Trim cover assembly

Abstract

A trim cover assembly is provided. An assembly is provided with a first layer sized to be disposed on a seat component. A tie is connected to the first layer to extend at least partially along or at least partially through a cushion of the seat component. A retainer is connected to the tie-down, and the retainer is sized to retain the tie-down and the first layer to the seat component. The second layer is stacked on and fixed to the first layer. The third layer is stacked on and fixed to the second layer.

Description

Technical Field

[0001] Aspects relate to seat assemblies and multi-layer trim covers, as well as methods for manufacturing seat assemblies and multi-layer trim covers. Brief Description of the Drawings

[0002] Figure 1 is a front perspective view of a seat assembly according to an embodiment;

[0003] Figure 2 is according to an embodiment Figure 1 partial cross-sectional view of the trim assembly of the seat assembly; and

[0004] Figure 3 is a perspective view of a trim clip of a seat assembly according to an embodiment. Detailed Description

[0006] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to those of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0007] It should be understood that the disclosed embodiments are merely exemplary, and that different and alternative forms are possible. These drawings are not necessarily to scale; some features may be exaggerated or reduced to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching one of ordinary skill in the art to implement the embodiments in accordance with the present disclosure in various ways.

[0008] "One or more" includes functions performed by one element, functions performed by more than one element (e.g., in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0009] It should also be understood that although, in some instances, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first layer may be referred to as a second layer, and similarly, a second layer may be referred to as a first layer, without departing from the scope of the various described embodiments. Both the first layer and the second layer are layers, but they are not the same layer.

[0010] The terms used in the description of the various embodiments described herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It should be further understood that when used in this specification, the terms "includes", "including", "comprises", and / or "comprising" specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0011] As used herein, the term "if" may optionally be construed to mean "when" or "upon" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the condition or event]" may optionally be construed to mean "when determining" or "in response to determining" or "when detecting [the condition or event]" or "in response to detecting [the condition or event]", depending on the context.

[0012] Figure 1 A seat assembly 200 is shown in accordance with some embodiments. The seat assembly 200 is described as a vehicle seat assembly 200. In accordance with some embodiments, the seat assembly 200 is for use in land vehicles, boats, aircraft, etc. The seat assembly 200 may be used in passenger vehicles, sit-down vehicles, etc. The seat assembly 200 may be an office chair, a comfort chair, etc.

[0013] The seat assembly 200 includes a seat bottom 210 that is sized to receive and support the pelvic region and thighs of an occupant. In some embodiments, a plurality of supports, tracks, or brackets 212 may be connected to the seat bottom 210 to support the seat bottom 210 on a supporting surface therebelow. In some vehicle embodiments, the brackets 212 are adapted to be mounted to a vehicle floor. A seat back 214 extends vertically from the seat bottom 210. The seat back 214 is sized to receive and support the pelvic, lumbar, thoracic, and shoulder regions of an occupant. A headrest 216 is also provided on the seat back 214 to receive and support the head of a seated occupant.

[0014] The seat bottom 210, the seat backrest 214, and the headrest 216 each include cushions 202a, 202b, 202c (“202”). Each of these cushions 202a, 202b, 202c can be formed separately or integrally with adjacent cushions 202a, 202b, 202c.

[0015] Figure 1 Shown is an assembly 100 as a trim cover assembly 100 according to some embodiments. The trim cover assembly 100 is sized to be mounted over the seat assembly 200 to receive and hide the underlying components, including the cushions 202a, 202b, 202c. Conventional trim cover assemblies are attached to the cushions or the frame of the seat assembly along one or more seams of the conventional trim cover assembly. The trim cover assembly 100 is attached to the cushions 202a, 202b, 202c at any location with or without seams.

[0016] In Figure 2 is shown in more detail the trim cover assembly 100. The trim cover assembly 100 can include a first layer 102. The first layer 102 can be sized to be disposed on the seat components of the seat assembly 200. The first layer 102 can be a base layer 102 that directly contacts the cushions 202. The first layer 102 can include a nonwoven material. For example, the first layer 102 can be provided with polypropylene fibers. The first layer 102 can be formed of olefin fibers. The first layer 102 can be a nonwoven fabric of, for example, man-made or natural fibers, known as which is a registered trademark of Propex Operating Company, LLC, a Delaware company incorporated in Delaware with its principal place of business at 4019 Industrial Boulevard, Chattanooga, Tennessee 37416. Alternatively, the first layer 102 can include a nonwoven material having similar physical properties to the material.

[0017] According to some embodiments, a fastener 104 is attached to the first layer 102. The fastener 104 can be connected to the first layer 102 to extend at least partially along or at least partially through the cushions 202 of the seat component 200. The fastener 104 can be provided by the same material as the first layer 102. Alternatively, the fastener 104 can be provided by a material different from the material of the first layer 102. The fastener 104 is a cord that can extend from a point or along a length. The fastener 104 can include a material having one or more of the following properties: odor resistant, antistatic, dustproof, or stain resistant.

[0018] According to some embodiments, the fastener 104 includes a retainer 106. The retainer 106 may include a material different from the material of the first layer 102. The retainer 106 may also include a material different from the material of the fastener 104. The retainer 106 may be formed separately from the fastener 104 and subsequently attached to the fastener 104. Each retainer 106 has a leading edge 112 for insertion into another retainer. Each retainer 106 has an abutting edge 114 for retaining engagement into another retainer.

[0019] The fastener 104 may be sized to hold the fastener 104 and the first layer 102 to the seat component 200. It is generally contemplated that the first layer 102 may include one or more fasteners 104, each fastener 104 having a retainer 106. The assembly 100 may further include a second layer 108 stacked on the first layer 102. The second layer 108 may be fixed to the first layer 102. The second layer 108 may include a foam material. The second layer 108 may include a polyester foam material. The second layer 108 alternatively may include a non-foamed polyester material or other non-foamed material. The second layer 108 may include a non-woven wool material.

[0020] The assembly 100 may additionally include a third layer 110 stacked on the second layer 108. The third layer 110 may be fixed to the second layer 108. The third layer 110 may include a cover. The cover may include a textile material. For example, the cover may include a warp knit, woven, double-needle bar, or double-layer textile. The cover may alternatively include a leather material.

[0021] The third layer 110 can be laminated and fixed to the second layer 108. The second layer 108 can be fixed to the first layer 102 via an adhesive-free lamination process. For example, the first layer 102 and the second layer 108 can be fixed together using thermal lamination or thermal bonding. The first layer 102 and the second layer 108 can be fixed together using, for example, hot zone bonding or hot spot bonding. By using heat to fix the first layer 102 to the second layer 108, the assembly 100 remains free of non-recyclable adhesives. The assembly 100 and the seat component 200 (on which the assembly is disposed) can be recycled more easily. In addition, using thermal lamination to fix the first layer 102 to the second layer 108 can give the trim cover 110 a smooth appearance without visible deformation on the outer surface or A-surface 204 of the trim cover 110 of the seat component 200. Similarly, the tensile load of the fastener 104 is distributed to the first layer 102 to avoid visible deformation on the outer surface 204 of the trim cover 110. The second layer 108 provides a buffer between the first layer 102 and the trim cover 110 to eliminate any tensile load resulting from the deformation of the trim cover 110. By avoiding visible deformation of the trim cover 110, the fastener 104 can be disposed anywhere along the trim cover assembly 100 and is not limited to seams. The fastener 104 can also be disposed within the concave region of the trim cover assembly 100.

[0022] The trim cover assembly 100 can also include a padding 202. One or more fasteners 104 of the first layer 102 can fix the fixed layers to the padding 202. All three fixed layers can be sized to be disposed on the seat component 200. The fixed layers can be disposed on the A-surface 226 of the padding 202, while the bottom side of the first layer 102 is in physical contact with the A-surface 226 of the padding 202, and the top side of the third layer 110 faces away from the A-surface 226 of the padding 202. The bottom side of the first layer 102 can be the side opposite to the second layer 108, and the top side of the third layer 110 can be the side opposite to the second layer 108. One or more fasteners 104 can extend from the first layer 102, partially around or through the padding 202, away from the A-surface 226 of the padding 202 and towards the B-surface 206 of the padding 202. A retainer 106 on one or more fasteners 104 can fix the fixed layers and one or more fasteners 104 below or near the hidden surface or B-surface 206 of the padding 202. The retainer 106 can fix the fixed layers 102, 108, 110 and one or more fasteners 104 to the frame 208 of the seat component 200. The fastener 104 and the retainer 106 can fix the fixed layers 102, 108, 110 to the padding 202 without visible deformation on the A-surface 204 of the trim cover assembly 100.

[0023] Any one of the first layer 102, the second layer 108, or the third layer 110 may include a material having one or more of the following properties: odor-proof, anti-static, dust-proof, or stain-proof. Any one of the first layer 102, the second layer 108, or the third layer 110 may also include recyclable materials or may include recycled materials, or both.

[0024] Figure 3 Shown is a decorative clip 300 according to an embodiment. The decorative clip 300 may function as known in the prior art and has a base 302 sized to be received within a groove in a liner 202. The base 302 holds the clip 300 against the underside of the liner 202. Optionally, the base 302 is fastened to the frame 208 of the seat assembly 200. The decorative clip 300 further includes a pair of retainers 304 extending from the base 302. The decorative clip retainers 304 receive the retainer 106 of the tie-down 104. During installation, the leading edge 112 of the tie-down retainer 106 engages the leading edge 306 of the decorative clip retainer 304. As the tie-down retainer 106 is further transferred into the decorative clip retainer 304, the decorative clip retainer 304 expands and allows the tie-down retainer 106 to be positioned between the retainers 304. Once installed, the abutting edge 114 of the tie-down retainer 106 engages the abutting edge 308 of the decorative clip 300 to secure the tie-down retainer 106 to the decorative clip 300 and thus secure the tie-down 104 and the trim cover assembly 100 to the decorative clip 300, with the liner 202 therebetween. Multiple decorative clips 300 may be employed and the multiple decorative clips 300 may be interconnected or bound together in an array or strip, referred to as a ganged clip 300. The decorative clip 300 may also be made of a similar recyclable material, polyester.

[0025] In another embodiment, the device 100 is provided with a decorative cover 110, a backing 108, and an attachment layer 102. The decorative cover 110 can be stacked on the backing 108 and fixed to the backing 108. The backing layer 108 can be stacked on the attachment layer 102 and fixed to the attachment layer 102. The backing layer 108 and the attachment layer 102 can be fixed by adhesive-free lamination. The attachment layer 102 can include at least one fastener 104 attached to the attachment layer 102. Each of the at least one fasteners 104 can include a retainer 106. The retainer 106 can fix the device 100 to the seat component 200. The seat component 200 can include a cushion 202. The device 100 can be provided on the A surface 226 of the cushion 202. The fastener 104 and the retainer 106 can partially surround or pass through the cushion 202 to fix the device 100. The retainer can fix the device below or near the B surface 206 of the cushion 202. The retainer can alternatively fix the device to the B surface 206 of the cushion 202. For example, the attachment layer 102 having the fastener 104 and the retainer 106 is fixed to the backing layer 108 by thermal lamination so that the visible deformation of the decorative cover 110 is minimized when the fastener 104 is under tension. The device 100 can also be mounted on the cushion 202 of the seat assembly 200, and the seat assembly 200 includes a frame 208, a cushion 202 supported by the frame 208, and a second retainer 300.

[0026] In other embodiments, a method for forming a three-layer decorative cover assembly 100 is provided, and the decorative cover assembly 100 has fasteners 104 and no visible deformation on the A surface 204 of the decorative cover 110. The three-layer decorative system can simulate bonded decoration without using non-recyclable adhesives. The method can include: attaching at least one fastener 104 to the first layer 102; attaching a retainer 106 to the at least one fastener 104; stacking a second layer 108 on the first layer 102; fixing the second layer 108 to the first layer 102; stacking the seat decorative cover 110 on the second layer 108; and fixing the seat decorative cover 110 to the second layer 108 to form a multi-layer decorative cover assembly 100. The method can also include fixing the second layer 108 to the first layer 102 by an adhesive-free lamination process. For example, the method can include fixing the second layer 108 to the first layer 102 by thermal lamination. Such a process can eliminate the need for an adhesive layer that may include non-recyclable materials, or eliminate the need for additional tools for connecting the layers of the decorative cover assembly. The method can also include fixing the decorative cover assembly 100 to the seat assembly 200 in a vehicle.

[0027] The first clause, which may or may not be combined with any one of the following clauses, provides a component having a first layer sized to be disposed on a seat component. A fastener is connected to the first layer to extend at least partially along or at least partially through the padding of the seat component. A retainer is connected to the fastener and sized to hold the fastener and the first layer to the seat component. A second layer is stacked on and fixed to the first layer. A third layer is stacked on and fixed to the second layer.

[0028] A second clause, which may be combined with any one of the preceding or following clauses, provides padding for the component, wherein the fastener and the retainer fix the first layer to the padding.

[0029] A third clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the first layer includes a non-woven material.

[0030] A fourth clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the first layer includes

[0031] A fifth clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the second layer includes a foam material.

[0032] A sixth clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the second layer includes a non-woven wool material.

[0033] A seventh clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the third layer includes a decorative cover.

[0034] An eighth clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the third layer includes a textile or leather material.

[0035] A ninth clause, which may be combined with any one of the preceding or following clauses, provides the component, wherein the second layer is laminated to the first layer.

[0036] A tenth clause, which may be combined with any one of the preceding or following clauses, provides a device having a decorative cover, a backing stacked on and fixed to the decorative cover, an attachment layer stacked on and fixed to the backing, at least one fastener attached to the attachment layer, and a retainer connected to the at least one fastener. When the at least one fastener is under tension, the backing minimizes visible distortion of the decorative cover.

[0037] Article 11, which can be combined with any one of the preceding or succeeding clauses, provides the described device, wherein the backing includes a material different from that of the decorative cover.

[0038] Article 12, which can be combined with any one of the preceding or succeeding clauses, provides the described device, wherein the decorative cover includes a material different from that of the attachment layer.

[0039] Article 13, which can be combined with any one of the preceding or succeeding clauses, provides the described device, wherein the backing is fixed to the attachment layer using heat.

[0040] Article 14 provides a seat assembly having a frame, a cushion supported by the frame, a second retainer, and the device described in any one of the preceding or succeeding clauses. The device is mounted above the cushion.

[0041] Article 15, which can be combined with any one of the preceding or succeeding clauses, provides the described device, wherein the retainer includes a material different from that of the attachment layer.

[0042] Article 16, which can be combined with any one of the preceding or succeeding clauses, provides a method: attaching at least one fastening member to a first layer; attaching a retainer to the at least one fastening member; stacking a second layer on top of the first layer; fixing the second layer to the first layer; stacking a seat decorative cover on top of the second layer; and fixing the seat decorative cover to the second layer to form a multi-layer decorative cover assembly.

[0043] Article 17, which can be combined with any one of the preceding or succeeding clauses, provides the described method, wherein the first layer includes a non-woven material.

[0044] Article 18, which can be combined with any one of the preceding or succeeding clauses, provides the described method, wherein the second layer includes a foam material.

[0045] Article 19, which can be combined with any one of the preceding or succeeding clauses, provides the described method, wherein the second layer includes a non-woven wool material.

[0046] Article 20, which can be combined with any one of the preceding or succeeding clauses, provides the described method, wherein the seat decorative cover includes a material different from that of the first layer.

[0047] Article 21, which can be combined with any one of the preceding or succeeding clauses, provides the described method, having the following steps: laminating the second layer to the first layer.

[0048] Article 22, which can be combined with any one of the preceding or succeeding clauses, provides the described method, having the following steps: fixing the decorative cover assembly to a seat cushion assembly in a vehicle.

[0049] While the various embodiments are described above, this does not mean that these embodiments describe all possible forms in accordance with the present disclosure. In this regard, the words used in this specification are descriptive rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. In addition, features of multiple embodiments implementing the embodiments can be combined to form additional embodiments in accordance with the present disclosure.

Claims

1. A component comprising: a first layer sized to be disposed on a seat component; a tie member connected to the first layer to extend at least partially along or at least partially through a pad of the seat component; a retainer connected to the tie down, the retainer being sized to retain the tie down and the first layer to the seat component; a second layer stacked on and secured to the first layer; and A third layer is stacked on the second layer and fixed to the second layer.

2. The assembly of claim 1, further comprising a gasket, wherein: The tie and the retainer secure the first layer to the liner.

3. The assembly according to claim 1, wherein: The first layer comprises a nonwoven material.

4. The assembly according to claim 3, wherein: The first layer includes 5. The assembly according to claim 1, wherein: The second layer includes a foam material.

6. The assembly according to claim 1, wherein: The second layer comprises a nonwoven fleece material.

7. The assembly according to claim 1, wherein: The third layer includes a decorative cover.

8. The assembly according to claim 6, wherein: The third layer comprises a textile or leather material.

9. The assembly of claim 1, wherein: The second layer is laminated to the first layer.

10. An apparatus comprising: Decorative hood; a backing stacked on and secured to the trim cover; an attachment layer stacked on and secured to the backing; at least one tie member attached to the attachment layer; and A retainer is connected to the at least one tie member, wherein the backing minimizes visible deformation of the trim cover when the at least one tie member is under tension.

11. The device according to claim 10, wherein: The backing includes a material different from that of the trim cover.

12. The device according to claim 10, wherein: The trim cover includes a different material than the attachment layer.

13. The device according to claim 10, wherein: The backing is secured to the attachment layer using heat.

14. The device according to claim 10, wherein: The retainer comprises a material different from a material of the attachment layer.

15. A seat assembly comprising: frame; a cushion supported by the frame; a second retainer; and The device of claim 10, wherein the device is mounted above the pad.

16. A method comprising: attaching at least one tie member to the first layer; attaching a retainer to the at least one tie member; stacking a second layer onto the first layer; securing the second layer to the first layer; stacking a seat trim cover onto the second layer; as well as The seat trim cover is secured to the second layer to form a multi-layer trim cover assembly.

17. The method according to claim 16, wherein: The first layer comprises a nonwoven material.

18. The method according to claim 16, wherein: The second layer includes a foam material.

19. The method according to claim 16, wherein: The second layer comprises a nonwoven fleece material.

20. The method according to claim 16, wherein: The seat trim cover includes a material that is different from a material of the first layer.

21. The method of claim 16, further comprising laminating the second layer to the first layer.

22. The method of claim 16, further comprising securing the trim cover assembly to a seat pad assembly in a vehicle.

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