Method of manufacturing a cover for a seat element

Abstract

Method for manufacturing a cover (1) for a seat element (10), in particular an automobile seat, the cover (1) having at least one curvature zone (5, 5a, 5b), comprising: providing a fabric layer (2), providing an underlayer (3), assembling by superimposing the fabric layer (2) and the underlayer (3) to form the cover (1), producing a plurality of seams passing through the fabric layer (2) and the underlayer (3), at predetermined locations, the locations of the seams being chosen to be located in said at least one curvature zone (5, 5a, 5b), three-dimensional shaping of the fabric layer (2) and the underlayer (3) to form said at least one curvature zone (5, 5a, 5b) of the cover (1). Abstract figure: Figure 7

Description

Title of the invention: Method for manufacturing a cover for a seat element Technical field

[0001] The present disclosure relates to the field of vehicle seats, particularly automobile seats, which comprise a cover. Such a cover plays in particular a finishing role and generally comprises at least one layer of appearance fabric. The cover may be part of at least one upholstery, typically fixed to a seat frame. The upholstery comprises, in addition to the cover, a layer of padding which contributes to the comfort of the seat, the cover covering the padding.

[0002] The present disclosure relates more particularly to a method of manufacturing a cover for a seat element, in particular but not exclusively for a seat base. The present disclosure also relates to a seat element comprising a cover obtained by such a method, as well as a seat comprising such a seat element. Prior art

[0003] A cover generally comprises, in addition to the appearance fabric layer, a sub-layer commonly called lamination. When placing the cover within the seat element, one may seek to form curves, in order to match the rounded shapes of the padding, for example. However, by forming curves, one creates uncontrolled folds such that it is difficult to maintain a beautiful appearance for the cover.

[0004] To obtain such curves while maintaining a beautiful appearance, it is known to assemble different fabrics together, in particular by sewing.

[0005] There is a need to manufacture a headdress having a rounded shape with at least one area of curvature, while maintaining a beautiful appearance. Abstract

[0006] The present disclosure improves the situation.

[0007] A method is proposed for manufacturing a cover for a seat element, in particular an automobile seat, the cover having at least one zone of curvature, comprising: a. providing a layer of fabric, b. provision of an underlay, c. assembly by superimposing the fabric layer and the underlayer to form the headdress, d. making a plurality of seams passing through the fabric layer and the underlay layer, at predetermined locations, the locations of the seams being chosen to be located in said at least one area of curvature, e. three-dimensional shaping of the fabric layer and the underlayer to form said at least one area of curvature of the cap.

[0008] The method makes it possible to obtain, thanks to the presence of seams arranged at chosen locations, a headdress having at least one area of curvature without any appearance defect such as a fold. The locations of the seams are in fact chosen so as to assist in the deformation of the fabric layer and the underlayer in said at least one area of curvature without creating folds.

[0009] The features set out in the following paragraphs may, optionally, be implemented, independently of one another or in combination with one another:

[0010] The seams may be longitudinal seams, extending along a longitudinal axis of the seat element.

[0011] Alternatively or additionally, the seams may be transverse seams, extending perpendicular to a longitudinal axis of the seat element.

[0012] Preferably, the production of a plurality of seams comprises at least the production of a plurality of longitudinal seams.

[0013] By "longitudinal axis of the seat element" is meant an axis which is specific to the seat element, and extends longitudinally. If several different seat elements have covers, each seat element will have its own longitudinal axis and will be considered independently of the other seat elements. For example, if the seat element is a seat, the longitudinal axis extends substantially horizontally from front to back or from back to front on the seat. If the seat element is a backrest, the longitudinal axis extends substantially vertically from top to bottom or from bottom to top on the seat.

[0014] The fabric layer is preferably made from a single piece. This means that the cover comprises only one piece, or patch, of fabric and not an assembly of several pieces of fabric fixed, for example sewn, together. In particular, the seams made do not participate in the assembly of two pieces of fabric together. Their role is only to connect the fabric layer and the underlayer together at chosen locations.

[0015] Said at least one zone of curvature may extend, at least partially, over a length of the longitudinal axis of the seat element, transversely to the longitudinal axis of the seat element. In other words, according to one example, the curvature is present over a certain length of the longitudinal axis, and extends transversely to the latter. Such a zone of curvature may be referred to as a zone of longitudinal curvature.

[0016] Said at least one area of curvature is preferably concave outwards. Alternatively, said at least one area of curvature is convex outwards. In another alternative, the cap comprises a plurality of areas of curvature, including at least one area of curvature that is concave outwards and at least one area of curvature that is convex outwards.

[0017] The longitudinal seams are preferably discontinuous. Thus, the longitudinal seams do not extend continuously over the entire length of the curvature zone. The longitudinal seams may be arranged at regular intervals, in particular to preserve an aesthetic appearance, or not. Several longitudinal seams are preferably aligned. In this case, the longitudinal seams may be aligned and discontinuous over the length of the curvature zone. The longitudinal seams are advantageously substantially rectilinear. They may form straight sections along the longitudinal axis. When they are discontinuous, the longitudinal seams may each have a length of between 30 mm and 100 mm, preferably between 50 mm and 80 mm. Alternatively, each longitudinal seam extends continuously over the entire length of the curvature zone.

[0018] The transverse seams are preferably discontinuous. The transverse seams may be arranged at regular or irregular intervals. Several transverse seams may be aligned. The transverse seams are advantageously substantially rectilinear. They may form straight sections along the transverse axis. When they are discontinuous, the transverse seams may each have a length of between 30 mm and 100 mm, preferably between 50 mm and 80 mm. Alternatively, each transverse seam extends continuously over the entire length of the transverse curvature zone.

[0019] The locations of the transverse seams may be chosen to be located in said at least one area of curvature. In such a case, said at least one area of curvature may extend, at least partially, over a length of the transverse axis perpendicular to the longitudinal axis of the seat element, parallel to the longitudinal axis. In other words, according to one example, the curvature is present over a certain length of the transverse axis, and extends parallel to the longitudinal axis. Such an area of curvature may be referred to as a transverse curvature area.

[0020] The cap may then comprise at least one zone of longitudinal curvature, and at least one zone of transverse curvature. Longitudinal seams may be present on said at least one zone of longitudinal curvature, while transverse seams may be present on said at least one zone of transverse curvature.

[0021] The method may include providing an adhesive film. In this case, the assembly may include bonding the fabric layer and the underlayer to using the adhesive film. The adhesive film is preferably inserted between the fabric layer and the underlay. The adhesive film can be heat-activated. In this case, bonding takes place by heat activation of the adhesive film placed between the fabric layer and the underlay.

[0022] The three-dimensional shaping is preferably carried out after the longitudinal and / or transverse seams have been made. Alternatively, the three-dimensional shaping takes place before the longitudinal and / or transverse seams have been made.

[0023] The underlayer preferably comprises a material selected from the group consisting of polyester wadding and foam, in particular polyurethane. The underlayer may have an initial thickness less than or equal to 15 mm, in particular less than or equal to 10 mm. The fabric layer may comprise a fabric selected from the group consisting of woven or knitted polyester fibers and a plastic-coated textile, comprising for example woven polyester fibers forming the textile, which is covered with a coating made of PVC (polyvinyl chloride) or polyurethane, also commonly called imitation leather or artificial leather.

[0024] The fabric layer preferably comprises, or is even formed from, woven polyester fibers.

[0025] When the seat element comprises padding, the method may comprise positioning the cover on the padding. In this case, the padding may comprise a solidified 3D tangle of continuous thermoplastic fibres arranged irregularly forming loops welded together.

[0026] The positioning of the cover on the padding may be implemented simultaneously with the three-dimensional shaping of the fabric layer and the underlayer to form said at least one curvature zone of the cover. In other words, the three-dimensional shaping of the fabric layer and the underlayer may be implemented by positioning the cover on the padding. Alternatively, the three-dimensional shaping of the fabric layer and the underlayer may be carried out using a tool such as a press, for example by thermoforming. In such a case, the fabric layer may be shaped in 3D using the tool, and the underlayer may be shaped in 3D using the tool, and then the fabric layer and the underlayer may be assembled together.

[0027] The method may include providing decorative seams outside of said at least one curvature area. Such decorative seams may create a desired pattern of seams on the cap including longitudinal and / or transverse seams and decorative seams. The decorative seams may have characteristics similar to the longitudinal seams or transverse seams and may notably extend parallel to one or the other.

[0028] When the seat element comprises a seat base comprising a tray and, on either side of the tray along a transverse axis perpendicular to the longitudinal axis, two edges, said at least one zone of curvature may be concave towards the outside and extend between the tray and each edge. In this case, the cover comprises two such zones of curvature, longitudinal, on either side of the tray, for the formation of each edge from the tray. The tray advantageously constitutes the seating zone of a user, that is to say the zone of contact of a user with the seat base, while the edges may surround this zone of contact.

[0029] When the seat element comprises padding, the method may comprise providing at least one fixing element intended to fix the cover to the padding. The method may then comprise, when producing the longitudinal, and / or transverse and / or decorative seams, superimposing said at least one fixing element under the underlayer, opposite the fabric layer, and sewing said at least one fixing element with the fabric layer and the underlayer.

[0030] According to another aspect, there is provided, in combination with the above, a vehicle seat element, in particular an automobile seat, comprising a cover obtained using the method as defined above.

[0031] The fabric layer and the underlayer may comprise at least 95% polyester. In one example, the fabric layer comprises polyester fibers woven together. In one example, the underlayer comprises non-woven polyester fibers. The seat element may comprise, in addition to the cover, padding comprising a solidified 3D tangle of continuous thermoplastic fibers arranged irregularly forming loops welded together. In this case, there is then provided a filling, comprising the cover and the padding, made of a material other than polyurethane foam. This material of the filling is advantageously a recyclable plastic material and its production generates less CO2 emissions than the production of a polyurethane foam, thus reducing the ecological impact of the seat element comprising this filling.In addition to the environmental benefits, the seat element incorporating this material for the upholstery can allow for a significantly lighter upholstery than a similar upholstery made from polyurethane foam. In addition, the upholstery material can be more breathable, allowing air and any moisture to pass through the upholstery better.

[0032] The seat element may be chosen from the group consisting of a backrest, in particular of a seat or bench, an armrest, a seat, in particular of a seat or bench, a headrest, a console, in particular central or rear, a part of these and a set of all or part of these, preferably a seat.

[0033] According to another aspect, there is provided, in combination with the above, a vehicle seat, in particular an automobile seat, comprising a seat element as defined below high. Brief description of the drawings

[0034] Other characteristics, details and advantages will appear on reading the detailed description below, and on analyzing the attached drawings, in which:

[0035] [Fig-1] is a schematically exploded side view of an example of a headdress when implementing the method according to an example.

[0036] [Fig.2] schematically shows a side view of a cap after assembly during implementation of the method according to an example.

[0037] [Fig.3] schematically shows a side view of a cap after three-dimensional shaping of the fabric layer and the underlayer to form said at least one curvature zone of the cap when implementing the method according to an example.

[0038] [Fig.4] schematically shows a side view of a headdress after seams have been made when implementing the method according to an example.

[0039] [Fig.5] schematically shows a side view of a cover after assembly to a padding, during the implementation of the method according to an example.

[0040] [Fig.6] shows a view similar to [Fig.5] when implementing another example method.

[0041] [Fig.7] shows schematically, in side and top view, and in perspective, partially cut away, an example of a seat element comprising a cover obtained using the method according to an example.

[0042] [Fig.8] shows schematically and partially, in front view, in perspective, partially cut away, an example of a seat comprising an example of a seat element comprising a cover obtained using the method according to an example. Description of the embodiments

[0043] The drawings and the description below contain, for the most part, elements of a certain character. They may therefore not only serve to better understand the present disclosure, but also contribute to its definition, where appropriate.

[0044] In the various figures, the same references designate identical or similar elements. For the sake of brevity, only the elements which are useful for understanding the embodiment described are shown in the figures and are described in detail below.

[0045] In the following description, when reference is made to absolute position qualifiers, such as the terms "front", "back", "top", "bottom", "left", "right", etc., or relative position qualifiers, such as the terms "above", "below", "upper", "lower", etc., or to orientation qualifiers, such as "horizontal", "vertical", etc., reference is made, unless otherwise specified, to the orientation of the figures or of a vehicle seat element or a vehicle seat in its normal position of use.

[0046] Figures 1 to 5 show different steps in implementing an example of a method for manufacturing a cover 1 for a seat element 10, in particular an automobile seat, the cover 1 having at least one zone of curvature 5.

[0047] Reference is now made to [Fig. 1]. This figure shows constituent elements of a headdress 1, namely a fabric layer 2 and a sub-layer 3. The method according to the present disclosure comprises providing the fabric layer 2 and the sub-layer 3. In this example, the fabric layer 2 comprises woven polyester fibers. The fabric layer 2 comprises a single piece of fabric and not an assembly of fabric pieces. The sub-layer 3 comprises non-woven polyester fibers in the form of wadding. The sub-layer 3 may have an initial thickness E less than or equal to 15 mm, in particular less than or equal to 10 mm.

[0048] Still in this example, as illustrated, the cover 1 also comprises a film of glue 4, in this example heat-activatable, arranged between the fabric layer 2 and the underlayer 3. In this case, the method comprises the provision of a film of glue 4.

[0049] In [Fig.2], the cover 1 is shown after assembly during the setting up implementation of the method, by superimposing the fabric layer 2 and the underlayer 3. In this example, the assembly further comprises the bonding of the fabric layer 2 and the underlayer 3, in this example by hot activation of the glue film 4.

[0050] [Fig. 3] shows the three-dimensional shaping of the fabric layer 2 and the sub-layer 3 to form, in this example, a curvature zone 5 of the cover 1. As can be seen, the production of this three-dimensional shaping of the fabric layer 2 and the sub-layer 3 creates at least one fold 6, in this example two. It is the locations of these folds 6 which will be chosen to produce seams, in this example longitudinal seams 7, during the implementation of the method, which longitudinal seams 7 are illustrated in [Fig. 4] and extend over the entire thickness of the cover, crossing the fabric layer 2 and the sub-layer 3. In this figure, it can also be seen that a decorative seam 9 has been produced, having no role other than that of forming a predefined harmonious pattern with the longitudinal seams 7.

[0051] The longitudinal seams 7 extend along a longitudinal axis X of the seat element 10 at the predetermined locations, the locations of the longitudinal seams being chosen to be located in the curvature zone 5.

[0052] The method makes it possible to obtain, thanks to the presence of seams arranged at chosen locations, a cap having at least one area of curvature without any appearance defect. The locations of the longitudinal seams are in fact chosen so as to assist in the deformation of the fabric layer and the underlayer. in said at least one area of curvature without making folds.

[0053] In the illustrated example, the three-dimensional shaping takes place before the longitudinal seams 7 are made, but it is possible to make the longitudinal seams 7 before the three-dimensional shaping, the locations of the longitudinal seams having been determined beforehand.

[0054] The longitudinal seams 7 produced do not participate in the assembly of two pieces of fabric together. Their role is only to connect the fabric layer 2 and the sub-layer 3 together at the chosen locations.

[0055] In this example, the curvature zone 5 is concave outwards.

[0056] In the example illustrated in [Fig.5], the seat element 10 comprises a ma- telassure 11. In this case, the method comprises positioning the cap 1 on the padding 11 as illustrated in [Fig.5]. In this example, the padding 11 comprises a solidified 3D tangle of continuous thermoplastic fibers arranged irregularly forming loops welded together.

[0057] Thus, in the illustrated example, there is a trim, comprising the cover and the padding, made of a recyclable plastic material and its production generates less CO2 emissions than the production of a polyurethane foam, thus reducing the ecological impact of the seat element comprising this trim. In addition to the advantages for the environment, the seat element comprising this material for the trim can make it possible to produce a trim that is significantly lighter than a similar trim made of polyurethane foam. Furthermore, the material of the trim can be more breathable, allowing air and any moisture to pass through the trim better.

[0058] The example illustrated in [Fig.6] differs from that of [Fig.5] in that the method comprises the provision of at least one fixing element 12, in particular several fixing elements 12, intended to fix the cover 1 to the padding 11. The method comprises, when producing the longitudinal seams 7 in particular but also, in this example, the decorative seams 9, the superposition of each fixing element 12 under the underlayer 3, opposite the fabric layer 2, and the sewing of each fixing element 12 with the fabric layer 2 and the underlayer 3, as illustrated.

[0059] [Fig. 7] shows an example of a seat element 10 comprising a cover 1 obtained using the method described above. However, in this example, the three-dimensional shaping is implemented after the seams have been made, in particular the longitudinal seams 7. Thus the seams are made flat.

[0060] In this example, the seat element 10 comprises a motor vehicle seat base. As can be seen, one of the curvature zones 5, denoted 5a, visible in this figure extends, at least partially, over a length of the longitudinal axis X of the seat element 10, transversely to the longitudinal axis X of the seat element 10. In other words, in the illustrated example, the curvature is present over a certain length of the longitudinal axis X, and extends transversely to the latter. Such a curvature zone 5 can be referred to as a longitudinal curvature zone 5a. In this example, the visible longitudinal curvature zone 5a is concave outwards.

[0061] The longitudinal seams 7 are discontinuous, arranged at regular intervals and aligned, as visible. They form straight sections in this example, with a length for example between 30 mm and 100 mm. They can be made in satin stitch.

[0062] In this example also, the cover 1 comprises a plurality of transverse seams 8. Indeed, the method, in this example, comprises the production of a plurality of transverse seams 8, extending perpendicular to the longitudinal axis X of the seat element 10 and passing through the fabric layer 2 and the underlayer 3, at predetermined locations. In this example, as visible, the transverse seams 8 are discontinuous, arranged at regular intervals and aligned. The transverse seams 8 form straight sections in this example, with a length for example between 30 mm and 100 mm. The locations of the transverse seams 8 are chosen to be located in a curvature zone 5, denoted 5b of the cover 1. In this example, the curvature zone 5b extends, at least partially, over a length of the transverse axis perpendicular to the longitudinal axis X of the seat element 10, parallel to the longitudinal axis X.In other words, according to this example, the curvature 5b is present over a certain length of the transverse axis Y, and extends parallel to the longitudinal axis X. Such a curvature zone 5 can be referred to as a transverse curvature zone 5b. In this example, the transverse curvature zone 5b is located at the front of the seat element 10, and is convex outwards. The three-dimensional shaping is implemented after the transverse seams 8 have been made in this example. Thus, the transverse seams 8 are made flat, in the same step as the longitudinal seams 7, for example.

[0063] The cover 1 comprises in this example at least one longitudinal curvature zone 5a and at least one transverse curvature zone 5b. Longitudinal seams 7 are present on the longitudinal curvature zone 5a, while transverse seams 8 are present on the transverse curvature zone 5b. The longitudinal seams 7 and the transverse seams 8 are of the same length in this example.

[0064] In this example also, the method comprises the production of decorative seams 9 outside the curvature zones 5a and 5b. Such decorative seams 9 make it possible, as visible in [Fig. 7], to create a desired pattern of seams on the cap 1 including in this example the longitudinal seams 7, the trans seams versales 8 and the decorative seams 9. In the illustrated example, the different seams 7, 8 or 9 together form a grid with distinct straight sections extending over several first lines parallel to each other and parallel to the longitudinal axis, including the longitudinal seams 7 and decorative seams 9, and over several second lines parallel to each other, perpendicular to the first lines, including the transverse seams 8 and decorative seams 9.

[0065] The decorative seams 9 are in this example arranged parallel to the longitudinal axis X or to the transverse axis Y and of the same length and appearance as the transverse seams 8 or the longitudinal seams 7, but they can take on another appearance and / or another orientation. In this example, the decorative seams 9 can be produced flat, before three-dimensional shaping, for example in the same step as the production of the longitudinal seams 7 and the transverse seams 8.

[0066] In the example illustrated in [Fig.8], the seat 100 comprises a seat element 10 forming a seat and a seat element 10 forming a backrest, partially visible. Each of these seat elements 10 comprises a cover made as described above.

[0067] The seat element 10 which comprises a seat base, the latter comprises, as visible, a plate 15 and, on either side of the plate 15 along the transverse axis Y perpendicular to the longitudinal axis X of the seat, two edges 16, only one of which is visible topped with padding 11 and a cover 1. In this example, the curvature zone 5 is concave towards the outside and extends between the plate 15 and each edge 16. Thus, there are at least two such curvature zones 5, which are longitudinal curvature zones 5a, on either side of the plate 15, for the formation of each edge 16 from the plate 15, even if only one is visible in [Fig.8]. The tray 15 advantageously constitutes the seating area of a user, that is to say the contact area of a user with the seat base, while the edges 16 can surround this contact area.

[0068] It should be noted that the seat element can be chosen from the group consisting of a backrest, in particular of a seat or bench, an armrest, a seat, in particular of a seat or bench, a headrest, a console, in particular central or rear, a part of these and a set of all or part of these, preferably a seat.

Claims

Claims

1. Method for manufacturing a cover (1) for a seat element (10), in particular an automobile, the cover (1) having at least one curvature zone (5, 5a, 5b), comprising: a. providing a fabric layer (2), b. providing an underlayer (3), c. assembling by superposition the fabric layer (2) and the underlayer (3) to form the cover (1), d. producing a plurality of seams passing through the fabric layer (2) and the underlayer (3), at predetermined locations, the locations of the seams being chosen to be located in said at least one curvature zone (5, 5a, 5b), e. three-dimensional shaping of the fabric layer (2) and the underlayer (3) to form said at least one curvature zone (5, 5a, 5b) of the cover (1).

2. A method according to claim 1, wherein the seams are longitudinal seams (7), extending along a longitudinal axis (X) of the seat element (10).

3. A method according to claim 2, wherein the longitudinal seams (7) are discontinuous, several longitudinal seams (7) being aligned.

4. A method according to any one of claims 1 to 3, wherein the seams are transverse seams (8), extending perpendicular to a longitudinal axis (X) of the seat element (10), the transverse seams (8) preferably being discontinuous, several transverse seams (8) being aligned.

5. Method according to any one of claims 1 to 4, comprising the provision of an adhesive film (4), the assembly comprising the bonding of the fabric layer (2) and the underlayer (3) using the adhesive film (4), in particular by hot activation of the adhesive film (4) arranged between the fabric layer (2) and the underlayer (3).

6. Method according to any one of the preceding claims, in which the three-dimensional shaping is carried out after the production of the seams, in particular longitudinal (7) and / or trans- versales (8).

7. Method according to any one of the preceding claims, in which the underlayer (3) comprises a material chosen from the group consisting of polyester wadding and foam, in particular polyurethane, the underlayer (3) having an initial thickness (E) less than or equal to 15 mm, in particular less than or equal to 10 mm.

8. A method according to any one of the preceding claims, the seat element (10) comprising padding (11), the method comprising positioning the cover (1) on the padding (11).

9. Method according to the preceding claim, in which the padding (11) comprises a solidified 3D tangle of continuous thermoplastic fibers arranged irregularly forming loops welded together.

10. Method according to any one of the preceding claims, the seat element (10) comprising a seat base comprising a plate (15) and, on either side of the plate (15) along a transverse axis (Y) perpendicular to the longitudinal axis (X), two rims (16), in which said at least one zone of curvature (5, 5a) is concave towards the outside and extends between the plate (15) and each rim (16).

11. Method according to any one of the preceding claims taken in combination with claim 8 or 9, comprising the provision of at least one fixing element (12) intended to fix the cover (1) on the padding (11), and, when making the seams, in particular longitudinal (7) and / or transverse (8), the superposition of said at least one fixing element (12) under the underlayer (3), opposite the fabric layer (2), and the sewing of said at least one fixing element (12) with the fabric layer (2) and the underlayer (3).

12. Seat element (10) of a vehicle, in particular a motor vehicle, comprising a cover (1) manufactured using the method according to any one of the preceding claims.

13. A vehicle seat element (10) according to the preceding claim, wherein the fabric layer (2) and the underlayer (3) comprise at least 95% polyester, the fabric layer (2) comprising polyester fibers woven together, and the underlayer (3) comprising non-woven polyester fibers.

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