METHOD OF MANUFACTURING A SEAT BACK CUSHION ASSEMBLY AND CUSHION ASSEMBLY MADE THEREBY

• US 20180334064A1
• Filed: 05/18/2017
• Published: 11/22/2018
• Est. Priority Date: 05/18/2017
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: MARQUES, Jose, NAVARRO, Nathalie
• Granted Patent: US 10,576,853 B2
• Time in Patent Office: Days
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for

Abstract

A method for manufacturing a vehicle seat cushion assembly includes providing an outer material to define an outer seating surface. A backing material is sewn to the outer material using a first sewing line against which a wadding material is placed in a central region of the cushion. To secure the wadding material, a second sewing line is run. Left and right wadding materials are placed between the sewing lines and the edges of the cushion. Additional sewing lines laterally cross the longitudinal sewing lines to imbue the cushion with a wrist watch-like appearance.

Claims

1. A method of manufacturing a seat cushion for a vehicle seat assembly, the seat cushion having side edges and top and bottom edges, the method comprising the steps of:

providing an outer material to define a surface that faces a seat occupant;

sewing a backing material to the outer material using a first longitudinally oriented sewing line;

placing a wadding material adjacent to the first longitudinally oriented sewing line in a centrally located region of the backing material;

sewing the backing material to the outer material using a second longitudinally oriented sewing line so that the wadding material is secured between the first and second sewing lines;

making a tiered sewing line between the first and second sewing lines running between the top and bottom edges;

disposing a wadding material between the outer and backing materials and between the first sewing line and an edge of the seat cushion;

disposing a wadding material between the outer and backing materials and between the second sewing line and an opposite edge of the seat cushion;

sewing along the edges of the seat cushion to further secure the wadding material;

making a plurality of laterally oriented sewing lines between the side edges of the seat back cushion; and

sewing the outer and backing materials together using additional sewing lines respectively disposed proximate the top and bottom edges of the seat cushion.

2. The method of claim 1, wherein the laterally oriented sewing lines are generally perpendicular to the first and second sewing lines.

3. The method of claim 1, wherein the one or more additional sewing lines include a pointe perle sewing line.

4. The method of claim 1, wherein the outer material includes leather and the backing material includes a woven tulle.

5. The method of claim 1, wherein the outer and backing materials have generally parallel longitudinal perimeters joined by generally parallel top and bottom edges that are joined by rounded corners.

6. The method of claim 1, wherein the wadding material includes a foam having constituents selected from the group consisting of a urethane material, a bio-based material and mixtures thereof.

7. The method of claim 1, wherein the wadding material includes foam having a thickness in an un-deflected state of about 15 mm and a density of about 28 Kg/cubic meter.

8. The method of claim 1, wherein the tiered sewing lines include a lateral segment and a longitudinal segment.

9. The method of claim 8, wherein the lateralp segment has a left end and a right end, and the longitudinal segment has a top end and a bottom end.

10. The method of claim 9, wherein the right end is connected to the top end and the bottom end is connected to the right end of a next segment and so on.

11. The method of claim 1, wherein the plurality of laterally oriented sewing lines includes a left stitch segment that runs across a left portion of the outer material, a middle segment that runs across a center portion of the outer material and a right segment that runs across a right portion of the outer material.

12. The method of claim 11, wherein the laterally oriented sewing lines and the longitudinally oriented sewing lines present an appearance that is akin to a wrist watch strap.

13. The method of claim 1, further including the step of applying a glazing on an underside of the outer material.

14. A vehicle seat cushion assembly comprising:

an outer material defining an outer seating surface that supports a seat occupant;

a backing material having a greater stretchability than a stretchability of the outer material, the backing material being attached to edges of an underside of the outer material;

a wadding material disposed between the outer and backing materials;

lateral and tiered sewing lines that secure the outer material, the backing and the wadding material, wherein the plurality of laterally oriented sewing lines includes a left stitch segment that runs across a left portion of the outer material, a middle segment that runs across a center portion of the outer material and a right segment that runs across a right portion of the outer material.

15. The vehicle seat cushion assembly of claim 14, further including a visual appearance that is akin to a wrist watch strap.