A component for a vehicle interior and a method of forming the component

Abstract

A component for a vehicle seat can have a trim cover and a storage bin coupled to the trim cover. The storage bin can have a flange, and the flange can be secured to the trim cover by a stitch line that extends at least partially through the flange and the trim cover.

Description

Technical Field

[0001] A component for vehicle interior trim and a method for forming the component are described and illustrated. Background Technology

[0002] Figure 1-2 An embodiment of a prior art vehicle seat 15 and an armrest 35 associated with the seat 15 is shown. A significant drawback is that the armrest 35 lacks the ability to store or securely hold items within or on it. Summary of the Invention

[0003] A component for a vehicle seat may have a trim cover and a storage compartment coupled to the trim cover. The storage compartment may have a flange, and the flange may be secured to the trim cover by a seam extending at least partially through the flange and the trim cover. The flange may have a recess that receives at least a portion of the seam, and the recess may have a groove deep enough to place the seam below the upper surface of the flange.

[0004] The stitching may have one or more rows of threads, which may form a continuous or discontinuous stitch pattern along at least a portion of the flange.

[0005] The stitching may have a top thread and a bottom thread, which are connected to each other at one or more bends.

[0006] The face line may extend from the upper surface of the flange through the thickness of the flange into the decorative cover and reverse at the one or more bends, and the bottom line may extend from the lower surface of the decorative cover into the thickness of the decorative cover and reverse at the one or more bends, wherein the face line and the bottom line overlap at the reversal of the face line and the bottom line.

[0007] The flange can extend continuously around the perimeter of the storage box and can have a width between approximately 5 mm and approximately 10 mm.

[0008] The flange can be flexible and elastic, and is configured to be selectively bent during coupling of the storage box to the decorative cover.

[0009] The storage box may have a generally vertical surface that extends from the inner edge of the flange and defines at least a portion of the chamber.

[0010] The storage box may have a core layer comprising a nonwoven fabric and a cover layer comprising a resin material, and the stitching may extend through the core layer and the cover layer.

[0011] The cover layer may be located at least partially on the core layer.

[0012] The storage box may have a base layer, and the base layer may contain resin.

[0013] The nonwoven fabric can be permeated with the resin of the base layer.

[0014] The component may have a pad coupled to at least one of the storage box and the decorative cover, and the storage box may be located between the decorative cover and the pad.

[0015] The liner may be made of foam material, which can be bonded to at least one of the storage box and the decorative cover.

[0016] The component may have an air gap between the storage box and the liner.

[0017] The flange can be offset vertically relative to the upper surface of the storage box. Attached Figure Description

[0018] Figure 1 It is a schematic perspective view of a vehicle seat with armrests in a stowed position, as known in the prior art; Figure 2 It is a schematic perspective view of a vehicle seat with armrests in the use position, as known in the prior art; Figure 3 It is a schematic perspective view of a vehicle seat with seat components in a stowed position; Figure 4 It is a schematic perspective view of a vehicle seat with seat components in the use position; Figure 5 This is a schematic perspective view of the seat component; Figure 6 This is a schematic perspective view of the seat component; Figure 6A This is a schematic perspective view of the seat component; Figure 7 This is an exploded schematic perspective view of the seat component; Figure 8 This is a schematic perspective view of the storage box; Figure 9A yes Figure 8 A schematic perspective view of the cross-section of the storage box; Figure 9B yes Figure 8 A schematic perspective view of the cross-section of the storage box; Figure 10 yes Figure 6 A schematic perspective view of the cross-section of a vehicle seat component; Figure 11 This is a schematic perspective view of a storage box being attached to a decorative cover; Figure 12 This is a schematic perspective view of a storage box being attached to a decorative cover; Figure 13 This is a schematic perspective view of a storage box being attached to a decorative cover; Figure 14 This is a schematic perspective view of a storage box being attached to a decorative cover; Figure 15 This is a schematic perspective view of the storage box and its flange; Figure 16 This is a schematic perspective view of a storage box being attached to a decorative cover; Figure 17 This is a schematic perspective view of the storage compartment being inserted into the seat components; Figure 18 This is a schematic perspective view of the seat component; Figure 19 This is a schematic perspective view of the seat component coupled to the vehicle seat; Figure 20 This is a schematic perspective view of the first step in the process of forming the storage box; Figure 21 This is a schematic perspective view of the second step in the process of forming the storage box; Figure 22 This is a schematic perspective view of the storage box; Figure 23 This is a schematic perspective view showing the steps of placing the storage box into the seat component; Figure 24 This is a schematic perspective view showing the steps of sewing the storage box into the seat component; Figure 25 This is a flowchart showing the steps involved in forming the seat components; Figure 26 This is a flowchart showing the steps involved in forming the seat components; Figure 27 This is a flowchart showing the steps involved in forming the seat components. Detailed Implementation

[0019] In order to overcome the shortcomings of existing technology designs, based on, as follows Figure 3-5 In an exemplary embodiment shown schematically, a component 20 for a vehicle interior (e.g., vehicle seat 10) may include an armrest 30 connected to a storage compartment 40.

[0020] While armrest 30 is mentioned, component 20 can also be used in other vehicle interior components. According to an exemplary embodiment not depicted, component 20 may include a headrest, or it may include a lid for a storage compartment. The headrest and lid are merely exemplary. It should be understood that the component can be used anywhere that is decorated. The component can be configured for: (a) a use position 50, where storage compartment 40 is available; and (b) a storage position 60.

[0021] According to at least Figure 6In an exemplary embodiment, the storage compartment 40 can be coupled to a trim cover 70 for vehicle interior (e.g., armrest 30) via stitch 80. The stitch 80 may comprise one or more rows of stitches 90 produced by a needle with thread 100 in one or more machines and / or by hand. The thread 100 may be cotton, nylon, or other fibers used for sewing.

[0022] According to one exemplary embodiment, the stitch pattern may be such as T90 / T90 or T135-T150 / T90, with a stitch pitch of 5 mm. The needle size may be such as #19 to #23, wherein the needle tip may be a diamond tip. The needle and stitch pattern may be designed to reduce / eliminate the risk of tearing or separation of the storage box and cover. While specific decorative patterns and needle sizes are mentioned, any pattern or needle size capable of preventing tearing or separation of the storage box and cover may be used.

[0023] The thread 100 may extend at least partially between the storage box 40 and the decorative cover 70. In some embodiments, the thread 100 may extend at least partially through the storage box 40 and the decorative cover 70 to connect the storage box and the decorative cover together. The stitch 80 may be continuous or discontinuous. For example, the stitch 80 may be as follows: Figure 6 As shown, it extends continuously around the storage box 40, or may exist within the length of the seam 80, such as Figure 6A The unstitched gap 110 is shown. In some embodiments, the suture 80 may be visible, invisible, or partially visible.

[0024] Storage box 40 may include at least Figure 7-8 The flange 120 is shown. The flange 120 may extend around the storage compartment 40 in a generally planar manner. As can be seen in the figure, this extension may be continuous, but in other cases, it may be discontinuous. According to an exemplary embodiment, the flange 120 may include a width of about 5-10 mm. A preferred width may be 8 mm.

[0025] like Figure 8 As shown, flange 120 may have an upper surface 130 and a lower surface 140, between which a substantially constant thickness is defined. In other cases, the thickness of flange 120 may vary around storage compartment 40.

[0026] Flange 120 may extend outward from storage compartment 40 and into the interior of the vehicle. In some cases, flange 120 may extend cantilevered from storage compartment 40.

[0027] According to at least Figure 6 In the exemplary embodiment shown, the flange 120 can be coupled to the decorative cover 70 via a seam 80. The seam 80 may include, for example... Figure 10The front trim 150 and / or back trim 160 are schematically shown. The front trim and back trim 150, 160 may be wholly or partially connected together. This connection may be between the decorative cover 70 and the storage compartment 40 (including the flange 120). Thus, the front trim 150 may have at least a first portion 170 that initially extends from the upper surface 130 of the flange 120 into the thickness of the flange 120 and toward the decorative cover 70. The front trim 150 may extend through the thickness of the flange 120 into the decorative cover 70.

[0028] The top line 150 may be reversed at a bend 180, and the second portion 190 may extend upward from the body 200 of the flange 120 toward the upper surface 130 of the flange 120. The top line 150 may be reversed within the decorative cover 70. The first portion 170 and the second portion 190 may be at least partially parallel to each other. The bottom line 160 may have at least a first portion 210 that initially extends from the bottom surface 220 of the decorative cover 70 into the thickness of the decorative cover 70. The bottom line 160 may be reversed at a bend 180, and the second portion 230 may extend downward from the body 240 of the decorative cover 70 toward the bottom surface 220. The top line 150 and the bottom line 160 may connect to each other at a bend 180, since the bend 180 may overlap each other.

[0029] According to at least Figure 11 and 12 In the exemplary embodiment shown, flange 120 may include a recess 250. Recess 250 may be formed in flange 120.

[0030] The suture 80 can be located in the depression 250, such as Figure 11 The recess 250 may include a continuous or discontinuous groove 260 in the flange 120. The recess 250 may have a depth of approximately the diameter of the line 100 plus 1 mm, such that at least the face line 150 may be located below the planar upper surface 130 of the flange 120. Placing the face line 150 below the planar upper surface 130 reduces the interaction of the face line 150 with abrasive conditions such as human contact, thereby increasing durability and providing an aesthetically pleasing appearance.

[0031] exist Figure 11-16 In an exemplary embodiment, flange 120 may be flexible and resilient, allowing it to be selectively bent or flattened so that decorative cover 70 can be attached by sewing. Resilience can be understood as the ability of flange 120 to return to its original shape after being bent. In other words, the shape of flange 120 may not be permanently changed by bending of flange 120. Furthermore, in some exemplary embodiments, flange 120 may be offset 270 relative to the top surface 280 of storage box 40, wherein offset 270 is designed to accommodate seam allowance.

[0032] According to at least Figure 17In the exemplary embodiment shown, the storage compartment 40 may include a generally vertical surface 290 that extends downward, wholly or partially, from the inner edge portion 300 of the flange 120. The vertical surface 290 may be generally transverse to the direction of the flange 120. In some cases, the vertical surface 290 may extend continuously around the storage compartment 40 and form its perimeter. For example, at least... Figure 8 As shown, the vertical surface 290 may be generally rectangular or elliptical, except for the notch 310 in some embodiments.

[0033] Component 20 may also include, for example, at least Figure 7 The padding 320 is schematically shown. The padding 320 may be wholly or partially attached (e.g., bonded) to the storage compartment 40 and / or the decorative cover 70. The padding 320 may be molded into the storage compartment 40 and thus have a shape at least partially complementary to the storage compartment 40. The padding 320 may comprise wholly or partially foam material and may be wholly or partially composed of polyurethane. While foam and polyurethane are mentioned, any material capable of coupling to the storage compartment 40 while maintaining the aesthetic and functional characteristics of the padding 320 may be used.

[0034] The storage box 40 can be coupled between the decorative cover 70 and the gasket 320. "Between" can be understood as meaning that the upper surface 130 of the flange 120 can directly contact the bottom surface 220 of the decorative cover 70, and the lower surface 140 of the flange 120 can directly contact the gasket 320.

[0035] The component may also include, for example: Figure 18 The frame 330 is schematically shown. The frame 330 may be located in the padding 320 or elsewhere on the component 20. The frame 330 may be made of a rigid material that extends at least partially around the component 20, for example, in the inner portion 340 of the component 20. The frame 330 may act as the skeleton of the component 20, to which other various parts of the component discussed herein may be attached or supported. In the case of the component being a handrail 30, the frame 330 may be connected to one or more joints 350 to allow the handrail 30 to rotate selectively upward or downward, which may be determined according to... Figure 19 Exemplary embodiments are shown below.

[0036] Such as at least Figure 17 As shown, the storage compartment 40 may include a chamber 360. The chamber 360 may be wholly or partially defined by a vertical surface 290 and / or a flange 120. As described above, and as at least... Figure 8 As shown, a notch 310 may be present in at least the vertical surface 290. The notch 310 can be used to form a structure in the storage compartment 40. In one embodiment, one or more notches 310 may divide a chamber 360 to form one or more areas. In some cases, these areas may be adapted as cup holders 370.

[0037] The notch 310 may extend radially inward from the vertical surface 290 of the chamber 360. Although Figure 8 Two notches 310 are shown, but any number of notches 310 can be used. For example, all notches 310 may extend radially inward to the same extent from the vertical surface 290 of the chamber 360. In other words, all notches 310 may extend radially inward by the same distance measured from the vertical surface 290. Although notches 310 extending radially inward by the same distance are mentioned, notches 310 may extend radially inward by different distances.

[0038] The chamber 360 may be one-piece, single, and integrally molded, or the chamber 360 may comprise multiple different parts. The chamber 360 may be watertight and may include tubular or cylindrical shapes. Although tubular or cylindrical shapes are mentioned, the chamber 360 may include any shape required to meet application needs.

[0039] Although the term cup holder is mentioned, it is understood that these areas are not limited to cup holder 370. Rather, these areas may include storage areas 380 for various liquid holding devices, or simply general-purpose storage areas 380.

[0040] The notch 310 and / or other structures associated with the storage compartment 40 may be configured to grip an object. According to one exemplary embodiment, the notch 310 may extend inwardly into the chamber 360. The notch 310 may form at least partially complementary surfaces 390 or contact points 390 for objects to be located within the storage area 380, such as at least... Figure 8 The notches 310 are schematically shown in the diagram. The size and shape of the notches 310 may be approximately equal to each other, or they may be of different sizes and shapes. Furthermore, the notches 310 may be distributed at equal or unequal intervals around the chamber 360.

[0041] In one exemplary embodiment, the storage box 40 may have one or more pads 320. For example... Figure 17 As shown, one or more air gaps 400 may be at least partially located between the liner 320 and the storage compartment 40. The presence of air gaps may be to allow slight expansion of the storage compartment, or the air gaps may be a product of tolerances. In other words, the storage compartment may not fit tightly against the liner.

[0042] In one exemplary embodiment, the pad 320 may be located at least partially around the vertical surface 290. The pad 320 may also be located near the base 420 of the storage compartment 40. The pad 320 may serve to absorb or deflect liquids, such as condensation from a liquid container. The pad 320 may also assist in gripping or securing any object or container located within the storage compartment 40.

[0043] In one exemplary embodiment, such as Figure 17As shown, wall 290 may include textured wall 410. The base 420 of storage compartment 40 may have the same or different texture as wall 290. For example, textured wall 410 may include textures such as raised protrusions (e.g., bumps, corrugations, grooves, and / or linear protrusions). While bumps, corrugations, grooves, and / or linear protrusions are mentioned, textured wall 410 may include any texture required to meet application needs.

[0044] The flange 120 of the storage box 40 may include width and thickness; the recess 310 of the storage box 40 may include a width and / or thickness greater than the width and / or thickness of the flange 120 of the storage box 40, such as... Figure 8 The diagram is shown in the middle.

[0045] Storage box 40 may comprise a single layer of flexible or non-flexible material. In one embodiment, storage box 40 may be constructed wholly or partially of a resin material. Storage box 40 may be an integral, monolithic, single, continuous, or molded storage box 40. In one case, storage box 40 may comprise molding resin.

[0046] exist Figure 9A and 9B In the depicted exemplary embodiment, the storage compartment 40 may include a core layer 430 and a covering layer 440 that may be at least partially located on the core layer 430. A stitch 80 may extend through the covering layer 440 and the core layer 430. In some cases, according to... Figure 9B In an exemplary embodiment, the storage box 40 may further include a base layer 450 beneath the core layer 430.

[0047] The core layer 430 may include a base fabric 460. The base fabric 460 may include a continuous or non-continuous nonwoven fabric, such as felt and / or mesh. The base fabric 460 may be configured to resist or prevent tearing of the storage compartment 40, the decorative cover 70, and / or the padding 320. According to an exemplary embodiment, the nonwoven nature of the base fabric 460 may provide tear resistance for one or all of the above features.

[0048] The cover layer 440 may include a skin 440. The skin 440 may be formed by spraying material, wholly or partially, onto the core layer 430. For example, a base fabric 460 may be at least partially encapsulated within the skin 440. The skin 440 may include a resin, such as a polyurethane material, which may form the skin 440. While polyurethane materials are mentioned, any resin required to meet the application requirements may be used.

[0049] Overlay 440 may include a texture. The texture of overlay 440 may be formed wholly or partially in overlay 440. The texture of overlay 440 may be any texture required to meet application needs, but as an example, the texture may be raised protrusions such as bumps, ripples, grooves and / or line protrusions.

[0050] In one exemplary embodiment, the base layer 450 may be composed of resin. For example, the base layer 450 may be composed of the same resin material as the cover layer 440, such as polyurethane. Although it is mentioned that the resin of the base layer 450 is composed of the same material as the resin of the cover layer 440, the resin of the base layer 450 may be composed of a different material than the resin of the cover layer 440.

[0051] A base layer 450 may be present when the core layer 430 comprises a material permeable to the resin of the cover layer 440. For example, the base layer may be formed from the resin flowing through the core layer. Similarly, when the core layer 430 comprises a material not permeable to the resin of the cover layer 440, the base layer 450 may not be present. Although it is mentioned that the base layer 450 may depend on the permeability of the core layer 430, the base layer 450 may be present under any conditions if desired.

[0052] The base layer 450 may have a thickness between about 0.1 mm and about 0.3 mm. The cover layer 440 may have a thickness between about 0.3 mm and about 0.8 mm, preferably 0.3-0.4 mm.

[0053] Although separate and distinct cover layer 440, core layer 430 and base layer 450 are mentioned, cover layer 440, core layer 430 and base layer 450 may simply define different depths of the same component, and may not be separate and distinct layers.

[0054] Storage box 40 can be coupled to decorative cover 70 at seam 480, such as Figure 16 As shown. The seam 480 may be at least partially embedded in the padding 320.

[0055] like Figure 11 , 12 As shown in Figure 13, as an example, flange 120 can overlap with decorative cover 70 such that the lower surface 140 of flange 120 directly contacts the upper surface 225 of decorative cover 70. Flange 120 can then be stitched to decorative cover 70. As previously described and as... Figure 11 and 12 As shown, the seam 80 that secures the flange 120 to the decorative cover 70 can be located in the groove 260.

[0056] like Figure 13 As shown, as an example, the decorative cover 70 can overlap with the flange 120, such that the lower surface 220 of the decorative cover 70 and the upper surface 130 of the flange 120 are in direct face-to-face contact. Figure 14As shown, flange 120 can be offset by 270 relative to the top surface 280 of storage box 40. Decorative cover 70 can overlap flange 120 and be secured to flange 120 via seam 80. Decorative cover 70 can be folded over the top of flange 120 such that the upper surface 225 of decorative cover 70 is in direct face-to-face contact with the upper surface 130 of flange 120. Although a folded decorative cover 70 is mentioned, decorative cover 70 can also be folded, and the bottom surface 220 of decorative cover 70 can be in direct face-to-face contact with the upper surface 130 of flange 120.

[0057] According to at least Figure 19-27 The exemplary embodiment shown indicates that a process for producing a vehicle interior component 20 may include forming a storage compartment 40, providing a trim cover 70, and coupling the storage compartment 40 to the trim cover 70. A liner 320 may be coupled to the storage compartment 40 and the trim cover 70 as described above and depicted in the accompanying drawings.

[0058] The steps of coupling the storage box 40 to the decorative cover 70 may include sewing the storage box 40 to the decorative cover 70 as described above and as depicted in the accompanying drawings. The steps of coupling the storage box 40 to the decorative cover 70 may also include sewing the flange 120 of the storage box 40 to the decorative cover 70.

[0059] The step of coupling the storage box 40 to the decorative cover 70 may further include sewing the storage box 40 to the decorative cover 70 at the seam 480, wherein the step of coupling the padding 320 to the storage box 40 and the decorative cover 70 may include embedding the seam 480 into the padding 320.

[0060] The stitching 80 used to sew the storage box 40 to the decorative cover 70 may extend through the entirety of the cover layer 440, the core layer 430, and the base layer 450 (if present), or the stitching may extend through only one or two of them.

[0061] according to Figure 19 In an exemplary embodiment, the step of forming the storage box 40 may further include inserting a section of nonwoven permeable fabric 500 into a mold 490. The mold 490 may have an upper mold portion 510 and a lower mold portion 520 that move together to shape the fabric 500 into the component 20. A gap 530 may be provided in the mold 490 to accommodate the thickness of the fabric 500.

[0062] according to Figure 20 In an exemplary embodiment, the step of forming the storage box 40 may further include injecting resin (e.g., polyurethane) into a mold 490 having a predetermined shape of the component 40. In this case, the mold 490 defines a gap 530 for receiving liquid resin between an upper mold portion 510 and a lower mold portion 520. The gap 530 defines the shape of the component 20.

[0063] Regardless of the method used to form component 20, component 20 can be determined according to... Figure 21 The exemplary embodiments are formed in the example. Furthermore, both methods can be used to form the flange 120, chamber 360, notch 310, and other features on the storage box 40.

[0064] The steps of forming the storage box 40 may further include (a) attaching the cover layer 440 to the core layer 430, and optionally (b) molding the base layer 450 and the cover layer 440 together to form the storage box 40 into a three-dimensional shape. The base layer 450 may be formed by selecting a core layer 430 that can be permeated with resin. In this case, when resin is applied to the core layer 430, the resin may flow through and / or pass through the core layer 430 to form the base layer 450.

[0065] The steps of forming the storage box 40 may further include (a) applying a resin (such as the aforementioned polyurethane material) to the base fabric 460, and (b) molding the resin and the base fabric 460 together to form the storage box 40 into a three-dimensional shape.

[0066] The liner 320 can be formed by injecting foam into an opening (not depicted) in the decorative cover 70. As the foam cures, the liner 320 can be wholly or partially bonded to the storage compartment 40 and the decorative cover 70. In some cases, the steps of coupling the liner 320 to the storage compartment 40 and the decorative cover 70 may include forming chemical bonds between the liner 320 and the storage compartment 40, and between the liner 320 and the decorative cover 70.

[0067] In accordance with the provisions of patent law, this device and / or method has been described in a manner considered to represent its preferred embodiment. However, it should be noted that this device and / or method may be implemented in a manner different from the specific description without departing from its spirit or scope.

Claims

1. A component for a seat, comprising: Decorative cover A storage box coupled to the decorative cover. The storage box includes a flange. The flange is secured to the decorative cover by a seam that extends at least partially through the flange and the decorative cover. The flange includes a recess configured to receive at least a portion of the seam. The recess includes a groove having a depth sufficient to place the seam below the upper surface of the flange.

2. The component according to claim 1, wherein the stitching comprises one or more rows of threads forming a continuous or discontinuous stitch pattern along at least a portion of the flange.

3. The component of claim 1, wherein the stitching comprises a top thread and a bottom thread, which are connected to each other at one or more bends.

4. The component of claim 3, wherein the face line extends from the upper surface of the flange through the thickness of the flange into the decorative cover and reverses direction at the one or more bends, and the bottom line extends from the lower surface of the decorative cover into the thickness of the decorative cover and reverses direction at the one or more bends, the face line and the bottom line overlapping at the reversed direction of the face line and the bottom line.

5. The component of claim 1, wherein the flange extends continuously around the periphery of the storage box and has a width between about 5 mm and about 10 mm.

6. The component of claim 1, wherein the flange is flexible, resilient, and configured to be selectively bent during coupling of the storage compartment to the decorative cover.

7. The component of claim 1, wherein the storage compartment further comprises a generally vertical surface extending from the inner edge of the flange and defining at least a portion of the chamber.

8. The component of claim 1, wherein the storage compartment further comprises a core layer comprising a nonwoven fabric and a cover layer comprising a resin material, wherein the stitching extends through the core layer and the cover layer.

9. The component of claim 8, wherein the cover layer is at least partially located on the core layer.

10. The component according to claim 8, wherein the storage box further comprises a base layer, wherein the base layer is composed of resin.

11. The component of claim 10, wherein the nonwoven fabric may be permeated with the resin of the base layer.

12. The component of claim 1, further comprising a pad coupled to at least one of the storage box and the decorative cover, the storage box being located between the decorative cover and the pad.

13. The component of claim 12, wherein the liner comprises a foam material and is bonded to at least one of the storage box and the decorative cover.

14. The component of claim 12, wherein an air gap exists between the storage box and the liner.

15. The component of claim 1, wherein the flange is offset vertically relative to the upper surface of the storage box.

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