Trim with three-dimensional protruding pad

Abstract

The invention relates to a trim with a three-dimensional protruding pad. Decorative assemblies and methods of making decorative assemblies with raised protruding shapes are provided. A protruding shape of the protrusion is defined between the first decorative sheet and the second decorative sheet. The protruding shape of the protrusion is formed by a protruding decorative sheet forming an appearance surface. The protruding trim sheet is joined to the first trim sheet at a first edge and to the second trim sheet at a second edge. The back panel is joined to the protruding trim panel to form a pocket. A protruding pillow is disposed in the pocket. The pillow has a plurality of cushioning materials that define a raised three-dimensional portion that includes a surface comfort.

Description

Technical Field

[0001] The present disclosure relates to an upholstery for a seat. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Figure 1 A seat having an upholstery with three-dimensional accent portions is shown in accordance with one embodiment.

[0003] Figure 2A Shown in more detail is Figure 1 a portion of the seat and upholstery in

[0004] Figure 2B A portion of a seat and upholstery is shown in accordance with another embodiment.

[0005] Figure 3 Shown is Figure 2A a cross-sectional view of the seat and upholstery in

[0006] Figure 4 A pillow insert is shown in accordance with one embodiment.

[0007] Figure 5 is a flow chart showing a method of forming a decorative assembly in accordance with one embodiment.

[0008] DETAILED DESCRIPTION

[0009] 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 one 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.

[0010] It should be understood that the disclosed embodiments are merely exemplary and that various and alternative forms are possible. The drawings are not necessarily to scale; some features may be enlarged or minimized 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 skilled in the art to variously practice the embodiments in accordance with the present disclosure.

[0011] "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 foregoing.

[0012] It should also be understood that although in some cases 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 contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0013] The terms used in the description of the various embodiments 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 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.

[0014] As used herein, the term "if" is optionally construed to mean "when", "upon", "in response to determining", or "in response to detecting", depending on the context. Similarly, the phrase "if determined" or "if detected [the stated condition or event]" is optionally construed to mean "when determined", "in response to determining", "when detected [the stated condition or event]", or "in response to detecting [the stated condition or event]", depending on the context.

[0015] Transportation seat styling trends require seat trim having a three-dimensional (3D) shape, such as a protruding portion with a raised shape. However, the challenge is to have a 3D protruding shape that is soft, can maintain its shape during durability cycles, and does not lose its shape during use.

[0016] The seat trim of the present application uses a pillow-like structure with a variety of hardness / stiffness cushioning materials that can provide a unique and resilient shape along the edges while allowing for a comfortable surface softness.

[0017] Figure 1Shows a seat 10 having an upholstery assembly 12 with three-dimensional protrusions 14. The seat 10 has a seat back 16, a seat bottom 18, and a headrest 20. The seat 10 may also have side bolsters 22, a shoulder area 24, or other seat support surfaces. The upholstery assembly 12 is disposed on a seat cushion to define a seat surface. The seat cushion 80( Figure 3 ) may be formed of cushioning material, such as foam, non-foam, padding, or other supportive seat cushion disposed on a seat frame. The upholstery assembly 12 covers the seat cushion.

[0018] Figure 2A A portion of the seat 10 and the upholstery assembly 12 is shown in more detail, showing the protrusion 14. The upholstery assembly 12 has an upholstery cover 28 formed by a first trim panel 30 and a second trim panel 32. The defined raised protrusion shape 14 is located between the first trim panel 30 and the second trim panel 32 and provides a styling element embedded in the upholstery cover having a raised shape / 3D shape. The raised accent panel 14 may be formed anywhere along the seat 10 (including the seat back 16, the seat bottom 18, the headrest 20, the side bolsters 22, the shoulder area 24, or other seat surfaces).

[0019] The raised protrusion 14 has a raised accent panel 34 that forms an exterior surface. As shown in more detail in the cross-sectional view of Figure 3 , the raised accent panel 34 is joined to the first trim panel 30 at a first edge 36 and to the second trim panel 32 at a second edge 38. The first trim panel 30, the second trim panel 32, and the raised accent panel 34 may be formed of leather, PVC, PU, textile material, suede, or any suitable upholstery material.

[0020] The raised protrusion 14 has a back panel 40 joined to the raised accent panel 34 to form a pocket 42. The back panel 40 includes a first back panel 46 and a second back panel 48. The stretchability of the first back panel 46 is greater than that of the second back panel 48. The second back panel 48 is formed of a less stretchable fabric to help urge the raised accent panel 34 to expand forward / upward, thereby providing a greater 3D effect and a higher raised height even when using a softer cushioning material.

[0021] A protruding pillow 44 is disposed in the pocket 42. The pillow 44 has a variety of cushioning materials to define the raised three-dimensional portion 14 while still providing a soft and comfortable surface feel along the three-dimensional portion.

[0022] As Figure 3As shown, the protruding pillow-like object 44 has two layers of cushioning materials, namely, a first layer 50 and a second layer 52. The first cushioning material 54 in the first layer 50 is more forward and closer to the appearance surface and adjacent to the protruding decorative piece 34. The outer cushioning material 54 is a softer material and provides a soft feeling for the seated user. The outer cushioning material 54 can be PES, cotton balls, or other softer fillers.

[0023] The second layer 52 has a second cushioning material 56 that is more inward and adjacent to the rear piece 40. The inner cushioning material 56 is a harder material than the outer cushioning material 54 to provide stability. The inner cushioning material 56 can be PET, silicon, or other more supportive cushioning fillers adjacent to the rear piece 40. The outer cushioning material 54 and the inner cushioning material 56 have different hardnesses. For example, the hardness of the outer cushioning material 54 can be less than the hardness of the inner cushioning material 56. The hardness of the cushioning material 56 can be based on the material properties of different hardnesses (e.g., stiffness, density, or concentration). For example, the first cushioning material 54 forming the outer layer 50 has a smaller filling density, while the second cushioning material 56 forming the inner cushioning layer 52 has a larger filling density.

[0024] The cushioning material of the protruding pillow-like object 44 further includes a foam strip 60. The foam strip 60 is positioned adjacent to the protruding decorative piece 34 along at least one of the first edge 36 or the second edge 38 or both edges 36, 38. The foam strip 60 has a greater stiffness and more compression resistance than the outer cushioning material 54 and the inner cushioning material 56, and helps to maintain the convex shape of the protruding pillow-like object even when covered with decorative materials and during repeated compression use in the seat. The density of the foam strip 60 is greater than the density of the first cushioning material 54 and the second cushioning material 56. The foam strip 60 can be a harder foam (e.g., EVA foam). The foam strip 60 formed of EVA maintains its flexibility and elasticity and quickly recovers from compression. The stiffness can vary based on the size and other characteristics of the foam strip 60. For example, the EVA foam strip can have a thickness of 3 - 40 mm and can have a density of 28 - 97 kg / m 3 and a density of. The EVA foam strip can have a hardness of 15 - 40 and a compressive strength of 25 - 70 kPa.

[0025] Figure 2B An alternative embodiment of the portion 14 with multiple protrusions is shown, where the multiple protrusions 14 are positioned adjacent to each other to form a seat surface with a quilted appearance. Each of the adjacent protrusions 14 includes a protruding decorative piece 34 and a rear piece 40 to form a pocket 42. As described above, the protruding pillow-like object 44 with multiple cushioning materials is inserted into the pocket 42.

[0026] Figure 4Shows the protruding pillow 44 removed from the decorative bag. As Figure 4 shown, the foam strip 60 has a width W to help define the height H of the raised protruding shape 14. The width of the foam strip ranges from 5 millimeters to 25 millimeters. However, the width W of the strip 60 can be any suitable size depending on the size, shape, or location of the protruding portion 14.

[0027] As Figure 5 shown in the steps of method 100 in, the pillow 44 can be formed separately from the decorative cover 28 and then subsequently inserted into the bag 42 formed in the decorative cover.

[0028] As Figure 5 shown, in step 110, the protruding pillow 44 is formed from a variety of cushioning materials. The pillow 44 is preformed with an outer fabric cover 70. The fabric cover 70 can be a non-woven fabric (e.g. ). However, the cover can be any suitable fabric, such as an inexpensive non-woven fabric. The pillow 44 also has an intermediate fabric layer separating the first cushioning layer 50 and the second cushioning layer 52. The intermediate fabric layer can also be a non-woven fabric to separate the outer cushioning layer 50 and the inner cushioning layer 52. The foam strip 60 is also joined to the fabric cover 70 along at least one edge seam 62.

[0029] After the outer fabric cover 70 and the intermediate layer 72 are joined together, the first cushioning material 54 is inserted into the cavity on one side of the intermediate layer 72. The second cushioning material 56 is inserted into the cavity on the other side of the intermediate layer 72. The first cushioning material 54 is inserted on the same side of the intermediate layer 72 as the foam strip 60.

[0030] In step 112, the decorative cover 28 with the protruding bag 42 is formed by joining at the edges 36, 38 using the protruding tabs 34 and the rear piece 40.

[0031] In step 114, the protruding bag 42 is joined to the adjacent decorative pieces 30, 32 to form the decorative cover 28. The bag 42 with the protruding decorative tabs 34 and the rear piece 40 is joined to the first decorative piece 30 along the first edge 36 at the first seam 76. The bag 42 is joined to the second decorative piece 32 along the second edge 38 at the second seam 78. The bag 42 can be joined to the first decorative piece 30 and the second decorative piece 32 by stitching, bonding, welding, or other suitable methods.

[0032] In step 116, the protruding pillow 44 is inserted into the protruding bag 42 to form the decorative assembly 12.

[0033] The trim piece assembly 12 can be fixed to the seat cushion 80 with tie downs 82. One tie down 82 can be located along a seam adjacent to the second edge 38 of the foam strip 60. Another tie down 82 can be located along a seam of the back piece 40 between the first back piece 46 and the second back piece 48.

[0034] In one embodiment, the trim assembly is provided with a first trim piece and a second trim piece. A raised protruding shape is defined between the first trim piece and the second trim piece. The raised protruding shape is formed by a protruding trim piece forming an exterior surface. The protruding trim piece is connected to the first trim piece at a first edge and to the second trim piece at a second edge. The back piece is connected to the protruding trim piece to form a pocket. A protruding pillow is disposed in the pocket. The pillow has a plurality of cushioning materials that define a raised three-dimensional portion including a surface comfort portion.

[0035] In another embodiment, the plurality of cushioning materials has a foam strip positioned along at least one of the first edge or the second edge. In another embodiment, the foam strip is positioned adjacent to the protruding trim piece along at least one of the first edge or the second edge. In another embodiment, the foam strip has a width that defines the height of the raised protruding shape. In another embodiment, the width of the foam strip is in the range of 5 millimeters to 25 millimeters. In another embodiment, the back piece includes a first back piece and a second back piece, wherein the stretchability of the first back piece is greater than that of the second back piece. In another embodiment, the first back piece is adjacent to the first edge and the foam strip.

[0036] In another embodiment, the plurality of cushioning materials includes an outer cushioning material adjacent to the protruding trim piece and an inner cushioning material adjacent to the back piece, wherein the outer cushioning material and the inner cushioning material have different hardnesses. In another embodiment, the hardness of the outer cushioning material is less than that of the inner cushioning material. In another embodiment, the stiffness of the foam strip is greater than the stiffness of the first cushioning material and the second cushioning material. In another embodiment, the density of the foam strip is greater than the density of the first cushioning material and the second cushioning material. In another embodiment, the outer cushioning material forms an outer layer including a smaller filling density, and the inner cushioning material forms an inner cushioning layer including a larger filling density. In another embodiment, the outer layer and the inner layer are separated by a fabric layer.

[0037] In at least one embodiment, the trim cover covers the seat cushion to define a seat surface.

[0038] In one embodiment, a method of forming a trim cover is provided. A protruding pocket including an exterior protruding piece and a back piece is connected to a first trim piece at a first seam. The protruding piece is connected to a second trim piece at a second seam. A protruding pillow is inserted into the protruding pocket to form a trim piece assembly. The protruding pillow has a plurality of cushioning materials.

[0039] In another embodiment, the method includes preforming a protruding pillow-like structure having an outer fabric covering. A foam strip is attached to the fabric covering. The protruding pillow-like structure is filled with cushioning material adjacent to the foam strip.

[0040] In another embodiment, the method includes a protruding pillow-like structure that further includes an intermediate fabric layer to define an outer pillow-like bag and an inner pillow-like bag. In another embodiment, the method includes filling the protruding pillow-like structure with a first cushioning material in the outer pillow-like bag and a second cushioning material in the inner pillow-like bag. In another embodiment, the method includes attaching a protruding tab, the attaching of the protruding tab including stitching the protruding bag to a first decorative piece and a second decorative piece. In another embodiment, the method includes securing the decorative piece assembly to the seat cushion with a fastening device at a seam adjacent to the foam strip.

[0041] Although the exemplary embodiments have been described above, this does not mean that these embodiments describe all possible forms of the invention. Rather, 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 invention. In addition, the features of multiple implemented embodiments can be combined to form additional embodiments of the invention.

Claims

1. A component, comprising: A first decorative piece; A second decorative piece; A raised protruding shape defined between the first decorative piece and the second decorative piece, the raised protrusion comprising: A protruding decorative piece forming an exterior surface, the protruding decorative piece being connected to the first decorative piece at a first edge and to the second decorative piece at a second edge; A back piece connected to the protruding decorative piece to form a pouch; and A protruding pillow disposed within the pouch, the pillow comprising a plurality of cushioning materials defining a raised three-dimensional portion including a surface comfort portion.

2. The component according to claim 1, wherein, The plurality of cushioning materials includes a foam strip positioned along at least one of the first edge or the second edge.

3. The component according to claim 2, wherein, The foam strip is positioned adjacent the protruding decorative piece along at least one of the first edge or the second edge.

4. The component according to claim 2, wherein, The foam strip includes a width defining the height of the raised protruding shape.

5. The component according to claim 4, wherein The width of the foam strip is in the range of 5 millimeters to 25 millimeters.

6. The component according to claim 2, wherein, The plurality of cushioning materials further includes an outer cushioning material adjacent the protruding decorative piece and an inner cushioning material adjacent the back piece, wherein the outer cushioning material and the inner cushioning material have different hardnesses.

7. The component according to claim 6, wherein, The hardness of the outer cushioning material is less than the hardness of the inner cushioning material.

8. The component according to claim 6, wherein The stiffness of the foam strip is greater than the stiffness of the outer cushioning material and the inner cushioning material.

9. The component according to claim 6, wherein, The density of the foam strip is greater than the density of the outer cushioning material and the inner cushioning material.

10. The component according to claim 6, wherein The outer cushioning material forms an outer layer with a smaller filling density, and the inner cushioning material forms an inner cushioning layer with a larger filling density.

11. The component according to claim 6, wherein, The outer layer and the inner layer are separated by a fabric layer.

12. The component according to claim 2, wherein The back piece includes a first back piece and a second back piece, wherein the stretchability of the first back piece is greater than the stretchability of the second back piece.

13. The component according to claim 12, wherein, The first back piece is adjacent the first edge and the foam strip.

14. A seat, comprising: The decorative cover according to claim 1; And A seat cushion, wherein the decorative cover covers the seat cushion to define the seat surface.

15. A method, comprising: Connecting a protruding pouch including an exterior protruding piece and a back piece to a first decorative piece at a first seam; Connecting the protruding piece to a second decorative piece at a second seam; And Inserting a protruding pillow including a plurality of cushioning materials into the protruding pouch to form a decorative piece assembly.

16. The method according to claim 15, further comprising: Pre-forming a protruding pillow structure including an outer fabric cover; Attaching a foam strip to the fabric cover; And Filling the protruding pillow structure with cushioning materials adjacent the foam strip.

17. The method according to claim 16, wherein, The protruding pillow structure further includes an intermediate fabric layer to define an outer pillow pouch and an inner pillow pouch.

18. The method according to claim 17 further comprises filling the protruding pillow structure with a first cushioning material in the outer pillow bag and a second cushioning material in the inner pillow bag.

19. The method according to claim 15, wherein, Connecting the protruding pieces includes sewing the protruding bag to the first decorative piece and the second decorative piece.

20. The method according to claim 16 further comprises fixing the decorative piece assembly to the seat cushion with a fastening device at a seam adjacent to the foam strip.

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