 68-1 of a seat cover 62, 62', 62", 62-1 formed by a cover material 70, 70', 70", 70-1. The PET cotton batting 64, 64', 64", 64-1 includes a web 74 of dispersed polyester fibers 76, 76', 76", 76-1 and optional melt polyester fibers 78, 78', 78", 78-1. The trim cover 26", 26-1 is optionally compression molded. The cover material 70, 70', 70", 70-1 can be formed from a polyester fabric. Including polyester fabric and PET batting 64, 64', 64", 64-1 allows the trim cover 26, 26', 26", 26-1 to be recyclable. In addition, the properties of the PET batting 64, 64', 64", 64-1 can be customized so that the PET batting 64, 64', 64", 64-1 can replace conventional polyurethane foam padding 94 or conventional spacer fabric 134 used in conventional trim covers 96.

[0072] The present invention has been described in an illustrative manner, and it will be appreciated that the terms used are intended to have the nature of descriptive rather than restrictive terms. In view of the above teachings, many modifications and variations of the present invention are possible. Therefore, it will be appreciated that within the scope of the appended claims, the present invention may be practiced in a manner other than that specifically described.

Claims

1. A decorative cover for a vehicle seat assembly, comprising: a seat cover having a lower surface; as well as A polyester batting is fixedly coupled to the lower surface of the seat cover, the polyester batting including polyester fibers.

2. The decorative cover according to claim 1, wherein: The polyester fibers comprise at least about 95% dispersed polyester fibers; and The polyester batting has a fiber denier of about 20D to about 25D and a batting thickness of about 3 mm to about 13 mm.

3. The decorative cover according to claim 1, wherein: The polyester fibers comprise at least about 95% dispersed polyester fibers; and The polyester batting has a fiber denier of about 35D to about 45D and a batting thickness of about 8 mm to about 15 mm.

4. The decorative cover according to claim 3, wherein: The seat cover comprises polyester fabric.

5. The decorative cover according to claim 1, wherein: The polyester fibers include at least about 60% and equal to less than about 90% dispersed polyester fibers and at least about 10% and equal to less than about 40% melt polyester fibers.

6. The decorative cover according to claim 5, wherein: The melt polyester fibers include bicomponent polyester fibers.

7. The decorative cover according to claim 6, wherein: The bicomponent polyester fiber includes a high temperature polyester fiber and a low temperature polyester fiber, the low temperature polyester fiber having a melting temperature greater than or equal to about 100° C. and less than or equal to about 180° C., the high temperature polyester fiber having a melting temperature greater than the melting temperature of the low temperature polyester fiber.

8. The decorative cover according to claim 7, wherein: The polyester batting has a fiber denier of about 20D to about 25D and a batting thickness of about 3 mm or more and about 13 mm or less.

9. The decorative cover according to claim 7, wherein: The polyester batting has a fiber denier of about 35D to about 45D and a batting thickness of about 8 mm to about 15 mm.

10. The decorative cover according to claim 7, wherein: The trim cover is compression molded to form a 3-dimensional shape after the polyester batting is fixedly coupled to the seat cover.

11. The decorative cover according to claim 7, wherein: The bicomponent polyester fiber has a side-by-side cross section, a core-sheath cross section, or a mixed fiber cross section.

12. The decorative cover according to claim 7, wherein: The dispersed polyester fibers include one or more of virgin polyester fibers, recycled polyester fibers, bio-based polyester fibers, and natural polyester fibers.

13. The decorative cover according to claim 7, wherein: The seat cover comprises polyester fabric.

14. The decorative cover according to claim 13, wherein: The polyester batting includes at least 60% recycled polyester fibers.

15. The decorative cover according to claim 14, wherein: The decorative cover is melt-recyclable.

16. A method of forming a trim cover for a seat assembly, comprising the steps of: providing a cover material having a lower surface; providing a polyester batting including polyester fibers; adhering the polyester batting to the lower surface of the cover material to form a laminated sheet; as well as The laminated sheet is cut to form the trim cover.

17. The method according to claim 16, wherein: The polyester batting includes dispersed polyester fibers.

18. The method according to claim 17, wherein: The polyester batting includes between about 10% and about 40% molten polyester fibers.

19. The method of claim 18, wherein: The melt polyester fiber comprises a bicomponent polyester fiber, and the bicomponent polyester fiber comprises a high-temperature polyester fiber and a low-temperature polyester fiber; The low-temperature polyester fiber has a melting temperature of about 100° C. or more and about 180° C. or less; and The high temperature polyester fiber has a melting temperature greater than the melting temperature of the low temperature polyester fiber.

20. The method according to claim 19, wherein: The polyester batting has a fiber denier of at least about 20D and less than or equal to about 45D.

21. The method of claim 20, further comprising the step of preheating the polyester batting prior to adhering the polyester batting to the cover material.

22. The method of claim 20, further comprising the step of compression molding the trim cover to form a 3-dimensional molded panel during compression molding, wherein: At least a portion of the low-temperature polyester fiber is melted at a molding temperature between about 100°C and about 180°C.

23. The method according to claim 22, wherein: The bicomponent polyester fibers have a melting temperature equal to or greater than about 100°C and equal to or less than about 130°C.

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