Trim cover assembly with improved recyclability

Abstract

A trim cover assembly for use in an automotive seat assembly includes a first cover piece, a second cover piece, and a plus pad. The first and second cover pieces are formed out of a cover material comprising polyethylene terephthalate fibers and include a first peripheral edge and a second peripheral edge, respectively. The trim cover assembly includes thread comprising polyethylene terephthalate fibers which forms a sewn seam fixedly coupling at least a portion of the first peripheral edge of the first cover piece to at least a portion of the second peripheral edge of the second cover piece. In addition, the plus pad is formed out of polyethylene terephthalate and is fixedly coupled to at least one of the first cover piece and the second cover piece.

Description

TRIM COVER ASSEMBLY WITH IMPROVED RECYCLABILITYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63 / 527,836, filed on July 20, 2023, the disclosure of which is hereby incorporated by reference in its entirety.FIELD AND BACKGROUND OF THE INVENTION

[0002] The present invention relates to a trim cover assembly for use in a seat assembly of an automotive vehicle. More particularly, the invention relates to a trim cover assembly for use in an automotive seat assembly.DESCRIPTION OF RELATED ART

[0003] Automotive vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above a vehicle floor. It is commonly known for certain seat assemblies to include a trim cover assembly covering portions of the seat cushion or the seat back. The trim cover assembly commonly includes a trim cover formed out of a cloth, a vinyl, a suede, and / or a leather. One commonly used cloth is a polyester cloth. In addition, the trim cover commonly includes a plurality7of cover pieces sewn together along sewn seams using thread formed out of nylon and / or polypropylene.

[0004] The trim cover assembly typically includes a plus pad comprising a polyurethane (PU) foam pad having a thickness of about 3 mm to about 12 mm. The polyurethane foam pad is typically permanently attached to the reverse side of the trim cover by chemical bonding, flame lamination, adhesive lamination, and / or by sewn seams using nylon and / or polypropylene thread.

[0005] It is common for the seat cushion and the seat back to include a molded base pad made of a polyurethane (PU) foam. In addition, components such as metal wires and plastic clips are commonly inserted into the molded base pad during the manufacturing process. However, the molded base pad is not easily recyclable when the molded base pad includes polyurethane foam, plastic clips formed out of polypropylene or polyethylene, and / or metal wires.

[0006] In addition, it is typical for various components of dissimilar materials to be sewn or attached to the trim cover assembly. The trim cover assembly^ is typically attached to themolded base pad and / or to other components of the seat assembly by mechanical fasteners such as plastic clips, metal rings, hook and loop fasteners, plastic fasteners, and the like. Thread, hook fasteners, and loop fasteners are typically formed out of nylon and / or polypropylene. Plastic fasteners and plastic clips are typically formed out of polyethylene and / or polypropylene. In certain seat assemblies, the trim cover is permanently attached to the molded base pad using an adhesive. Further, polypropylene retainers are often fixedly coupled to the trim cover assembly so that the trim cover assembly may be fixedly coupled to other components of the seat assembly and / or to other components of the vehicle structure.

[0007] Often, the dissimilar materials within the trim cover assembly cannot be easily separated to allow for recycling of the trim cover assembly. As a result, the molded base pad and the trim cover assembly are often disposed in a landfill at end of life since these components are difficult to recycle.

[0008] It is desirable for the molded base pad to be formed out of commonly recycled materials such as polyethylene so that the molded base pad may be easily recycled. Further, it is desirable that the trim cover assembly be entirety formed out of materials comprising polyethylene so that the trim cover assembly may be easily recycled.SUMMARY OF THE INVENTION

[0009] According to one embodiment, there is provided a trim cover assembly for use in an automotive seat assembly. The trim cover assembly includes a first cover piece, a second cover piece, and a plus pad. The first and second cover pieces are formed out of a cover material comprising polyethylene terephthalate fibers and include a first peripheral edge and a second peripheral edge, respectively. The trim cover assembly includes thread comprising polyethylene terephthalate fibers which forms a sewn seam fixedly coupling at least a portion of the first peripheral edge of the first cover piece to at least a portion of the second peripheral edge of the second cover piece. In addition, the plus pad is formed out of polyethylene terephthalate fibers and is fixedly coupled to at least one of the first cover piece and the second cover piece.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0011] Figure 1 is a perspective view of a seat assembly including a seat cushion, a seat back, and trim cover assemblies covering the seat cushion and the seat back, according to one embodiment of the present invention;

[0012] Figure 2 is an exploded perspective view of the seat assembly of Figure 1;

[0013] Figure 3 is a cross-sectional view of the seat cushion of Figure 1 taken along line 3-3;

[0014] Figure 4 is a perspective view of a retaining clip, according to one embodiment of the present invention;

[0015] Figure 5 is a perspective view of a hook and loop fastener, according to one embodiment of the present invention;

[0016] Figure 6 is a cross-sectional view of a bi-component polyester fiber, according to one embodiment of the present invention;

[0017] Figure 7 is a perspective view of an attachment retainer, according to one embodiment of the present invention;

[0018] Figure 8 is a side view of a plastic clip, according to one embodiment of the present invention;

[0019] Figure 9 is an upper perspective view of a base pad, according to one embodiment of the present invention;

[0020] Figure 10 is a lower perspective view of the base pad of Figure 9;

[0021] Figure 11 is a perspective view of a trim cover assembly, according to one embodiment of the present invention;

[0022] Figure 12 is an enlarged cross-sectional view of portion 12 of the trim cover assembly of Figure 3;

[0023] Figure 13 is an enlarged cross-sectional view of portion 12 of the trim cover assembly of Figure 3, according to another embodiment of the present invention;

[0024] Figure 14 is an enlarged cross-sectional view of portion 12 of the trim cover assembly of Figure 3, according to another embodiment of the present invention;

[0025] Figure 15 is an enlarged perspective view of portion 15 of the trim cover assembly of Figure 11;

[0026] Figure 16 is an enlarged perspective view of portion 15 of the trim cover assembly of Figure 11, according to another embodiment of the present invention;

[0027] Figure 17 is a schematic illustrating a process of constructing a trim cover assembly, according to one embodiment of the present invention;

[0028] Figure 18 is a schematic illustrating a process of constructing a trim cover assembly from recycled polyethylene terephthalate obtained from recycled trim cover assemblies, according to one embodiment of the present invention; and

[0029] Figure 19 is a schematic illustrating a known process of disposing a conventional trim cover assembly into a landfill.DETAILED DESCRIPTION OF THE INVENTION

[0030] Figures 1-18 illustrate a trim cover assembly 10 and components thereof for use in an automotive vehicle seat assembly 12 according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top. bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0031] Figure 1 illustrates a perspective view of a vehicle seat assembly 12 having trim cover assemblies 10, according to embodiments of the present invention. Figure 2 shows an exploded view of the seat assembly 12 of Figure 1. Referring to Figures 1 and 2, the seat assembly 12 has a seat back 14 pivotally connected to a seat cushion 16 and a head restraint 18 coupled with the seat back 14, as is commonly known in the art. The seat cushion 16 extends between a frontend 20 and an opposite rear end 22 adjacent the seat back 14. The seat cushion 16 includes a base pad 24 forming a support layer within the seat cushion 16 and includes other optional components. For example, the base pad 24 optionally includes lower bolsters 26 integrally formed and / or assembled with the base pad 24.

[0032] Referring to Figure 3, one exemplary embodiment of the base pad 24 is formed out of polyethylene terephthalate (hereinafter, "PET”) foam 28 configured to replace a conventional polyurethane foam pad (not shown) typically included in a conventional seat assembly (not shown). The conventional polyurethane foam pad is not melt-recyclable and is often disposed of in a landfill at end of life. The base pad 24 is configured to be easily recyclable since the base pad 24 is formed out of PET foam 28. The base pad 24 includes opposing side surfaces 30, 32 extending between a top surface 34 and a bottom surface 36 and optionally includes integrated bolsters 26, channels 38 extending along the top surface 34, recessed features 40 formed in the top surface 34, and the like as non-limiting examples. Depicted in Figures 2 and 3, the base pad 24 optionally includes one or more retaining clips 42 insert-molded into the base pad 24. An exemplary retaining clip 42 is shown in Figure 4 and includes one or more retention features 44 extending from a clip base 46. The retaining clip 42 is formed out of polyethylene terephthalate (PET). It will be appreciated that the size, shape, and number of retaining clips 42 insert-molded into the base pad 24 might vary without altering the scope of the present invention. While not shown in the Figures, one or more retaining clips 42 might alternatively be fixedly coupled to the base pad 24 using a PET adhesive.

[0033] Depicted in Figures 2, 3, and 5, the base pad 24 optionally includes one or more hook and loop fasteners 48 fixedly coupled to the base pad 24 by a PET adhesive (not shown). The hook and loop fasteners 48 commonly include a hook fastener 50 configured to be removably coupled to a loop fastener 52, as depicted in Figure 5. Referring to Figure 5, the hook fastener 50 typically includes a plurality of hook features 54 projecting from a hook backing 56, as is commonly known in the art. In addition, the loop fastener 52 typically includes a plurality’ of loop features 58 projecting from a loop backing 60, as is commonly known in the art. The hook fastener 50 and the loop fastener 52 are formed out of polyethylene terephthalate (PET). In the embodiment shown in Figure 3, the hook fastener 50 is shown fixedly coupled to the top surface 34 of the base pad 24 and optionally positioned within the recessed feature 40 of the base pad 24. However, it will be appreciated that a loop fastener 52 might be fixedly coupled to the base pad 24 instead of the hook fastener 50 without altering the scope of the present invention. Thebase pad 24 is readily melt-recyclable when the base pad 24, optional fasteners such as the retaining clip 42. the hook and loop fasteners 48, and the PET adhesive are all formed out of polyethylene terephthalate so that the base pad 24 lacks polyurethane, polypropylene, nylon, and other dissimilar materials which might prevent recycling of the base pad 24.

[0034] A second embodiment of the base pad 24' is shown in Figures 9 and 10, where like primed reference numerals represent similar elements as those described above. The base pad 24' of the second embodiment shown in Figures 9 and 10 is formed out of a PET batting 62 configured to replace a conventional polyurethane foam pad (not shown) ty pically included in certain seat assemblies. Replacing the conventional polyurethane foam base pad with the base pad 24' formed from PET batting 62 allows the base pad 24' to be recycled since the base pad 24' lacks polyurethane content. The base pad 24' might be recycled either mechanically, chemically, or by melting so that the polyester content might be respun into new recycled polyester fibers (rPET). As such, the base pad 24' might be recycled instead of disposing the base pad 24' in a landfill. Only significant differences between the two embodiments are reflected in the Figures and the description below.

[0035] The base pad 24' of the second embodiment shown in Figures 9 and 10 includes one or more side surfaces 30' extending between a top surface 34' and a bottom surface 36'. The base pad 24' optionally includes one or more molded features 63 and optionally includes one or more retaining clips 42' insert-molded into the base pad 24'. In addition, the base pad 24' optionally includes one or more of a retaining clip 42', a hook fastener 50', and a loop fastener 52' fixedly coupled to one or more of the top surface 34' and the bottom surface 36' with a PET adhesive (not shown). The retaining clips 42', the hook fasteners 50', the loop fasteners 52' and the adhesive are formed out of polyethylene terephthalate (PET) so that the base pad 24' is easily recyclable without requiring removal of dissimilar materials from the base pad 24'.

[0036] The base pad 24' is formed by compression molding the PET batting 62. One example of a base pad 24' formed from PET batting 62 is shown in PCT application number PCT / US2024 / 015466, the disclosure of which is hereby incorporated by reference in its entirety. In more detail, the PET batting 62 is formed out of a random web 64 of bulk polyester fibers 66 and melt polyester fibers 68. The melt polyester fibers 68 are selected to have a melting temperature less than the melting temperature of the bulk polyester fibers 66. The melting temperature of the melt polyester fibers 68 and the ratio of the bulk polyester fibers 66 relative to the melt polyester fibers 68 are selected based in part on the desired flexibility' (i.e.,“firmness”) and structural stability of the PET batting 62. In addition, the melting temperatures of the polyester fibers 66. 68 are selected based in part on the selected processing steps to prepare the base pad 24'. In more detail, the firmness of the base pad 24' might be increased by increasing the percentage amount of melt polyester fibers 68 relative to the percentage amount of the bulk polyester fibers 66 in the PET batting 62. Further, the firmness of the base pad 24' might be decreased by decreasing the percentage amount of the melt polyester fibers 68 relative to the percentage amount of the bulk polyester fibers 66 in the PET batting 62. The PET batting 62 in one exemplary embodiment includes at least about 60% and less than or equal to about 90% bulk polyester fibers 66 and at least about 10% and less than or equal to about 40% melt polyester fibers 68. In another exemplar}' embodiment, the PET batting 62 includes about 85% bulk polyester fibers 66 and about 15% melt polyester fibers 68. It will be appreciated that the PET batting 62 might contain up to about 5% of dyes and other additives without varying the scope of the present invention.

[0037] The bulk polyester fibers 66 generally include one or more of virgin polyester fibers (PET), recycled polyester fibers (rPET), bio-based polyester fibers, natural polyester fibers, and the like as non-limiting examples. The melt polyester fibers 68 might have a cross-section comprising a single type of polyester fiber (i.e., a “monofilament polyester fiber”). The melting temperature of the melt polyester fibers 68 formed out of monofilament fibers and the ratio of the bulk polyester fibers 66 relative to the melt polyester fibers 68 are selected based in part on the desired fl exibility and structural stability’ of the PET batting 62.

[0038] In an alternate embodiment shown in Figure 6, the melt polyester fibers 68 might include bi-component polyester fibers 70 comprising high-temp polyester fibers 72 and low- temp polyester fibers 74. The high-temp polyester fibers 72 and the low-temp polyester fibers 74 are simultaneously extruded using generally known methods to form a variety of crosssections, such as a side-by-side extruded cross-section (Figure 6), a core and sheath extruded cross-section (not shown), an extruded mixed fiber cross-section (not shown), and the like, to combine the physical and aesthetic properties of two different polyester fibers 72, 74. The inclusion of high-temp polyester fibers 72 within the melt polyester fibers 68 provides additional structure and durability' to the bi-component polyester fibers 70. The loyv-temp polyester fibers 74 are selected to have a melting temperature less than the melting temperature of the high-temp polyester fibers 72 and less than the melting temperature of the bulk polyester fibers 66. The melting temperatures of the loyv-temp polyester fibers 74, the high-temppolyester fibers 72, and the bulk polyester fibers 66, respectively, and the ratio of the bulk polyester fibers 66 relative to the melt polyester fibers 68 are selected based in part on the desired flexibility and structural stability of the PET batting 62. It will be appreciated that the cross-section of the bi-component polyester fibers 70 along with the respective melting temperatures of the high-temp polyester fibers 72, the low-temp polyester fibers 74, and the bulk polyester fibers 66 might vary without altering the scope of the present invention. In addition, it will be appreciated that the melting temperature might alternately be described as a molding temperature without altering the scope of the present invention.

[0039] It will be appreciated that the properties of the PET batting 62 are customizable for various seating applications by varying the fiber denier, the ratio and properties of the bulk polyester fibers 66 and the melt polyester fibers 68, the thickness of the PET batting 62, the melt polyester fibers 68 comprising monofilament polyester fibers and / or bi-component polyester fibers 70, the selection of specific high-temp polyester fibers 72 and low-temp polyester fibers 74 within the bi-component polyester fibers 70. the cross-section of the bi- component polyester fibers 70, the inclusion of a batt stabilization method, and the like, to obtain a desired balance of flexibility, structure, and air permeability. Also, it will be appreciated that the polyester fibers 66, 68, 70, 72, 74 optionally comprise recycled polyester fibers (rPET) which are polyester fibers spun from flakes prepared by flaking post-consumer PET plastic bottles.

[0040] Referring to Figures 1 and 2, the seat cushion 16 also includes a seat frame 76 configured to support the base pad 24. In addition, the seat frame 76 is typically supported by a seat base 78 configured to support the seat cushion 16 above a vehicle floor (not shown). The seat cushion 16 is encased with a cushion trim cover 80 optionally adjoined to one or more side pieces 82 and other optional components to form a cushion trim cover assembly 84. As illustrated in Figure 2, the cushion trim cover assembly 84 is assembled with the base pad 24 to form the seat cushion 16. The cushion trim cover assembly 84 provides a seating surface for an occupant of the seat assembly 12.

[0041] Referring to Figures 1 and 2, the seat back 14 extends between a top end 86 and an opposite bottom end 88 adjacent the rear end 22 of the seat cushion 16. The seat back 14 includes a front surface 90 and a back surface 92. The seat back 14 typically includes a back pad 94 as well as other optional components supported by a seat back frame 96. The back pad 94 provides a support layer within the seat back 14 and is formed from a PET foam 28 and / orPET batting 62 comprising PET fibers 66, 68, 70, 72, 74 as previously described above in reference to the base pad 24. In addition, the back pad 94 optionally includes one or more other fastening components, such as retaining clips 42, 42', hook and loop fasteners 48, and the like, as previously described in reference to Figures 2-5, 9, and 10. The back pad 94 and components which are insert-molded and / or permanently attached to the back pad 94, such as retaining clips 42, 42', are formed out of PET so that the back pad 94 might be recycled without removing dissimilar materials. Further, the hook and loop fasteners 48 are formed out of PET and are fastened to the back pad 94 with a PET adhesive so that these components might be recycled along with the back pad 94.

[0042] Depicted in Figures 1 and 2, the front and back surfaces 90. 92 of the seat back 14 are encased in a seat back trim cover assembly 98, a back panel assembly 100, and other optional trim components providing a seating surface for the occupant of the seat assembly 12. The seat back 14 is typically encased by one or more side pieces 102, a seat back trim cover 104 covering the front surface 90, a seat back panel 106 covering the back surface 92, and other optional components to form the seat back trim cover assembly 98 for the seat back 14. Further, the seat back trim cover 104, the seat back panel 106, the side pieces 102, the back pad 94, and the seat back frame 96 are assembled together to form the seat back 14. The seat back panel 106 is typically attached to a rear surface of the seat back frame 96 and provides structural support for the seat back 14. In certain embodiments, the seat back trim cover 104 is directly adjoined to the seat back panel 106 without including intermediary side pieces 102. In certain embodiments, the seat back panel 106 is attached to other optional components, such as additional trim pieces, fasteners, a pad, and the like as non-limiting examples, and is generically described as a back panel assembly 100.

[0043] The cushion trim cover 80, the seat back trim cover 104, the seat back panel 106, and the like, are generically described herein as a trim cover 108. As such, when a specific trim cover 108 is shown and / or described herein, such as a cushion trim cover 80, a seat back trim cover 104, a seat back panel 106, and the like, it is with the understanding that other embodiments of the present disclosure include alternate trim covers 80, 104, 106, 108. Likewise, any specific trim cover 108, such as the cushion trim cover 80, the seat back trim cover 104, the seat back panel 106, and the like, adjoined with a second component, such as a side piece 82, 102, a fastener, other optional components, and the like, is generically described as a trim cover assembly 10. As such, when a specific trim cover assembly 10 is shown and / ordescribed herein, such as a cushion trim cover assembly 84, a seat back trim cover assembly 98, a back panel assembly 100. and the like, it is with the understanding that other embodiments of the present disclosure include alternate trim cover assemblies 10, 84, 98, 100. In addition, the base pad 24 and the back pad 94 are generically described herein as seat pads 110. As such, when a specific seat pad 110 is shown and / or described herein, such as the base pad 24, the back pad 94, and the like, it is with the understanding that other embodiments of the present disclosure include alternate pads 24. 94. 110.

[0044] An exemplary7trim cover assembly 10 is illustrated in Figure 11, according to one embodiment of the present invention. A cross-sectional view of the seat cushion 16 of Figure 1 is depicted in Figure 3. illustrating a cross-sectional view of a portion of the trim cover assembly 10. In addition, an enlarged cross-sectional view of a portion of the trim cover assembly 10 of Figure 3 is shown in Figure 12. Referring to Figure 11, the exemplary' trim cover assembly 10 includes a trim cover 108 comprising a first cover piece 112 which fixedly coupled to a second cover piece 114 with a sewn seam 116. In addition, the trim cover 108 is fixedly coupled to one or more side pieces 102 by additional sewn seams 116. The side pieces 102 are optionally fixedly coupled to a back panel assembly 100 using additional sewn seams 116. In addition, one or more stitched lines 118 are optionally formed in the trim cover assembly 10 which improves an overall appearance and shape of the trim cover assembly 10. As discussed further below, the sewn seams 116 and stitched lines 118 are formed using generally known sewing processes with polyethylene terephthalate (PET) thread comprising polyethylene terephthalate (PET) fibers, such as polyester thread, so that the trim cover assembly 10 might be easily melt-recycled.

[0045] Shown in Figures 3 and 12, the trim cover 108 includes a front surface 120 (i.e., an ‘"A- surface”) facing outward of the seat assembly 12 and a back surface 122 (i.e., a “B-surface”) opposing the front surface 120. The trim cover 108 is formed out of a cover material 124 comprising a PET textile, such as a polyester fabric and the like, formed out of polyethylene terephthalate (PET) fibers which comprise 100% virgin PET, recycled PET (rPET), and / or a mix of virgin PET and rPET. Virgin PET is PET manufactured from raw materials that lack rPET content.

[0046] Also depicted in Figures 3 and 12. the trim cover assembly 10 includes a plus pad 126. which has an upper surface 128 permanently attached to the back surface 122 of the trim cover 108 using a variety7of known methods, such as adhesively laminated by a PET adhesive, flame-laminated, powder-laminated, tack sewn, chemically adhered, or the like as non-limiting examples. The plus pad 126 improves the appearance and comfort associated with the trim cover 108. In the embodiment shown in Figure 12, the plus pad 126 is formed out PET batting 130 comprising a random web 132 of bulk polyester fibers 134 and optionally melt polyester fibers 136. The melt polyester fibers 136 might comprise monofilament polyester fibers and / or bi-component polyester fibers 70, as described above. In certain embodiments, the upper surface 128 of the PET batting 130 in sheet form is assembled with and / or fixedly coupled to the back surface 122 of the cover material 124 in sheet form prior to cutting the trim cover 108 and the plus pad 126 out of the cover material 124 and the PET batting 130, respectively.

[0047] In addition, the web 132 of the bulk polyester fibers 134 and the optional melt polyester fibers 136 forming the PET batting 130 might be stabilized in sheet form using various known methods, commonly described as a multi-knit batting, a non-woven batting, a hot-melt batting, and the like, as non-limiting examples, to improve handling and cutting of the PET batting 130. The multi-knit batting is formed by stitch-bonding the web 132 with longitudinal yarns (not shown) to bond and hold the web 132 in place. The non-woven batting is formed by needles punched through the web 132 to push the web 132 into a consistent stable batt. The hot-melt batting is formed from a web 132 which includes bulk polyester fibers 134 and melt polyester fibers 1 6. To form the hot-melt batting, the web 132 is passed through a warmer (not shown) which causes at least part of the melt polyester fibers 136 to melt and bond with the remaining polyester fibers 134, 136 in the web 132. Also, melt polyester fibers 136 are typically included within the PET batting 130 when the PET batting 130 is preheated or tempered while in sheet form to improve handling during cutting and sewing operations.

[0048] The PET batting 130 typically has a thickness 138 of about 3 mm to about 13 mm. It will be appreciated that the thickness 138 of the PET batting 130 might vary without altering the scope of the present invention. The PET batting 130 typically has a fiber denier (D) of at least about 5 D and less than or equal to about 40 D. The fiber denier of the PET batting 130 is selected based in part on the specific application of the trim cover 108. For example, the PET batting 130 might have a fiber denier of greater or equal to about 1 D and less than or equal to about 10 D when used in applications where air permeability is not required. In applications where the PET batting 130 is replacing a conventional polyurethane foam plus pad, a fiber denier greater or equal to about 20 D and less than or equal to about 25 D might be selected. Further, the PET batting 130 might be selected to have a fiber denier greater or equal to about35 D and less than or equal to about 45 D when a minimum amount of air permeability is desired. It will be appreciated that the fiber denier of the PET batting 130 may vary without altering the scope of the present invention.

[0049] Melt polyester fibers 136 are typically included within the PET batting 130 when the PET batting 130 is compression-molded before and / or after attaching the PET batting 130 to the trim cover 108. In one embodiment, the PET batting 130 might contain up to about 40% of melt polyester fibers 136 with the remaining of the PET batting 130 formed out of bulk polyester fibers 134. In another embodiment, the PET batting 130 might contain about 10% of melt polyester fibers 136 with the remaining of the PET batting 130 formed out of bulk polyester fibers 134. The firmness and / or stiffness of the compression-molded PET batting 130 might be increased by increasing the relative percentage of the melt polyester fibers 136 in relation to the percentage of bulk polyester fibers 134. In contrast, the firmness and / or stiffness of the compression-molded PET batting 130 might be decreased by decreasing the relative percentage of the melt polyester fibers 136 in relation to the percentage of bulk polyester fibers 1 4. It will be appreciated that the PET batting 130 might contain up to about 5% of dyes and other additives without varying the scope of the present invention. It will also be appreciated that the percentage amount of melt polyester fibers 136 and the percentage amount of bulk polyester fibers 134 might vary without altering the scope of the present invention.

[0050] A second embodiment of the trim cover assembly 10' is shown in Figure 13, where like primed reference numerals represent similar elements as those described above. The trim cover 108' of the second embodiment shown in Figure 13 includes a plus pad 126' formed out of a PET batting 130' configured to replace a conventional spacer-fabric typically included in a conventional seat assembly (not shown) having a conventional heating and ventilation system (not shown). Conventional spacer-fabrics are typically inserted between the heating and ventilation system and the trim cover to maintain air permeability and air flow. Cost savings and labor savings are obtained related to the trim cover 108' by substituting the PET batting 130' for the conventional spacer-fabric. Only significant differences between the two embodiments are reflected in the Figures and the description below.

[0051] The trim cover assembly 10' shown in Figure 13 includes a trim cover 108' formed out of a cover material 124' comprising a PET textile and having a front surface 120' and a back surface 122', as shown in the first embodiment. In addition, the trim cover assembly 10' includes the plus pad 126' comprising PET batting 130' and having an upper surface 128'fixedly coupled to the back surface 122' of the trim cover 108'. The PET batting 130' is fixedly coupled to the trim cover 108' either while the cover material 124' and the PET batting 130' are in sheet form and / or after the PET batting 130' and cover material 124' are cut into desired shapes.

[0052] A key performance metric for textiles used in trim covers 108' for a seat assembly having a heating and ventilation system is air permeability, which is evaluated per ASTM D737. Preferably, the minimum level of permeability required through the trim cover 108' (arrow 140) while the seat assembly is unoccupied is about 100-120 cfm (cubic feet per minute) to ensure adequate performance of the heating and ventilation system. In order to ensure adequate airflow (arrow 140) through the trim cover 108', the PET batting 130' is selected to have a fabric denier greater or equal to about 35 D and less than or equal to about 45 D. In one exemplary embodiment, the PET batting 130' preferably has a fabric denier of about 40 D. In an exemplary embodiment, the PET batting 130' comprises about 95% to about 100% of recycled bulk polyester fibers 134' and up to about 5% of dyes and other additives. Further, the PET batting 130' might lack melt polyester fibers 136'. However, it will be appreciated that the PET batting 130' might include melt polyester fibers 136' and that the PET batting 130' might be preheated or tempered while in sheet form to improve handling during cutting and sewing operations. In addition, the PET batting 130' might include melt polyester fibers 136' if the PET batting 130' is compression-molded prior to assembling the PET batting 130' with the trim cover 108' and / or after the PET batting 130' is attached to the trim cover 108'. Also, the PET batting 130' is generally selected to have a batting thickness 138' greater or equal to about 8 mm and less than or equal to about 15 mm. In one exemplary embodiment, the PET batting 130' preferably has a batting thickness 138' of about 10 mm. Preferably, the PET batting 130' comprises at least about 60% or more rPET fiber content and is recyclable at end of life using commonly known melt-recycling processes.

[0053] A third embodiment of the trim cover assembly 10” is shown in Figure 14, where like double primed reference numerals represent similar elements as those described above. The trim cover assembly 10” of the third embodiment shown in Figure 14 includes a trim cover 108” formed out of a cover material 124” comprising a PET textile and having a front surface 120” and a back surface 122". The trim cover assembly 10" also includes a plus pad 126" comprising PET batting 130” and having an upper surface 128" fixedly coupled to the back surface 122" of the trim cover 108", as shown in the first embodiment. In addition, the trimcover assembly 10” includes one or more additional components, as further described below. Only significant differences between the third embodiment and the prior embodiments are reflected in the Figures and the description below.

[0054] Referring to Figure 14, the trim cover assembly 10" includes a secondary pad 142 formed out of a second PET batting 144 and having an upper surface 146 fixedly coupled to a lower surface 148 of the plus pad 126". In certain embodiments, the second PET batting 144 has the same density, fiber denier, percentage of bulk polyester fibers, percentage and composition of melt polyester fibers, thickness, and the like, as the PET batting 130" forming the plus pad 126". In other embodiments, one or more properties of the second PET batting 144 varies from the properties of the PET batting 130", including one or more of the thickness, fiber denier, density, percentage of bulk polyester fibers, percentage and composition of the melt polyester fibers, and the like as non-limiting examples. For example, the second PET batting 144 might be firmer than the PET batting 130" to provide additional support for the trim cover 108". Alternatively, the second PET batting 144 might be configured to replace a conventional spacer-fabric typically included in a conventional seat assembly (not shown) having a conventional heating and ventilation system (not shown). As such, the second PET batting 144 might have a higher fiber denier than in the PET batting 130", as a non-limiting example, so that the second PET batting 144 is able to maintain air permeability and airflow with the trim cover assembly 10".

[0055] Also shown in Figure 14, the trim cover assembly 10" optionally includes a scrim backing 150 attached to a lower surface 152 of the secondary pad 142. The scrim backing 150 comprises a woven textile and / or a non-woven textile formed out of PET fibers. The scrim backing 150 is optionally included within the trim cover assembly 10" to improve handling of the trim cover assembly 10" during various cutting, sewing, and other manufacturing processes. It will be appreciated that the scrim backing 150 might be attached to the lower surface 148 of the plus pad 126" when the secondary pad 142 is omitted from the trim cover assembly 10".

[0056] A fourth embodiment of the trim cover assembly 10-1 is shown in Figure 15, where reference numerals with the designator “-1” represent similar elements as those described above. The trim cover assembly 10-1 of the fourth embodiment shown in Figure 15 includes a plus pad 126-1 formed out of a PET foam 154. In addition, the trim cover assembly 10-1 includes a trim cover 108-1 fixedly coupled to a side piece 102-1 by a sewn seam 116-1. Onlysignificant differences between the two embodiments are reflected in the Figures and the description below.

[0057] Referring to Figure 15, the trim cover assembly 10-1 includes the trim cover 108-1 formed out of a cover material 124-1 comprising a PET textile and having a front surface 120- 1 and a back surface 122-1 extending from a first peripheral edge 156. The plus pad 126-1 is fixedly coupled to the back surface 122-1 of the trim cover 108-1 and has a pad edge 158 optionally spaced apart from the first peripheral edge 156 along the back surface 122-1 of the trim cover 108-1.|0058| The PET foam 154 forming the plus pad 126-1 might be assembled to the back surface 122-1 of the trim cover 108-1 by a variety of methods without altering the scope of the present invention. For example, the PET foam 154 in sheet form might be flame-laminated onto the back surface 122-1 of the cover material 124-1 in sheet form followed by cutting the laminated assembly of the PET foam 154 and the cover material 124-1 into the desired shape to form the trim cover assembly 10- 1. Alternatively, the components of the PET foam 154 might be applied in liquid form to the back surface 122-1 of the cover material 124-1 and cured to form the PET foam 154. After the PET foam 154 is cured, the layered assembly of the PET foam 154 and the cover material 124-1 is cut to form the trim cover assembly 10-1. In another alternative, the trim cover 108-1 might be vacuum- formed and / or compression-molded into a desired shape followed by applying the components of the PET foam 154 in liquid form onto the back surface 122-1 of the trim cover 108-1 and curing the PET foam 154 to form the trim cover assembly 10-1.

[0059] Also depicted in Figure 15, the side piece 102-1 includes a front surface 160 and a back surface 162 extending from a second peripheral edge 164. During a sewing process, the peripheral edges 156, 164 ofthe trim cover 108-1 and the side piece 102-1 are generally aligned with the front surfaces 120-1, 160 facing each other. Next, a sewn seam 116-1 is formed joining the trim cover 108-1 to the side piece 102-1 using generally known sewing processes. As depicted in Figure 15, the sewn seam 116-1 comprises a plurality of thread stitches 166 extending through the trim cover 108-1 and the side piece 102-1. The thread stitches 166 are formed out of a polyethylene terephthalate (PET) thread 166, such as polyester thread, so that the trim cover assembly 10-1 might be easily melt-recycled. In the embodiment shown in Figure 15, the sewn seam 116-1 extends through the trim cover 108-1 and the side piece 102- 1 but does not go through the PET foam 154 since the pad end 158 is spaced apart from thesewn seam 116-1. However, it will be appreciated that the sewn seam 116-1 might also be formed through the PET foam 154 without altering the scope of the present invention.

[0060] A fifth embodiment of the trim cover assembly 10-2 is shown in Figure 16, where reference numerals with the designator “-2” represent similar elements as those described above. The trim cover assembly 10-2 shown in Figures 16 includes a plus pad 126-2 formed out of a PET batting 130-2 having an upper surface 128-2 attached to the back surface 122-2 of the trim cover 108-2 and an opposing lower surface 148-2 facing away from the trim cover 108-2. Only significant differences between the embodiments are reflected in the Figures and the description below. The PET batting 130-2 has a peripheral edge 168 generally aligned with the first peripheral edge 156-2 of the trim cover 108-2. During a sewing process, the peripheral edges 156-2, 164-2 of the trim cover 108-2 and the side piece 102-2 are generally aligned with the front surfaces 120-2, 160-2 facing each other. Next, a sewn seam 116-2 is formed joining the trim cover 108-2 to the side piece 102-2 using generally known sewing processes. As depicted in Figure 16, the sewn seam 116-2 comprises a plurality of thread stitches 166-2 extending through the trim cover 108-2, the PET batting 130-2, and the side piece 102-2. The thread stitches 166-2 are formed out of a polyethylene terephthalate (PET) thread, such as polyester thread, so that the trim cover assembly 10-2 might be easily melt-recycled. It will be appreciated that the sewn seam 116-2 might pass through the trim cover 108-2 and the side piece 102-2 without going through the PET batting 130-2, without altering the scope of the present invention, such as when the peripheral edge 168 of the PET batting 130-2 is spaced apart from the peripheral edge 156-2 of the trim cover 108-2.

[0061] Also shown in Figures 7 and 16, the trim cover assembly 10-2 optionally includes an attachment retainer 170 fixedly coupled to a component of the trim cover assembly 10-2, such as to side piece 102-2 as a non-limiting example. The attachment retainer 170 has a generally J-shaped cross-section in profile with a hook portion 172 extending from a wall portion 174 and including a retention feature 176 extending from the hook portion 172. The attachment retainer 170 is commonly described as a “J-clip”, a “J-channel”, and the like. The attachment retainer 170 is generally configured such that the trim cover assembly 10-2 might be fixedly coupled to a structure attachment (not shown) within the seat frame 76, seat back frame 96, and / or to another component of the seat assembly 12. The attachment retainer 170 is formed out of polyethylene terephthalate (PET) and attached to the trim cover assembly 10-2 using a sewn seam 1 16-2 formed with polyester thread, as illustrated in Figure 16. Alternatively, theattachment retainer 170 is fixedly coupled to the trim cover assembly 10-2 by a PET adhesive (not shown). It will be appreciated that the number, placement, and shape of the attachment retainers 170 fixedly coupled to the trim cover assembly 10-2 might vary without altering the scope of the present invention.

[0062] Referring to Figures 8 and 16, the trim cover assembly 10-2 optionally includes one or more plastic clips 178, alternatively described as a “push-in rivet”, a “retainer clip”, a “push type retainer”, and the like, and formed out of polyethylene terephthalate (PET). Shown in Figure 8, an exemplary plastic clip 178 includes a shaft 180 extending axially from a clip head 182. The shaft 180 typically includes a plurality of flexible fingers 184 extending radially away from the shaft 180 and configured to frictionally engage with a mounting hole (not shown) in a component of the seat assembly 12. In the embodiment shown in Figure 16, the trim cover assembly 10-2 includes a hole 186 extending through the plus pad 126-2, the trim cover 108- 2, and the side piece 102-2 and spaced between the sewn seam 116-2 and the peripheral edges 156-2, 164-2, 168. To fixedly couple the trim cover assembly 10-2 to a component such as the base pad 24, the shaft 180 of the plastic clip 178 is inserted into the hole 186 in the trim cover assembly 10-2 and inserted into a corresponding mounting hole (not shown) in a component of the seat assembly 12. Removal of the plastic clips 178 from the trim cover assembly 10-2 is not required prior to melt-recycling the trim cover assembly 10-2 because the plastic clips 178 are formed out of polyethylene terephthalate (PET).

[0063] Also shown in Figure 16, the trim cover assembly 10-2 optionally includes hook and loop fasteners 48-2 fixedly coupled to the plus pad 126-2 by a PET adhesive 188. The hook and loop fasteners 48-2 commonly include a hook fastener 50-2 configured to be removably coupled to a loop fastener 52-2, as depicted in Figure 5. The hook fastener 50-2 and the loop fastener 52-2 are formed out of polyethylene terephthalate (PET). In the embodiment shown in Figure 16, the loop fastener 52-2 is shown fixedly coupled to the lower surface 148-2 of the plus pad 126-2. However, it will be appreciated that a hook fastener 50-2 might be fixedly coupled to the plus pad 126-2 without altering the scope of the present invention. Further, it will be appreciated that one of the hook fastener 50-2 and the loop fastener 52-2 might be adhered to an alternate component of the trim cover assembly 10-2 by a PET adhesive 188 and / or sewn to a component of the trim cover assembly 10-2 by a sewn seam 116-2 formed of polyethylene terephthalate thread, without altering the scope of the present invention.

[0064] Depicted in Figure 19, conventional seat assemblies 198 often include conventional trim cover assemblies 200 which contain dissimilar materials. For example, the conventional trim cover assembly 200 might include a trim cover material 202 formed out of cloth, vinyl, leather, and the like. In addition, it is commonly known for the conventional trim cover assembly 200 to include a plus pad 204 (“plus pad”) formed out of a polyurethane foam which is permanently attached to the trim cover material 202. In addition, the conventional seat assemblies 198 typically include a conventional base pad 206 and a conventional back pad 208 formed out of polyurethane foam. In addition, the conventional trim cover assemblies 200 often contain thread, hook fasteners, and / or loop fasteners (not shown) formed out of nylon or polypropylene. Further, it is common for conventional trim cover assemblies 200 to include plastic retainers (not shown) formed out of polyethylene and / or polypropylene. Often, it is difficult to disassemble the trim cover assembly 200 from the pads 206, 208. It is common for conventional trim cover assemblies 200, conventional base pads 206, and conventional back pads 208 to be disposed in a landfill 210 at the end of useful life of the conventional seat assembly 198, as illustrated by arrow 212 in Figure 19.

[0065] Referring to Figure 17, the trim cover assemblies 10 according to the present invention include a cover material 124 comprising a PET textile which is laminated to a plus pad 126 comprising PET foam 28 and / or PET batting 62 to form a laminated trim cover 108. In addition, sewn seams 116 joining components of the trim cover assembly 10 are formed using a polyester (PET) thread 166. Further, fasteners such as loop fasteners 52, hook fasteners 50, attachment retainers 170, plastic clips 178, and the like are formed out of PET. As such, the trim cover assembly 10 is formed out of components comprising solely of PET and lacks dissimilar materials. Therefore, the trim cover assembly 10 and the attached components 50, 52, 116, 166, 170, 178 might be recycled at the end of useful life of the trim cover assembly 10 to produce recycled PET fiber 214.

[0066] Depicted in Figure 18, the recycled PET material 214, such as rPET fiber, rPET pellets, and the like, are combined with additional base materials 216 to form seating materials 218, such as PET thread, PET batting, PET foam, PET textile, plastic molded components, and the like formed out of PET. In addition, the recycled PET material 214 optionally comprises recycled polyester fibers (rPET) which are polyester fibers spun from flakes prepared by flaking post-consumer PET plastic bottles. Next, the trim cover assembly 10, the base pad 24, and the back pad 94 are assembled from the seating materials 218. At the end of useful life ofthe trim cover assembly 10, the trim cover assembly 10 might be shredded, along with the base pad 24 and the back pad 94, to form shredded PET material 220. The trim cover assembly 10 can be completely recycled without requiring secondary operations to remove parts with dissimilar material. The shredded PET material 220 is processed through generally known manufacturing processes, such as mechanically recycling the shredded PET material 220, chemically recycling the shredded PET material 220, and / or by melting the shredded PET material 220 to produce recycled PET material 214. The recycled PET material 214 is optionally respun into new rPET fibers to be used in future plus pads 126 comprising recycled PET fibers. In addition, the recycled PET material 214 is used to form additional components to produce new trim cover assemblies 10, base pads 24, and back pads 94 comprising recycled PET materials 214.

[0067] As discussed above, the trim cover assembly 10, 10', 10", 10-1, 10-2 of the present invention includes components formed out of polyethylene terephthalate (“PET”), including a cover material 124, 124', 124", 124-1 comprising a PET textile, a plus pad 126, 126', 126", 126-1, 126-2 formed out of PET foam 154 and / or PET batting 130, 130', 130", 144, sewn seams 116, 1 16-1, 116-2 and stitched lines 118 formed out of polyester (PET) thread 166, and optionally including one or more of hook and loop fasteners 48, 48-2 formed out of PET, attachment retainers 170 formed out of PET, and / or plastic clips 178 formed out of PET. The trim cover assembly 10, 10', 10", 10-1, 10-2 ofthe present invention lacks dissimilar materials, including polypropylene, polyurethane, nylon, leather, and vinyl to improve recyclability and eliminate secondary operations required to remove dissimilar materials prior to recycling the PET.

[0068] The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:

1. A trim cover assembly for use in an automotive seat assembly, comprising: a first cover piece which is formed out of a cover material comprising polyethylene terephthalate fibers and having a first peripheral edge; a second cover piece which is formed out of the cover material comprising polyethylene terephthalate fibers and having a second peripheral edge; thread comprising polyethylene terephthalate fibers and forming a sewn seam fixedly coupling at least a portion of the first peripheral edge to at least a portion of the second peripheral edge; and a plus pad which is formed out of polyethylene terephthalate and which is fixedly coupled to at least one of the first cover piece and the second cover piece.

2. The trim cover assembly as set forth in claim 1, wherein the plus pad is laminated or adhered to one or more of the first cover piece and the second cover piece.

3. The trim cover assembly as set forth in claim 2, wherein the plus pad comprises at least 95% polyethylene terephthalate.

4. The trim cover assembly as set forth in claim 3, wherein the plus pad is formed out of a batting comprising polyethylene terephthalate fibers.

5. The trim cover assembly as set forth in claim 3, wherein the plus pad is formed out of a polyethylene terephthalate foam.

6. The trim cover assembly as set forth in claim 5, further comprising a base pad which is formed out of one or more of a polyethylene terephthalate foam and a batting comprising polyethylene terephthalate fibers; wherein the base pad is fixedly attached to one or more of the first cover piece, the second cover piece, and the plus pad.

7. The trim cover assembly as set forth in claim 6, further comprising one of a hook fastener or a loop fastener which is fixedly coupled to one or more of the first cover piece, the second cover piece, and the plus pad; wherein the one of the hook fastener or the loop fastener is formed out of polyethylene terephthalate.

8. The trim cover assembly as set forth in claim 7, further comprising an other one of the hook fastener or the loop fastener which is fixedly coupled to the base pad; wherein the other one of the hook fastener or the loop fastener is formed out of polyethylene terephthalate.

9. The trim cover assembly as set forth in claim 6, wherein the base pad further comprises a retaining clip which is insert-molded into the base pad; wherein the retaining clip is formed out of polyethylene terephthalate.

10. The trim cover assembly as set forth in claim 9, further comprising an attachment retainer fixedly coupled to the trim cover assembly; wherein the attachment retainer is formed out of polyethylene terephthalate.

11. The trim cover assembly as set forth in claim 6, further comprising a plastic clip fixedly coupled to the trim cover assembly; wherein the plastic clip is formed out of polyethylene terephthalate.

12. The trim cover assembly as set forth in claim 6, further comprising a spacer-fabric spaced between the plus pad and the base pad; wherein the spacer-fabric is formed out of polyethylene terephthalate fibers.

13. The trim cover assembly as set forth in claim 10. wherein the trim cover assembly lacks polyurethane, polypropylene, and nylon.

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