Padded element for a vehicle, and a method of manufacturing it

• US 20020067064A1
• Filed: 10/24/2001
• Published: 06/06/2002
• Est. Priority Date: 10/31/2000
• Status: Active Grant

• Current Assignee: Faurecia Sieges D'Automobile (Stellantis NV)
• Original Assignee: Faurecia Sieges D'Automobile (Stellantis NV)
• Inventors: Senechal, Jerome, Rancon, Herve, Edouibi, Nordine, Jaillet, Laurent
• Granted Patent: US 6,733,072 B2
• Time in Patent Office: Days
• US Class Current: 297/452.27
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B60N 2/002 Seats provided with an occupancy detection means mounted therein or thereon detection means responsive to presence or absence of children B60N2/266
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: B60N 2/70 Upholstery springs ; Upholstery

Abstract

A padded element for a vehicle, the element comprising padding of flexible synthetic foam which supports a flexible member and which presents a support face for coming to bear against a user, said support face being covered by:

a film suitable for providing a barrier against the synthetic foam before it polymerized;

a first compressible flexible layer covering the film on its side opposite side to the padding and presenting permeability to air of less than 200 l.m⁻².s⁻¹ under a pressure difference of 100 Pa, and presenting a load-bearing capacity of 5 kPa;

a second flexible layer presenting a load-bearing capacity of 12 kPa; and

a flexible outer decorative covering.

Claims

1. / A padded element for a vehicle, the element comprising flexible synthetic foam padding supporting at least one flexible member that is less flexible than the foam and that presents a support face for a user to bear against, said support face being covered by a flexible outer decorative covering, and a flexible lining being interposed between the flexible member and the outer decorative covering,

wherein the lining is less than 20 mm thick and comprises superposed layers of flexible materials that are distinct from the foam constituting the padding, the flexible lining comprising at least:

a film adapted to constitute a barrier against the synthetic foam prior to its polymerization, said film adhering to the synthetic foam; and

at least a first compressible flexible layer covering the film on the opposite side to the padding and adhering to said film, the first flexible layer presenting;

permeability to air that is less than 200 l.m<sup>−

2</sup>.s<sup>−

1</sup> under a pressure difference of 100 Pa;

load-bearing capacity lying in the range 3 kPa to 12 kPa; and

thickness lying in the range 1 mm to 10 mm.

2. / A padded element according to claim 1, in which the padding is made of polyurethane foam and the film comprises firstly a main component selected from polysaccharides and animal proteins, and secondly a plasticizing agent selected from:

caprolactone, polylactic acid, cellophane, paper, polyethylene, and isocyanate.

3. / A padded element according to claim 1, in which the first flexible layer is made of a material selected from synthetic foams and non-woven fabrics.

4. / A padded element according to claim 1, in which the flexible lining further comprises a second compressible flexible layer interposed between the first flexible layer and the outer decorative covering, said second flexible layer adhering to said decorative covering and presenting:

thickness lying in the range 1 mm to 6 mm; and

load-bearing capacity lying in the range 5 kPa to 20 kPa.

5. / A padded element according to claim 4, in which the second flexible layer is made of a material selected from synthetic foams and non-woven fabrics.

6. / A padded element according to claim 4, in which the second flexible layer adheres to the first flexible layer.

7. / A padded element according to claim 1, in which the flexible member adheres to the film.

8. / A padded element according to claim 1, in which the outer decorative covering forms at least one reentrant line which penetrates into the padding, said padding supporting at least two flexible members adhering to the film of the flexible lining, said flexible members being placed on either side of the reentrant line and being interconnected via at least one flexible strap which forms a loop extending towards the inside of the padding away from the reentrant line formed by the outer decorative covering.

9. / A padded element according to claim 8, in which the strap is spaced apart from the reentrant line of the outer decorative covering by the padding having a thickness of not less than 55 mm.

10. / A padded element according to claim 1, in which the flexible lining and the outer decorative covering form a laminate having a total thickness of not more than 8 mm.

11. / A padded element according to claim 1, constituting a seat element.

12. / A method of manufacturing a padded element according to claim 1, the method comprising the following steps:

a) at least one flexible lining is placed in a mold defining a bottom cavity, the film being placed towards said cavity and the flexible member adhering to the film;

b) suction is established in the mold pressing said flexible lining against the mold;

c) flexible synthetic foam in the still unpolymerized state is cast into the mold cavity against the film of the flexible lining; and

d) the synthetic foam is allowed to polymerize.

13. / A method according to claim 12, in which during step a), a laminate is placed in the mold, the laminate comprising both the flexible lining and the outer decorative covering.