Method for forming motor vehicle seat uphosltery

• US 10,137,615 B2
• Filed: 08/01/2014
• Issued: 11/27/2018
• Est. Priority Date: 08/02/2013
• Status: Active Grant

• Current Assignee: Faurecia Sieges D'Automobile (Stellantis NV)
• Original Assignee: Faurecia Sieges D'Automobile (Stellantis NV)
• Inventors: Thomas, Julie, Etienne, Fabrice, Lemarchand, Robert
• Primary Examiner(s): Yi, Stella K
• Application Number:
  US14/907,950
• Publication Number:
  US 20160167260A1
• Time in Patent Office: 1,579 Days
• CPC Class Codes: B29C 31/008 Handling preformed parts, e.g. inserts B29C37/001 takes precedence; for injection moulding B29C45/14008; for blow moulding B29C49/2408; for thermoforming B29C51/165
• CPC Class Codes: B29C 43/183 the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/569 Shaping and joining components with different densities or hardness
• CPC Class Codes: B29D 99/0092 Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/256 Sheets, plates, blanks or films
• CPC Class Codes: B29K 2623/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2601/00 Upholstery
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/15 with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B60N 2/5833 by hook-and-loop type fasteners
• CPC Class Codes: B60N 2/5891 : characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for

Abstract

A method for producing a cover element for upholstery of a motor vehicle seat element, includes at least one layer of foam and a cap made at least from a covering material. The forming of the cover element includes the steps of: placing the cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix; holding the cap pressed against the matrix by suction; placing the at least one layer of foam against a back of the covering material; and applying a forming punch defining a rear face of the cover element.

Claims

1. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:

placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;

maintaining the cap pressed against the matrix by suction;

placing said at least one layer of foam against a back of said covering material; and

applying a forming punch defining a rear surface of the cover element;

wherein a foam thickness of the at least one layer of foam is obtained by spraying foam on a substrate supported by a suction plate.

2. The method of claim 1, wherein said substrate is a polyethylene film.

3. The method of claim 1, wherein said substrate comprises a slit foam layer.

4. The method of claim 1, wherein said substrate comprises a woven or nonwoven textile.

5. The method of claim 1, wherein the cap has a permeability to air smaller than 300 liters/m² per second.

6. The method of claim 1, wherein the cap further comprises a barrier layer made of polyurethane.

7. The method of claim 6, wherein the covering material is assembled with the barrier layer by sewing along style feature lines.

8. The method of claim 1, wherein the covering material is skin.

9. The method of claim 1, wherein a thickness of the cover element is in the range from 5 to 40 mm.

10. The method of claim 1, wherein elements for fastening the cover element to a support block are embedded in the at least one layer of foam.

11. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:

placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;

maintaining the cap pressed against the matrix by suction;

placing said at least one layer of foam against a back of said covering material; and

applying a forming punch defining a rear surface of the cover element;

wherein the cap has a permeability to air smaller than 300 liters/m² per second.

12. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:

placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;

maintaining the cap pressed against the matrix by suction;

placing said at least one layer of foam against a back of said covering material; and

applying a forming punch defining a rear surface of the cover element;

wherein the cap further comprises a barrier layer made of polyurethane.