Method of forming a fabric covered article

• US 20070131347A1
• Filed: 12/13/2005
• Published: 06/14/2007
• Est. Priority Date: 12/13/2005
• Status: Abandoned Application

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Boes, Klaus, Muller, Karsten, Hoffmann, Ralf, Koidl, Markus, Behnke, Michael
• Application Number:
  US11/301,902
• Publication Number:
  US 20070131347A1
• Time in Patent Office: Days
• US Class Current: 156/272.200
• CPC Class Codes: B29C 63/025 applied by a die matching with the profile of the surface of resilient articles, e.g. cushions, seat pads
• CPC Class Codes: B29C 65/1412 Infrared [IR] radiation
• CPC Class Codes: B29C 65/1432 direct heating of the surfaces to be joined
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/7841 Holding or clamping means for handling purposes clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/301 Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/5326 said single elements being substantially flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7484 Leather
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/91216 enabling contactless temperature measurements, e.g. using a pyrometer
• CPC Class Codes: B29C 66/91221 of the parts to be joined
• CPC Class Codes: B29C 66/91411 of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/919 characterised by specific temperature, heat or thermal flux values or ranges specific electrical resistance values B29C66/81262
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• 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 1/00 : Layered products having a non-planar shape
• CPC Class Codes: B32B 2305/022 : Foam
• CPC Class Codes: B32B 2310/0825 : using IR radiation
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60N 2/5875 : by adhesion, e.g. gluing
• CPC Class Codes: B60N 2/7017 : characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B68G 7/052 : with webs secured to the core, e.g. by stitching

Abstract

A method of forming a fabric covered article includes providing a substrate and trim cover laminate. The trim cover laminate includes a trim cover portion and a heat-activated adhesive portion laminated to a B-side surface of the trim cover portion, the adhesive portion defining an exposed surface. The exposed surface of the adhesive portion is exposed to heat, thereby activating the adhesive portion. The substrate is positioned onto the activated adhesive portion of the trim cover laminate to bring the substrate and the trim cover portion into contact with one another, thereby forming a fabric covered article.

Claims

1. A method of forming a fabric covered article, the method comprising the steps of:

providing a substrate;

providing a trim cover laminate comprising a trim cover portion and a heat-activated adhesive portion laminated to a B-side surface of the trim cover portion, the adhesive portion defining an exposed surface;

exposing the exposed surface of the adhesive portion to heat, thereby activating the adhesive portion; and

positioning the substrate onto the activated adhesive portion of the trim cover laminate to bring the substrate and the trim cover portion into contact with one another, thereby forming a fabric covered article.

2. The method according to claim 1, wherein the substrate is a foam pad.

3. The method according to claim 1, wherein the adhesive portion is an adhesive film.

4. The method according to claim 1, wherein the heat is provided from a source of radiant heat.

5. The method according to claim 4, wherein the source of radiant heat is a source of infrared energy.

6. The method according to claim 1, further including the step of applying a force to one of the substrate and the trim cover laminate to press the substrate onto the adhesive portion of the trim cover laminate, thereby accelerating the bond of the trim cover portion to the substrate.

7. The method according to claim 6, wherein the force applying step occurs in a press.

8. The method according to claim 7, wherein the step of exposing the exposed surface of the adhesive portion to heat occurs in the press prior to the application of force.

9. The method according to claim 1, wherein the trim cover portion comprises non-porous fabric.

10. The method according to claim 1, wherein the trim cover portion comprises leather.

11. The method according to claim 1, further including exposing an A-side surface of the substrate to heat.

12. The method according to claim 11, wherein the A-side surface of the substrate and the exposed surface of the adhesive portion are simultaneously exposed to heat.

13. The method according to claim 12, wherein the heat is provided from a source of radiant heat.

14. The method according to claim 13, wherein the source of radiant heat is a source of infrared energy.

15. A method of forming a fabric covered article, the method comprising the steps of:

disposing heat-activated adhesive on one of an A-side surface of a substrate and a B-side surface of a trim cover portion, the adhesive defining an exposed surface;

disposing the substrate and the trim cover portion in a press;

exposing the exposed surface of the adhesive to heat within the press, thereby activating the adhesive; and

positioning one of the substrate and the trim cover portion onto the other of the substrate and the trim cover portion having the activated adhesive thereon to bring the substrate and the trim cover portion into contact with one another, thereby forming a fabric covered article.

16. The method according to claim 15, wherein the heat is provided from a source of radiant heat.

17. The method according to claim 16, wherein the source of radiant heat is a source of infrared energy.

18. The method according to claim 15, further including the step of applying a force to one of the substrate and the trim cover portion to press the trim cover portion onto the substrate, thereby accelerating the bond of the trim cover portion to the substrate.

19. The method according to claim 15, further including exposing the A-side surface of the substrate and the B-side surface of the trim cover portion to heat.

20. A method of forming a fabric covered article, the method comprising the steps of:

laminating heat-activated adhesive on a B-side surface of a trim cover portion to define a trim cover laminate, the adhesive defining an exposed surface;

disposing a substrate and the trim cover laminate in a press;

exposing the exposed surface of the adhesive and an A-side surface of the substrate to infrared energy within the press, thereby activating the adhesive; and

applying a force to one of the substrate and the trim cover laminate to bring the substrate and the trim cover portion into contact with one another, thereby accelerating the bond of the trim cover portion to the substrate and forming a fabric covered article.