Automotive seat assembly having an integral tear seam

• US 6,523,237 B1
• Filed: 11/21/2000
• Issued: 02/25/2003
• Est. Priority Date: 05/21/1998
• Status: Expired due to Fees

• Current Assignee: Magna Imperio Systems Corp.
• Original Assignee: Magna Imperio Systems Corp.
• Inventors: Srivastava, Manoj, Hadley, Philip W., Fileccia, Scott, Persha, Sean, Kopec, Gary
• Primary Examiner(s): Nelson, Jr., Milton
• Application Number:
  US09/700,964
• Time in Patent Office: 826 Days
• Field of Search: 297/216.13, 297/216.1, 297/216.14, 280/730.2, 280/728.3, 29/911, 29/91, 294/32, 294/321, 294/47, 29/33.R, 296/50, 156/73.1, 156/580.1, 156/580.2, 264/118, 264/119
• US Class Current: 29/91.1
• CPC Class Codes: B29C 2791/008 Using vibrations during moulding
• CPC Class Codes: B29C 59/007 Forming single grooves or ribs, e.g. tear lines, weak spots by moulding B29C37/0057; folding lines B29C53/06; in metal articles B21D17/00; by cutting B26D3/08
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/743 using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc B29C65/2046 takes precedence
• CPC Class Codes: B29C 65/7437 the tool being a perforating tool perforating as mechanical pre-treatment B29C66/02242
• CPC Class Codes: B29C 65/7441 for making welds and cuts of other than simple rectilinear form
• CPC Class Codes: B29C 65/7443 by means of ultrasonic vibrations
• CPC Class Codes: B29C 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/244 said joint lines being non-straight, e.g. forming non-closed contours
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/80 General aspects of machine operations or constructions and parts thereof
• CPC Class Codes: B29C 66/81417 being V-shaped
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/81433 being toothed, i.e. comprising several teeth or pins comprising a single tooth B29C66/81429, or being patterned
• CPC Class Codes: B29C 66/8242 Pneumatic or hydraulic drives using fluid pressure directly acting on the parts to be joined B29C66/8266
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B60R 2021/0006 Lateral collision
• CPC Class Codes: B60R 21/207 in vehicle seats
• CPC Class Codes: B60R 21/2165 characterised by a tear line for defining a deployment opening
• CPC Class Codes: Y10T 29/481 : Method

Abstract

An automotive seat assembly is provided with an integrated side impact airbag. The seat assembly comprises a seat cushion and a seat back mounted to the seat cushion. A seat cushion trim cover material covers the seat cushion and a seat back trim a cover material covers the seat back. The seat assembly is characterized by a tear seam integrally formed within a bolster section of the seat back trim cover material. The tear seam defines a frangible line of weakness within the trim cover material wherein the airbag will tear through the tear seam when the airbag is deployed and inflated to a position outside of the seat assembly. The subject invention also includes a manufacturing apparatus for forming the tear seam in the trim cover material. The apparatus comprises a template (48) supporting the trim cover material (28). A C-shaped raised ridge (50) extends upwardly from the template to abut the inside surface of the trim cover material (28). A welder (52) is disposed adjacent the outside surface of the trim cover material (28) such that the trim cover material is wedged between the template (48) and the welder (52). The welder is aligned with the raised ridge to form the tear seam within the trim cover material.

Claims

1. A method of integrally forming tear seam (44) within a multilayered seat cover material (24, 26) having at least one outer layer (32) and at least one inner layer (34, 36) by using an ultrasonic welder (46) and a template (48) having a raised ridge (50), said method comprising the steps of;

placing the cover material (24, 26) over the template (48) within an inside surface (30) of the inner layer (34, 36) in contact with the raised ridge (50);

moving the ultrasonic welder (46) adjacent an outside surface (28) of the outer layer (32) in alignment with the raised ridge (50) of the template (48) and wedging the trim cover material (24, 26) between the ultrasonic welder (46) and the raised ridge (50); and

ultrasonically heating the layer (34, 36) with the ultrasonic welder (46) to form a tear seam (44) having at least one of the inner layers (34, 36).

2. A method as set forth in claim 1 wherein the ultrasonically heating of the trim cover material (24, 26 is further defined as heating the inner layers (34, 36) to at least a partially molten state.

3. A method as set forth in claim 2 wherein the ultrasonic welder (46) wedges the trim cover (24, 26) onto the raised ridge (50) until the trim cover material (24, 26) solidifies.

4. A method as set forth in claim 3 wherein the forming of the tear seam (44) is further defined by forming a substantially V-shaped tear seam (44).

5. A method as set forth in claim 4 wherein the forming of the tear seam (44) is further defined by providing a substantially triangular shaped ridge (50) for forming the V-shaped tear seam (44).