Seat with bonded features

Abstract

Bonded features for a seat may have a first seat trim piece with a first facing edge, a second seat trim piece with a second facing edge, and a bonding material connecting the first facing edge and the second facing edge. The first facing edge and the second facing edge may be located within the bonding material.

Description

[0001] TITLE

[0002] SEAT WITH BONDED FEATURES

[0003] FIELD

[0004] The application relates to a seat with bonded features, such as for a vehicle seat.

[0005] BACKGROUND

[0006] It is well-known to cover seats, such as seats in vehicles, with trim to enclose the structural features of the seat to make the seat more comfortable and functional, to protect the seat and to enhance the aesthetics of the seat. Often, seats are covered with different types of trim materials to achieve the purposes above. Known methods, such as sewing, for attaching and joining of trim materials together limit the options for seat designers. Further, sewing is a labor and cost intensive process that contributes to the expense of the seat. And, in some applications, sewing fails to provide a watertight seam that may be needed to protect the underlying seat features.

[0007] Additionally, the various features and contours of the seat that must be covered by the trim have limited the options for current seat designers in producing an aesthetically pleasing seat while also meeting performance and cost goals using current technologies.

[0008] For example, soft materials that are often used with current seat designs cannot be successfully sewn over multiple surface angles because the materials will wrinkle. Sewing also increases the thickness of connected materials and can result in the materials bunching. Soft materials also often require a backing or core material to preserve a desired shape and provide a preferred durability. The backing / core material adds cost, thickness and weight to the design.

[0009] Sewing soft materials also require certain minimums distances, such as minimum radii and minimum spacing so that the sewing machine operator has sufficient room to orient the sewing machine onto the material and so that the operator can manipulate the materials with their fingers. In some cases, sewing requires a minimum radius of approximately 65 mm to connect two features or to add a feature. A minimum of approximately 35 mm must be kept between piping; a minimum of 27 mm is required for other features, such as patterns. These minimums associated with sewing undesirably limit, the designs, features, aesthetics and / or materials that may be used in a seat.

[0010] Sewing also has certain restrictions when it comes to tolerances. Generally, sewing can only provide a tolerance of + / - 3.5 mm between seams. Further, sewing tolerances are cumulative along the length of the sew, which can add + / - 3.5 mm per intersection resulting in large gaps for a long sew length. In some cases, the lack of tight tolerances in sewing can result in a seat trim that is offset and not symmetrical.

[0011] Sewing also disadvantageously requires the material to be punctured with a needle, which leaves holes in the trim materials, particularly at the intersection of the trim materials. Puncturing the appearance surface of a seat is fraught with issues including the creation of unsightly holes. Further, if the seat is to be water resistant or waterproof, a second step and materials to waterproof the holes must be added to the manufacturing process, which adds time and cost. Additionally, there may be tension issues with the thread in the holes resulting in wrinkling, bunching and / or breaking. Sewing processes also require adjacent trim pieces to be notched at regular intervals to assist with alignment between the trim pieces. For example, notches in the trim material every 200 mm for straight trim runs and at every 100 mm for curved trim are required to join the trim material by sewing. Notching requires special machinery as well as technicians to align the notches for a sewing process.

[0012] Further, adding a badge or label to a seat with known sewing techniques requires a backing plate, which undesirably adds thickness to the badge, makes the badge less flexible, and reduces the types of materials that can be used. In some cases, fasteners may also be required to secure sewn features together. Current sewing techniques also make alignment and registration of the badge time consuming and difficult. Additionally, if the badge is not precisely attached, there may be gaps between the badge and the trim. The gaps can result in the badge / label becoming loose and detaching.

[0013] It is also known to attach trim materials with an adhesive tape. The tape requires an additional material to be bought and stocked as well as a separate manufacturing step to apply it. The tape also has the same disadvantages of sewing with alignment of the trim materials and compounding issues with tolerances across a seat cover. The tape also requires the trim materials to be stacked, which adds thickness and produces a more pronounced material intersection. Further, in most cases, the tape cannot be adequately attached leading to the trim materials becoming disconnected.

[0014] In view of the challenges associated with joining seat trim materials it would be advantageous to use a method, product and resulting trim that permits a wide variety of trim materials to be attached to one another in new and unique ways that produced attractive, symmetrical, durable, thin, cost-effective, weatherproof, adhesive free, and highly functional seat covers.

[0015] SUMMARY

[0016] Bonded features for a seat may comprise a first seat trim piece with a first facing edge, a second seat trim piece with a second facing edge, and a bonding material connecting the first facing edge and the second facing edge. The first facing edge and the second facing edge may be located within the bonding material.

[0017] DESCRIPTION OF THE FIGURES

[0018] Fig. 1A is a schematic cut away side view of one embodiment of a portion of a tool for forming a seat;

[0019] Fig. IB is a schematic cut away side view detail from Fig. 1 A;

[0020] Fig. 1C is a schematic cut away side view detail from Fig. 1 A;

[0021] Fig. 2 is a schematic cut away side view of bonded trim pieces;

[0022] Fig. 3 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0023] Fig. 4 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0024] Fig. 5 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0025] Fig. 6 is a schematic cut away side view of an embodiment for bonding features of a seat; Fig. 7 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0026] Fig. 8 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0027] Fig. 9 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0028] Fig. 10 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0029] Fig. 11 is a schematic cut away side view of an embodiment for bonding features of a seat;

[0030] Fig. 12 is a schematic cut away side view of an embodiment of a seat with bonded features;

[0031] Fig. 12A is a schematic cut away side view detail from Fig. 12;

[0032] Fig. 12B is a schematic cut away side view detail from Fig. 12;

[0033] Fig. 12C is a schematic cut away side view detail from Fig. 12;

[0034] Fig. 12D is a schematic cut away side view detail from Fig. 12;

[0035] Fig. 12E is a schematic cut away side view detail from Fig. 12;

[0036] Fig. 12F is a schematic cut away side view detail from Fig. 12;

[0037] Fig. 13 is a schematic perspective view of a bonded feature for a seat;

[0038] Fig. 14A is a schematic perspective view of a bonded feature for a seat;

[0039] Fig. 14B is a schematic cut away side view from Fig. 14A;

[0040] Fig. 15A is a schematic perspective view of a bonded feature for a seat;

[0041] Fig. 15B is a schematic cut away side view from Fig. 15 A; Fig. 16 is a schematic perspective view of a bonded feature for a seat;

[0042] Fig. 16A is a schematic cut away side view from Fig. 16;

[0043] Fig. 17 is a schematic cut away side view of a prior art design for connecting seat trim;

[0044] Fig. 18 is a schematic perspective view of a bonded feature for a seat;

[0045] Fig. 19 is a schematic perspective view of a bonded feature for a seat;

[0046] Fig. 20 is a schematic perspective view of a bonded feature for a seat;

[0047] Fig. 21 is a schematic perspective view of a bonded feature for a seat;

[0048] Fig. 22 is a schematic view of one embodiment of a seat with bonded features;

[0049] Fig. 23 is a schematic perspective view of one embodiment of a seat with bonded features;

[0050] Fig. 23 A is a partial schematic upper cut away perspective view through Fig. 23;

[0051] Fig. 24 is a schematic perspective view of one embodiment of a seat with bonded features; and

[0052] Fig. 25 is a schematic perspective view of one embodiment of a seat with bonded features.

[0053] DETAILED DESCRIPTION

[0054] The concepts disclosed herein may assume various alternative orientations and step sequences, except where expressly specified to the contrary. Further, the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments. Hence, specific dimensions, directions or other physical characteristics relating to the disclosed embodiments are not to be considered as limiting, unless expressly stated otherwise.

[0055] Turning to Figs. 1A, IB and 1C, one embodiment of a tool 30 for forming a seat part 32 is depicted. The tool 30 may be comprised of a bowl 34 and a lid 36. While the bowl 34 is depicted under the lid 36, their positions and respective functions may be reversed. The following will describe the bowl 34 and lid 36 in the orientation depicted in Fig. 1A. In some cases, a pad 35 (shown in Fig. 2) may be included. The tool 30 may be part of an injection mold machine or process.

[0056] The bowl 34 may define a generally hollow, or negative, depression that at least partially has the desired shape of a seat or seat part 32. The lid 36 may have a positive shape that fits at least partially into or adjacent the depression in a complementary fashion. In some cases, when the lid 36 is located in or adjacent the bowl 34, a gap 38 may be created between at least some parts of the lid 36 and some parts of the bowl 34. The gap 38 may have different thicknesses, sizes, shapes and designs between the lid 36 and the bowl 34. The different sizes, shapes and designs may be useful in joining different seat parts 32, such as trim pieces, of different sizes, shapes and types and in forming outward facing surfaces 40 in and for different portions of a seat. In other embodiments, the gap 38 may be substantially constant in width and height.

[0057] The tool 30 is adapted to receive trim pieces 32 therein, such as between the bowl 34 and the lid 36. The trim pieces 32 may be of different sizes, shapes and / or thicknesses to one another. Further, the trim pieces 32 may be of different materials such as natural or synthetic leather, textiles and fabrics, composite materials, plastics, naturally occurring materials, suede, canvas, metal and / or related materials. The trim pieces 32 may be adapted to cover all or part of any portion of a seat and may extend in whole or in part in the gap 38.

[0058] The tool 30 is designed to receive one or more liquified materials in the gap(s) 38 between the lid 36 and the bowl 34 as well as at least partially between selected trim pieces 32. In some cases, there may be a multi-stage introduction of various liquified materials to provide different connections among different trim pieces 32. As noted above, the liquified material may be provided through injection molding but other processes and delivery methods may be used.

[0059] The liquified material may at least partially take on the shape defined by the gap 38 between the bowl 34 and lid 36 as well as any gaps 38 between the trim pieces 32. The liquified material is allowed to cool and when cooled it may have at least partially taken on the shape of the gaps 38, the lid 36 and / or the bowl 34. Further, it may have bonded at least in part to the trim pieces 32. By way of one example, the bowl lid 34 / 36 may be provided with textures and / or shapes that are imparted to the bonding material 42 when the material 42 is dry and set.

[0060] The bonding material 42 may be such as plastic, a rubber material and / or a silicon material. The bonding material may comprise a thermosetting plastic or a thermoplastic. A thermosetting plastic, also known as a thermoset, a thermoset polymer and / or a thermosetting resin, may be such as a polymer that is irreversibly hardened by heat.

[0061] In some cases, the starting material for a thermoset is a liquid or soft solid. Heat provides energy for covalent bond formation, cross-linking the polymer subunits and curing / hardening the plastic. Sometimes the heat is applied externally, but it may come from the chemical reaction of mixing ingredients. Adding pressure, a catalyst, and / or a hardener can increase the curing rate. Once cured, a thermosetting plastic cannot be remelted, so it is formed into its final shape by injection molding, extrusion molding, compression molding, spin casting, etc.

[0062] In one embodiment the material 42 may be polyurethane, silicone, vulcanized rubber and / or polyoxybenzylmethylenglycolanhydride also known as Bakelite. Depending on the need or application, the material 42 may be opaque, transparent or entire light blocking when it is dry and set. One or more colors or dye or may be added to the material 42 so that a color or colors extends through the material 42 in whole or part.

[0063] Turning now to Figs. IB, 1C and 2 embodiments of a cross-section of bonded trim pieces 32 are schematically depicted. It may be desirable to join the trim pieces 32 together at their facing edges 44. The facing edges 44 may be such as the perimeter edges of the trim pieces 32. In some cases, when they are joined by the bonding material 42, the facing edges 44 do not overlap with one another in an appreciable way, such as having them vertically stacked on one another which can result in an increased thickness of the trim pieces 32.

[0064] The facing edges 44 may be at least partially located in a groove, or depression 46, of the tool 30, such as the bowl 34. While the bowl 34 is noted as having the groove 46, one, some or all of the grooves 46 may also be located in the lid 36. It may also be possible for the lid 36 and bowl 34 to have the grooves 46.

[0065] Continuing with the example where the groove 46 is located in the bowl 34, in some cases, the facing edges 44 may be at least partially angled toward a bottom 48 of the groove 46; the facing edges 44 do not need to be parallel one another. Further, the facing edges 44 may at least partially abut one another, or there may be a gap between the facing edges 44. In other cases, as shown in Fig. 12E, the facing edges 44 may be generally coplanar with one another. In this case or in others, no groove is required; the bonding material 42 may be simply located between the facing edges 44.

[0066] At least the facing edges 44 are encapsulated in the bonding material 42. The material 42 may be sufficient to secure the facing edges 44 therein in a permanent or semi-permanent fashion so that the edges 44 are bonded. In the depicted embodiment, the material 42 is shown as substantially filling the groove 46 in which the facing edges 44 are located.

[0067] In some cases, the material 42 does not extend above the outward facing surfaces 40 of the pieces 32. Instead, it may be preferred that the bonding material 42 remains below the outward facing surfaces 40 of the material 42.

[0068] In other cases, such as shown in Figs. 12A, 12B and / or 12E, at least a portion of the material 42 may extend above the outward facing surfaces 40 of the pieces 32 such that it becomes part of the A-surface 50 of the seat. The A-surface 50 of the seat is the outermost surface of the seat which an occupant has direct contact with. In most cases, the A-surface is not substantially blocked, covered, or occluded by another seat surface or structure. Other situations may locate the bonding material 42 substantially coplanar with the surfaces 40 of the joined trim pieces 32 so as to provide a substantially continuous outward facing A-surface 50. In any of the above-mentioned cases, the bonding material 42 may contribute to forming an A-surface 50 of the bonded trim pieces 32. Fig. 2 depicts one situation where a plurality of generally equally sized and shaped trim intersections 52 may extend across a cushion material 54, each filled with bonding material 42 and each joining facing edges 44 of trim pieces 32. However, based on the above, it may be readily appreciated that the trim intersections 52 and thus the locations, types, sizes and shapes of the intersections 52 may vary.

[0069] Fig. 3 depicts one embodiment for securing facing edges 44 located within a bonding material 42 all of which may be located in the facing groove 46 of a tool 30 or within a groove 56 in a seat, such as in cushion material 54 of a seat. The facing edges 44 may extend into the groove 56 so that they are located below an upper edge 58 of the groove 56. Further, outward facing surfaces 40 of the bonding material 42 may also be located below the upper edge 58 of the groove 56. The facing edges 44 may extend into the bonding material 42 so that they are encased in and surrounded by the bonding material 42 to fix the edges 44 to the bonding material 42. The facing edges 44 may extend through an upper surface 60 of bonding material 42, but the edges 44 may be located in sides 62 of the bonding material 42 as well. The bonding material 42 may extend continuously between the trim pieces 32 to provide a continuous joining surface between the two trim pieces 32. From this, it can be appreciated that the material 42 thus forms part of the outward facing surfaces 40 of the joined trim pieces 32.

[0070] The bonding material 42 is depicted as having a generally square cross-section, but other shapes and sizes may be permissible as suggested in the other figures. By way of one example, the bonding material 42 may be tapered from its upper surface 60 as it extends downwardly. This may provide the bonding material 42 with a triangular or cone shape. It may be desirable to secure the facing edges 44 and / or the bonding material 42 to a listing 64, such as a listing pocket. The listing 64 may be a fleece or other woven or non-woven materials. In one example depicted in Fig. 3, a first end portion 66 of the listing 64 may be connected to the bonding material 42. The listing 64 may be such as a length of fabric, or cord. The listing 64 may be attached to a side 62, or any surface, of the bonding material 42 such as by sewing, adhesive, mechanical connectors, bonding material extension or other permissible connection methods. Fig. 3 shows one case where stitching 68 may be used at the point of contact of the listing 64 and the bonding material 42. In other cases, stitching 68 may extend a greater extent, including entirely, about the bonding material 42. In another embodiment, the listing 64 may be directly bonded with the material 42 so that stitching 68 or other attachment is not required. The listing 64 may be attached to the bonding material 42 at or below the connection of the facing edges 44.

[0071] A second end portion 70 of the listing 64 may be attached to an attachment device 72, such as a hog ring, located at a bottom portion 74 of the groove 56. In such a case, the listing 64 may extend at an angle between the side 62 of the bonding material 42 and the attachment device 72 located substantially directly below the bonding material 42.

[0072] Fig. 4 depicts a variation on Fig. 3, wherein the listing 64 may be at least partially embedded in the bonding material 42. In this instance the listing 64 may extend into the bonding material 42 through a lower surface 76 of the bonding material 42 in a substantially transverse manner to the lower surface 76. Fig. 4 shows the listing 64 extending into the bonding material 42 to a particular degree and in a location, but other degrees of extension and location into the bonding material 42 may be used. In another variation the listing 64 may be co-formed, co-injected or co-extruded with the bonding material 42 such that the two are unitary, one piece and integrally formed.

[0073] Fig. 5 depicts yet another variation wherein a U-shaped listing 64 is provided. A lowermost portion 80 of the listing 64 may be secured to, such as through, the attachment device 72, which may be a hog ring, at the bottom portion 74 of the groove 56. Two upwardly extending end portions 82 of the listing 64 may be secured directly to the trim pieces 32. Thus, the listing 64 may extend on either side 62 of the bonding material 42. In one embodiment, the end portions 82 of the listing 64 may be connected to the trim pieces 32, such as through one or more sewn stitches 68. While sewing is mentioned, other attachment methods, such as with adhesive, mechanical fasteners, and / or welding, are also permissible.

[0074] Fig. 5 depicts the stitches 68 deforming the trim pieces 32; the deformation is exaggerated in the figure for illustration purposes. In most cases, outward facing surfaces 40 of the trim pieces 32 and the bonding material 42 may be relatively uniform and continuous. In some cases, the outward facing surfaces 40 and the upper surface 60 of the bonding material 42 may be substantially co-planar.

[0075] Fig. 6 depicts a variation wherein the two end portions 82 of the listing 64 may be directly attached to the bonding material 42. As shown in the figure, the two end portions 82 of the listing 64 may be directly attached, or bonded, to the sides 62 of the bonding material 42 such as through an adhesive, welding, mechanical fasteners, or the like. In such a case, the end portions 82 of the listing 64 may directly overlap, such as enclose, the bonding material 42 at least in part. Fig. 7 schematically depicts another embodiment for securing trim pieces 32 located within a bonding material 42 within a groove 56. The trim pieces 32, groove 56, and bonding material 42 may be as noted above. In this instance a listing 64 may have a first end portion 66 attached to the bonding material 42 as described above. A second end portion 70 of the listing 64 may be connected to loop tape 84. The loop tape 84 may form one part of a hook and loop fastener system 86. The second part of the system 86, such as the hooks 88, may be secured to the bottom portion 74 of the groove 56. The two parts 84, 88 of the system 86 may be connected to one another to secure the trim pieces 32 and the bonding material 42 within the groove 56.

[0076] Fig. 8 depicts a variation on the embodiment in Fig. 7 where the loop tape 84 is connected, such as stitched 68, at least partially about the bonding material 42. By way of the example in Fig. 8, the loop tape 84 may extend from one side 62 of the bonding material 42 to another side 62 of the bonding material 42 by extending below the lower surface 76 of the bonding material 42. The loop tape 84 may be suspended below the bonding material 42 and extend in a substantially continuous fashion from one side 62 of the bonding material 42 to another side 62 of the bonding material 42. A gap 90 may exist between the bottom of the bonding material 42 and the loop tape 84. End portions of the loop tape 84 may be attached to the sides 62 of the bonding material 42 such as through sewing stitches 68 or other attachment structures. The loop tape 84 may have one portion of a hook and loop fastener system 86 (such as the loop portion) facing away from bonding material 42 at least partially along its length. As in the other cases, the attachment of the loop tape 84 and its attachment to the bonding material may be located below the attachment of the trim pieces 32 to the bonding material 42. As shown in the figure, hooks, which may be in the form of hook tape 88, which may be the other part of the hook and loop fastener system 86, may be located within the groove 56. The hook tape 88 is shown in one portion of the groove 56 extending for a predetermined length but other locations and lengths, including portions separated by gaps, may be used.

[0077] Fig. 9 depicts a variation of Fig. 8. In this case, the loop tape 84 may be directly bonded to the bonding material 42 such as through an adhesive. The direct attachment of the loop tape to the bonding material may eliminate the gap 90 between the two shown in Fig- 8.

[0078] Fig. 10 depicts another embodiment for securing trim pieces 32 located within a bonding material 42 within a groove 56. The trim pieces 32, groove 56 and bonding material 42 may be as noted above. A listing 64, which may be coextruded and / or coinjected with the bonding material 42 may be secured to at least one side 62 of the bonding material 42. In the depicted embodiment, an upper portion of the listing 64 may be attached, such as through sewn stitches 68, to a lower portion 92 of the bonding materials 42. While stitches 68 are mentioned, other attachments such as adhesives, welding and / or mechanical attachments may be used. These may be in addition to, or separate from, the stitches 68.

[0079] The listing 64 may extend downwardly from the bonding material into the groove. More particularly, first and second side parts 94, 96 of the listing 64 extending from the two sides 62 of the bonding material 42 may angle toward one another as they approach the bottom portion 74 of the groove 56. In some cases, the two parts 94, 96 of the listing 64 may merge to a combined downwardly directed structure that may be oriented generally transverse the groove bottom 48.

[0080] Lower portions of the two listing parts 94, 96 may be attached together. Various materials may be used to attach the listing parts 94, 96 together. In one embodiment, a portion of bonding material 42 may be used to attach the listing parts 94, 96 together. The bonding material may be shaped so that it creates an attachment portion 98. It may be preferred to have the attachment portion 98 at least partially enclose and / or encapsulate the two parts 94, 96 of the listing 64 in a secure manner such that they cannot be easily removed therefrom.

[0081] In another case, the listing 64 is removed and the bonding material 42 securing the trim pieces 32 is extended downwardly to create a one piece, unitary and integrally formed attachment portion 98, as shown in Fig. 11. As shown in Fig. 11, the attachment portion 98 may generally have the form of an arrowhead or chevron, but other shapes are permissible. Such other shapes may be partially or wholly circular or polygonal.

[0082] As shown in Figs. 10 and 11, the attachment portion 98 may be located within a clip 100 attached, or connected, to the bottom portion 74 of the groove 56. The clip 100 may have a retention portion 102 located in the bottom of the groove. The retention portion 102 may have two upstanding arms 104. The arms 104 may be separated from one another by a gap 106. At least the arms 104 may be formed of an elastic material so that they can be selectively moved apart to receive the attachment portion 98 therein and then the arms 104 move back into their original position to at least partially close over the attachment portion 98. Barbs 108, or at least portions that extend toward one another from the arms 104, may be attached to the arms 104. The barbs 108 may be one piece, unitary and integrally formed with the arms 104. The barbs 108 function to reduce the gap 106 size and help to retain the attachment portion 98.

[0083] The attachment portion 98 may be located within the gap 106 defined by the arms 104 with the listing 64 extending upwardly between the barbs 108 and outward from the clip 100. The arms 104 and barbs 108 help retain the attachment portion 98 in the gap of the clip 100.

[0084] The clip 100 may also have a base portion 110 that is located within the groove 56 or outside of the groove 56. The embodiment depicted in Figs. 10 and 11 shows the base portion 110 outside of the groove 56 (such as beneath it) with the arms 104 extending upwardly from the base portion 110 within the groove 56. The base portion 110 may have a wider dimension than the arms 104 to provide a large surface that can be secured to other seat parts or material. From the above, it can be appreciated that the trim pieces 32 are secured to the groove 56 and / or clip 100.

[0085] In the example depicted in Fig. 11, the bonding material 42 may have an upper portion 112 in which the trim pieces 32 may be attached, such as embedded, as previously described. In some embodiments, the upper portion 112 may transition to a body portion 114. The body portion 114, as well as the upper portion 112, may be tapered, or cone shaped. In the exemplary embodiment, the upper portion 112 tapers to the body portion 114 in a smooth, cone-shaped fashion. The body portion 114 extends downward into the groove 56 and may transition to the attachment portion 98. The upper portion 112, the body portion 114 and the attachment portion 98 may be one piece, unitary and integrally formed.

[0086] Turning now to Fig. 12, one embodiment wherein the above-mentioned bonding material 42 may be used to connect an information piece 116, such as a badge / label with one or more trim pieces 32 and a pass-through 118 with one or more trim pieces 32 in a seat 120 are depicted. The trim pieces 32 and bonding material 42 may be located in a groove 56 as noted above, or they may comprise the outward facing surfaces 40 of the seat 120 as shown in the figure.

[0087] Looking now at Figs. 12 and 12A-12C, the information piece 116 may be comprised of a central body portion 122 with a perimeter portion 124. As shown in Figs. 12A-12C, at least a portion of the perimeter portion 124 may be connected to the bonding material 42 in the same or similar manner as described above. As such, the perimeter portion 124 may be directly embedded and encased in the bonding material 42. Fig. 12A shows that the bonding material 42 may have a generally convex shape, while Fig. 12B shows the bonding material 42 may have a generally concave shape. The concave / convex shapes are not limited to information pieces 116 but may also be used in any of the applications noted herein.

[0088] Figs. 12C, 12E and 12F depict the bonding material 42 connected to and extending continuously about the perimeter portion 124 of the information piece 1 16 to secure it to the trim pieces 32. As shown in Fig. 12E, the bonding material 42 may be generally coplanar with an upper surface 126 of the information piece 116 and the outward facing surfaces 40 of the trim pieces 32. The information piece 116, trim pieces 32 and bonding material 42 may all reside in direct facing contact with an upper surface 128 of cushioning material 54 for the seat 120. The information piece 116 does not require sewing, support material, such a backing plate on the underside of the piece 116, and / or mechanical fasteners, in order to for it to be robustly attached it to the trim pieces 32. As such the piece 116 is permanently connected to the trim pieces 32 without any gaps in a generally coplanar (thus reducing thickness), as well as smooth and continuous fashion.

[0089] From Fig 12C, it can be appreciated that a light source 125 may be located adjacent the bonding material 42 and / or the information piece 116. The light source 125 may at least partially and / or selectively illuminate the bonding material 42 and / or the information piece 116.

[0090] Figs. 12 and 12D depict one embodiment of the pass-through 118 in a seat portion, which may be a seat back. The pass-through 118 may be comprised of a tube or pipe, which does not need to be round or oval. Instead, in this embodiment, the pass- through 118 may have a generally square or rectangular shape. The pass-through 118 may extend entirely through the seat 120, such as from a front surface to a rear surface. In other applications, the pass-through 118 may connect two or more portions of seat 120 and the pass-through 118 may dead end into a portion of the seat 120; as such the pass- through 118 only needs to pass through at least one layer of the seat 120.

[0091] The bonding material 42 may be connected to and extend continuously about a perimeter 130 of the pass-through 118 to secure it to the trim piece 32. The perimeter 130 may be directly embedded into and encased within the bonding material 42. The bonding material 42 may be generally coplanar with an upper surface 132, or entrance, of the pass-through 1 18 and outward facing surface 40 of the trim piece 32. The entrance of the pass-through 118, the trim piece 32 and the bonding material 42 may all reside in direct facing contact with the upper surface 128 of the cushioning material 54 for the seat 120. The pass-through 118 does not require sewing, other support structures and / or mechanical fasteners to robustly attach it to the trim piece 32. As such the entrance of the pass through 118 is permanently connected to the trim piece 32 without any gaps in a generally coplanar, as well as smooth and continuous fashion.

[0092] In some cases, the pass-through 118 may have a body portion 134 that extends through the at least one seat layer to a second surface 136 which may have trim pieces 32. The pass-through 118 may also have an end portion 138 that may contact the second surface 136. The end portion 138 may be bonded to the second surface 136 with the bonding material 42 or it may be attached thereto such as clipped or hooked.

[0093] Turning now to Figs. 13 and 14A-14B, an embodiment depicting the use of the bonding material 42 to create and / or connect accent pieces 140, such as pieces 140 of different sizes, shapes, materials, colors, and / or textures, to one or more trim pieces 32 is provided. In Fig 13, bonding material 42 is shaped to create an accent piece on a corner of a seat, such as a front edge of seatback, but the accent piece 140 may be located in other locations on the seat 120.

[0094] Fig. 13 depicts the use of a single, primary accent piece 140 while Figs. 14A and 14B depict the use of primary 140 and secondary 142 accent pieces. The accent piece or pieces 140, 142 may be constructed in whole or in part with the bonding material 42. From Fig. 14B one use and attachment of the accent piece or pieces 140, 142 can be understood. The trim piece 32 may be directly embedded into the primary accent piece 140 by extending through a side wall 144 of the primary accent piece 140, such as noted above. In some cases, the secondary accent piece 142, which may be a different size, color and / or shape than the primary accent piece 140, may be associated with the primary accent piece 140. In the depicted embodiment, the primary accent piece 140 may at least partially surround the secondary accent piece 142. Thus, perimeter edges 146 of the secondary accent piece 142 may be directly connected with, such as embedded in or formed with, inside perimeter edges 148 of the primary accent piece 140. The result may be bonding material 42 formed as an accent piece 140, 142 that is largely coplanar with the surrounding trim pieces 32. The accent pieces 140, 142 may reside in direct facing contact with an upper surface 128 of cushioning material 54 for the seat 120. The accent pieces 140, 142 do not require sewing, support material, such a backing plate on the underside of the accent pieces 140, 142, and / or mechanical fasteners, in order for the accent pieces 140, 142 to be robustly attached to the trim piece 32. As such the accent pieces 140, 142 are permanently connected to the trim piece 32 without any gaps in a generally coplanar (thus reducing thickness), as well as smooth and continuous fashion.

[0095] Turning now to Figs. 15 A, 15B and 18, another application of the bonding material 42 to connect for seat trim pieces 32 is depicted. In this instance, the bonding material 42 is formed as trim piping and joins trim pieces 32 together where the trim pieces 32 may have relatively sharp angles between them. The bonding material 42 may join the trim pieces 32 together as described above, and which can be appreciated from Fig. 15B. The piping may have a relative small width dimension that may be about the same as its height dimension. In some cases, the bonding material 42 may have a round cross-section. The bonding material 42 is particularly advantageous as used in angular piping because it creates a permanent robust bond between the trim pieces 32, no additional materials are required to create or support the bond, it is pliable so its shape can be easily controlled, and it is soft so it will not irritate a seat occupant. Importantly also is the ability of the material 42 to be contorted into a variety of sizes, shapes and angles. Indeed, unlike when trim pieces 32 are stitched together, the bonding material 42 does not have a minimum radius (e.g. at least a radius of 65 mm) or minimum distance (e.g, at least 35 mm) that must be used to prevent the wrinkles in the trim pieces 32 or the bonding material 42. Instead, sharp angles and corners 149 may be used with the bonding material 42 with a minimum distance between piping being approximately 10 mm. As such, the bonding material 42 allows for trim pieces 32 intersections comprising two comers, three corners or four comers of joined adjacent trim pieces 32, as shown in Fig. 18.

[0096] Fig. 16 depicts another embodiment utilizing the bonding material 42 described above. In this case, the bonding material 42 may be used to permanently connect a plurality trim pieces 32 of various shapes and sizes where the bonding material 42 may extend at various angles, shapes and sizes between the trim pieces 32. Fig. 16 depicts the bonding material 32 as trim piping. The trim piping as well as the trim pieces 32 may have relatively sharp angles between them. For example, the angles may be such as acute angles. The acute angles may be a low as less than 10 degrees.

[0097] Fig. 16 depicts the advantages the bonding material 42 has over sewing in that there are no size constraints for the trim pieces 32, it reduces / eliminates dependency on sewing machine operators and the risks they must take to sew tight areas while protecting their fingers, as well as the other advantages noted above. There being no constraints on trim piece 32 sizes that can be joined, the present technology permits trim pieces 32 to be joined that are far smaller than sewing will permit, which is usually limited to trim pieces 32 no smaller than 27 mm in width. Fig. 16 depicts trim pieces 32 having a width less than 27 mm in width that are joined by the bonding material 42.

[0098] From the foregoing figures as well as those that follow, it can be readily appreciated that trim pieces 32 may be joined with the bonding material without sewing. As such, the trim pieces 32, particularly at their facing edges 44, may be free of damage, such as holes, from a sewing process. Thus, the outward facing surfaces 40 may be free from sewing needle apertures thus giving them a continuous, smooth and finished appearance advantageous over the sewing art.

[0099] Fig. 16A depicts a cross-section showing the bonding material 42 joining two trim pieces 32. The cross-section may be such as through bonding material 42 used to create the accent piece as shown in Fig. 13. The upper surface 60 of the bonding material 42 may be generally coplanar with at least in part outward facing surfaces 40 of the trim pieces 32. As such, at least across the upper surface 60 of the bonding material 42 and the outward facing surfaces 40 of the joined trim pieces 32, there are no wrinkles or pleats. A lower surface 76 of the bonding material 42 and lower surfaces 150 of the trim pieces 32 may all reside in direct facing contact with the upper surface 128 of cushioning material 54 for the seat 120. The bonding material 42 does not require sewing, support material, such a backing plate on the underside of the bonding material, and / or mechanical fasteners, in order for it to be robustly attached to the trim pieces 32. As such the bonding material 42 is permanently connected to the trim pieces 32 without any gaps in a generally coplanar, as well as smooth and continuous fashion. The connection between the bonding material 42 and the trim pieces 32 is also free of holes in the trim pieces 32 or the bonding material 42, which is required with sewing. Further, the bonding material 42 does not require the trim pieces 32 to be notched to ensure proper alignment of the trim pieces 32.

[0100] Fig. 17 depicts one embodiment of a prior art trim 152 to trim 152 connection made by sewing 154. The connection would have required a join seam 156 that requires stack up of trim 152 as well as lamination 158 and pad 160 that are folded back onto themselves and then sewn together. This old technology results in trim 152, lamination 158 and pad 160 bunching at the connection, which can create bulges, assuming the trim 152 size is large enough to join at all. The significant reduction in thickness of the prior art connection compared to the thickness of the bonding material connection is clear.

[0101] Figures 19 and 20 depict another application of the bonding material 42 for seat features. These figures depict that the bonding material 42 may be any size and shape and contain images or text, herein designated information 162. The information 162 may be molded into the bonding material 42 while it is in the mold as described above. In one example information may be formed into the upper, outer surface 60 of the bonding material 42. The information may also be recessed or extended from the upper, outer surface 60. The bonding material 42 may be secured to surrounding or adjacent trim pieces 32 as shown and described above. For example, in Fig. 19 the bonding material 42 may surround the information 162 and be secured to a perimeter portion 164 thereof.

[0102] Providing the information 162 via the bonding material 42 is advantageous over the prior art because in the past the information was provided on separate buttons or tags that needed to be stocked, supplied, etc. The buttons or tags were often intentionally or unintentionally removed because they extended from the seat surface. The prior art buttons / tags may be uncomfortable to come in contact with or been unsightly to the occupants. Further, the buttons and tags required at least 17 mm of spacing from the button / tag to a seam so they could be attached by sewing. The bonding material 42 permits the information 162 to be directly incorporated into the trim pieces 32, has no limits on the size or location, and permanently affixes the information to the seat trim material.

[0103] Fig. 21 depicts another use of the bonding material 42 wherein it is used to create another seat feature. In this case, the seat feature may be an ISOFix feature. ISOFix is the international standard for attachment points for child safety seats in vehicles, such as passenger cars. The ISOfix feature may be a cup 166 with surrounding, upstanding side walls 168 connected to and by a lower base portion 170. The walls 168 and base 170 may be curvilinear but other shapes are permissible. A slot 172 may extend through at least a portion of the base 170 and the walls 168 to accommodate a latch bar. The ISOfix feature may be entirely formed of the bonding material 42, such as in a mold as described above. Thus, the ISOfix feature may be substantially continuous, unitary, one piece and integrally formed. A surrounding, perimeter edge 174 of the cup 166 may be directly bonded to the surrounding trim pieces 32 as described above to secure the cup to the trim pieces 32.

[0104] In the prior art, the ISOfix feature comprised a first cup piece and then a second trim piece to extend around the cup piece. The second trim piece needed to overlap the first cup piece by 10-15 mm which increased the size of the feature. The second trim piece typically is not attached to the first trim piece, so the two pieces often separate from one another creating loose parts and unsightly gaps.

[0105] Fig. 22 depicts another advantage of utilizing the bonding material 42 to connect seat trim pieces 32 together across large surfaces including across a seating surface. Namely, the bonding material 42 can precisely connect a plurality of trim pieces 32 together without regard to size, shape and / or angle of the trim pieces 32 with little to no consideration for tolerance between individual pieces or tolerance stack up across the pieces. The result may be a completely trimmed seat surface that is vertically symmetrical along an axis 176 from side to side of the seat as shown in Fig. 22. By completely trimmed surface, in one example, it may mean that a front seat surface (the surface facing an occupant) that extends across the seat back, that is comprised of a plurality of trim pieces 32 as well as the bonding material 42 that connects them, is vertically symmetrical from a bottom edge to a top edge of the seat back. In some cases, the headrest is not a separate piece (as shown in Fig. 22), but it is integrated into the seatback. In such a case, the trim piece(s) comprising the headrest may also be vertically symmetrical with the rest of the seat back.

[0106] The bonding material 42 described herein advantageously j oins trim pieces 32 without any misalignment of the trim pieces 32. Instead, the trim pieces 32 are aligned at a predetermined distance (which may be known, fixed distances) across a backrest or seat surface, and they are joined without deviation from those distances across the entire backrest or seat surface. In the sewing prior art + / - 4 mm tolerances are found, thus resulting in misaligned seams and a non-symmetrical alignment of the trim across various aspects of the seat. Figs. 23 and 23 A depict another embodiment wherein trim pieces 23 comprising a front portion 178 and trim pieces 23 for a rear portion 180 of a seat 120, such as for a seat back 182, are connected together with bonding material 42. It may be that the front portion 178 is designed to substantially cover a front side 184 of the seat back 182 and a rear portion 180 is designed to substantially cover a rear side 186 of the seat back 182. Bonding material 42 may join the front and rear portions 178, 180 substantially along their intersections (e.g., one side and opposite side). The bonding material 42 may be substantially continuous about the intersection. In some cases, side panels 188 may extend between the front portion 178 and the rear portion 180 and bonding material 42 may connect the side panels 188 with the front and rear portions 178, 180. The bonded front and rear portions 178, 180 may create a receptacle for cushion material 54, such as foam. As may be appreciated from Fig. 23A, the cushion material 54 may be located between the front portion 178 and the rear portion 180 to create a seat back 182 or other seat part. In some cases, a frame 190 may be located between the portions 178, 180 to provide support and shape for the seat back 182.

[0107] Utilizing one or more of the concepts above, seats 120 of various sites and shapes and comprised of various trim pieces 32 may be created as shown in Figs. 24-25. From these figures, it can be appreciated that trim pieces 32 having various A-surfaces 50, including various textures, colors, graining, patterns, sizes, shapes and designs may be integrated into the seat 120 regardless of their location on the seat base, seat back and / or headrest. The bonding material 42 described herein may be used to join the various trim pieces 32 together. Further, the bonding material 42 may be colored, embossed with graining and / or patterns, and / or developed into various size and shapes to fit the needs of the application and / or to create certain aesthetics.

[0108] By way of just one example, and to expand on the concepts introduced above, the bonding material 42 may be provided with a texture to provide the appearance of graining of various types. Further yet, the texture may be adapted to provide the appearance of leather graining. The bonding material 42 may also be colored such that it may be complementary to any adjacent seating surface or trim. When used with leather, or leatherdike, trim or seating surfaces, the textured and colored bonding material 42 may be matched in a complementary fashion to seamlessly blend and / or provide a continuous surface.

[0109] Texturing may also include adding a stitching or thread-like appearance in the bonding material 42. It may also include adding other patterns as well as logos and / or images in whole or in part to the bonding material 42.

[0110] Further, the concepts herein permit the various trim pieces 32 to be located at any orientation with respect to one another thus permitting raised and recessed surfaces. As noted above, a light source may also be used with or in the bonding material 42 to illuminate the bonding material 42, the trim pieces 32 and / or the surroundings and associated structures.

[0111] From the above, it can be appreciated that the concepts disclosed herein may be used to create the A surfaces 50 on the seat 120 that are at least partially injected molded.

[0112] In view of the above, it may be appreciated that bonded features for a seat may comprise a first seat trim piece with a first facing edge, a second seat trim piece with a second facing edge, and a bonding material connecting the first facing edge and the second facing edge.

[0113] In some cases, the first facing edge and the second facing edge may be located within the bonding material.

[0114] In some cases, the bonding material may comprise a thermoset plastic.

[0115] In some cases, the first facing edge and the second facing edge do not vertically overlap with one another.

[0116] In some cases, the first facing edge and the second facing edge each have upper and lower surfaces and an end surface and at least a portion of each upper surface, each lower surface and each end surface may be encased within the bonding material.

[0117] In some cases, the bonding material may have a color blended within it.

[0118] In some cases, the bonding material may be configured to transmit light.

[0119] In some cases, in a first condition the bonding material may be a liquid and in a second condition the bonding material may be solidified.

[0120] In some cases, in the second condition, the bonding material may bond the first and second facing edges.

[0121] In some cases, a listing may connect the bonding material to a base of a groove in a seat component.

[0122] In some cases, the bonding material may extend from the first and second trim pieces to a base of a groove in a seat component.

[0123] In some cases, an angle between the first seat trim piece and the second seat trim piece may be less than 10 degrees.

[0124] In some cases, the bonding material may connect a plurality of trim pieces wherein the bonding material between trim pieces may be 10 mm apart. In some cases, at least one of the first seat trim piece or the second seat trim piece may be less than 27 mm in width.

[0125] In some cases, there may be no intervening structures between the bonding material, the first seat trim piece, the second seat trim piece and cushioning material beneath them all.

[0126] In some cases, there may be no sewing needle apertures present in the facing edges of the first seat trim piece, the second seat trim piece and the bonding material.

[0127] In some cases, the thermoset plastic may be a polyurethane.

[0128] In another embodiment, the first facing edge and the second facing edge may be encased within the bonding material.

[0129] In another embodiment, the first and second facing edges may be connected without adhesive.

[0130] In some cases, the bonding material comprises a polyurethane.

[0131] In another embodiment, a seat may have the bonded features as noted herein.

[0132] In another embodiment, a seat trim cover for a seat may have the bonded features noted herein.

[0133] In another embodiment, a seat trim cover may be created by the process that may comprise providing a first seat trim piece with a first facing edge, providing a second seat trim piece with a second facing edge, and where the first facing edge and the second facing edge may be attached in a bonding material.

[0134] In another embodiment, a method for bonding features for a seat may comprise providing a first seat trim piece with a first facing edge, providing a second seat trim piece with a second facing edge, where the first facing edge and the second facing edge may be located in a bonding material comprised of a plastic to connect the edges.

[0135] In accordance with the provisions of the patent statutes, the present device has been described in what is considered to represent its preferred embodiments. However, it should be noted that the device can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.

Claims

What is claimed is:

1. Bonded features for a seat, comprising: a first seat trim piece with a first facing edge, a second seat trim piece with a second facing edge, and a bonding material connecting the first facing edge and the second facing edge.

2. The bonded features of claim 1, wherein the first facing edge and the second facing edge are located within the bonding material.

3. The bonded features of claim 1, wherein the bonding material comprises a thermoset plastic.

4. The bonded features of claim 1, wherein the first facing edge and the second facing edge do not vertically overlap with one another.

5. The bonded features of claim 1, wherein the first facing edge and the second facing edge each have upper and lower surfaces and an end surface and at least a portion of each upper surface, each lower surface and each end surface are encased within the bonding material.

6. The bonded features of claim 1, wherein the bonding material has a color blended within it.

7. The bonded features of claim 1, wherein the bonding material is configured to transmit light.

8. The bonded features of claim 1, wherein in a first condition the bonding material is liquid and in a second condition the bonding material is solidified.

9. The bonded features of claim 8, wherein in the second condition, the bonding material bonds the first and second facing edges.

10. The bonded features of claim 1, wherein a listing connects the bonding material to a base of a groove in a seat component.

11. The bonded features of claim 1, wherein the bonding material extends from the first and second trim pieces to a base of a groove in a seat component.

12. The bonded features of claim 1, wherein an angle between the first seat trim piece and the second seat trim piece is less than 10 degrees.

13. The bonded features of claim 1, wherein the bonding material connects a plurality of trim pieces wherein the bonding material between trim pieces is 10 mm apart.

14. The bonded features of claim 1, wherein at least one of the first seat trim piece or the second seat trim piece is less than 27 mm in width.

15. The bonded features of claim 1, wherein there are no intervening structures between the bonding material, the first seat trim piece, the second seat trim piece and cushioning material beneath them all.

16. The bonded features of claim 1, wherein no sewing needle apertures are present in the facing edges of the first seat trim piece, the second seat trim piece and the bonding material.

17. The bonded features of claim 3, wherein the thermoset plastic is a polyurethane.

18. The bonded features of claim 1, wherein the first and second facing edges are connected without adhesive.

19. A seat with the bonded features of claim 1.

20. A seat trim cover for a seat with the bonded features of claim 1.

21. Bonded features for a seat, comprising: a first seat trim piece with a first facing edge, a second seat trim piece with a second facing edge, and a bonding material connecting the first facing edge and the second facing edge, wherein the first facing edge and the second facing edge are encased within the bonding material, wherein the bonding material comprises a polyurethane.

22. A seat trim cover created by the process of providing a first seat trim piece with a first facing edge, providing a second seat trim piece with a second facing edge, and attaching the first facing edge and the second facing edge in a bonding material.

23. A method for bonding features for a seat, comprising: providing a first seat trim piece with a first facing edge, providing a second seat trim piece with a second facing edge, and locating the first facing edge and the second facing edge in a bonding material comprised of a plastic to connect the edges.

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