Method for providing illuminated components and components formed from the method

A method of illuminating a component, having an outer skin layer, the method including the steps of: forming a seam of the outer skin layer; and locating an elongated light conducting medium in the seam.

BACKGROUND

This invention relates to an illuminated structure and more particularly, the invention relates to a method for providing illuminated stitching wherein the stitching provides an illuminated component.

Currently, most stitching found in an article of manufacture is of the functional variety, wherein 2 or more pieces of material (e.g., leather, vinyl, thermoplastic polyolefin (TPO), cloth, polyurethane skin, or other man made or natural skin items, etc.) are cut from a pattern and sewn together (cut-n-sew) prior to being wrapped around a component such as a seat cushion, head rest, arm rest, console lid, instrument panel, door trim, console, substrate, etc.

A simulated functional or non-functional stitch has been used in some applications; however, the ability to offer a simulated stitch with a changing color or illumination is not production feasible at this time. Additionally, more manufactures are requesting a real or “live” stitch be used on decorative components to provide the look and feel of a true cut-n-sew component at reduced cost. Still further, the ability to change the appearance of functional stitching is also desirable.

Accordingly, it is desirable to provide an illuminated stitch (functional or non-functional) on a stitched component.

SUMMARY OF THE INVENTION

A method of illuminating a component, having an outer skin layer, the method including the steps of: forming a seam of the outer skin layer; and locating an elongated light conducting medium in the seam.

Alternatively, the component can also consist of a hard panel only wherein the light conducting medium is attached to the backside of the component via tape or decorative stitching that penetrates the hard panel. A continuous or discontinuous channel, molded-in or secondarily trimmed into the panel serves as a means of transmitting the light from the back to front side of the panel.

A trim component having a seam wherein an elongated light conducting or light generating medium is located in the seam.

DETAILED DESCRIPTION

Various embodiments of the present invention are directed to alternative means of adding accent lighting to an article of manufacture and in one non-limiting embodiment, an automotive vehicle interior by integrating lighting as part of the sewing operation. Various embodiments of the invention are also applicable to any and all industries which manufacture a product containing a decorative and/or functional stitch.

One embodiment described herein proposes the use of the sewing process to incorporate accent lighting to a vehicle interior. In accordance, with exemplary embodiments of the present invention accent lighting can be sewn into a component using, but not limited to, one of the following methods:

1) Use of a light pipe, fiber optic cable, or other light conducting medium and/or generating medium as a thread that is sewn into a trim component that produces an illuminated stitch when connected to a light source.

When the lighting source is used as a thread as mentioned above, the light conducting medium should be of a diameter and construction to be passed through a needle within a chain stitch or lock stitch type sewing machine. Chain stitch type sewing is the preferred method, as the thread is subjected to much less abrasion and torsion during stitching. Of course, other stitch types can be used and are contemplated to be within the scope of various embodiments of the present invention.

2) Light pipe, fiber optic cable, or other light conducting medium or light generating medium that is sewn into the seam which either joins two materials together or produces a visual effect that simulates the joining of two materials. When connected to a light source, the light conducting medium emits light to illuminate the join seam produced by the sewing operation.

When encapsulated within the join seam as described in second embodiment above, the light conducting medium can be of any number of diameters and constructions to provide the degree of light intensity and visual effect required by the manufacturer. For example, when encapsulated as part of deck seam design, the following assembly steps can be followed:

Step a) Use single or double needle machine to join two pieces of material together. Thread tension on inside seam should be reduced to allow joined materials to separate slightly when placed under tension.

Step b) Fold top layer of material back upon itself and stitch to join seam, outside of initial join seam stitch, produced a deck type fold in the materials.

Step c) Insert light conducting medium between the two materials at the join seam.

As mentioned above and will be discussed herein, the light conduction medium can be incorporated into the seam during or after sewing and in one embodiment, the medium is integrated during the sewing process to avoid damaging the medium during post-seam sewing installation. Accordingly, one exemplary embodiment is directed to incorporating the side emitting fiber optic cable during the sewing process as opposed to inserting it after the seams have been made.

In the methods described above and herein, light intensity and color can be varied by the end consumer based on individual taste. Illumination timing and frequency can also be tied, but not limited, to vehicle function(s), such as turn signal indicators, music volume, vehicle speed, engine RPM and/or acceleration. Accordingly and in various alternative embodiments, the illumination of the light conducting medium and/or generator can be coupled to a controller or microcontroller51(see the dashed lines ofFIGS. 15A, 15B, 21A and 21B) of the aforementioned vehicle functions (illustrated schematically by box53) such that the illumination of the medium is varied accordingly. Still further, the controller or microcontroller51may be used to vary the illumination in non-vehicular applications wherein other functions (e.g., music volume, beat, detected light, etc. or any other application wherein variation of the illumination is desired) are used to vary the illumination.

Turning now to the drawings, wherein to the extent possible like reference numerals are utilized to designate like components throughout the various views and various embodiments of the present invention. As shown throughout the FIGS., it is seen that an interior portion12of a vehicle or any other manufacturable component is illustrated. In one implementation interior portion12is a portion of an instrument panel of a vehicle. Of course, other configurations and components are also contemplated and thus various embodiments disclosed herein need not be limited to vehicular applications as they are but one of many applications.

As best illustrated inFIG. 1, the interior portion12comprises an outer skin layer15or layers secured to each other and each having a substantially smooth outer surface and an underside facing away from the outer surface. The outer skin layer15can be any one of leather, vinyl, thermoplastic polyolefin (TPO), cloth, combinations thereof etc.) that are cut from a pattern and sewn together (cut-n-sew) prior to being wrapped around a component such as a seat cushion, head rest, arm rest, console lid, instrument panel substrate, etc. or any other component wherein illuminated stitches or seams are desired.

In one embodiment and in order to enhance the softness of portion12, a layer of cushioning support material can be provided in the region below the outer skin layer15. It is contemplated that the cushioning support material may be of any number of different constructions although a foamed material such as cross linked polypropylene (XLPP) foam may be potentially preferred. Also a substrate panel17of dimensionally stable plastic or other suitable material is preferably disposed below the cushioning support material.

In one embodiment, the cushioning support material and the substrate panel serve cooperatively to provide a support structure for the outer skin layer15.

It one embodiment, a polyurethane foam (PUR) forms the cushioning support material and may be blown between the outer skin layer15and the substrate panel17so as to form a multi-layered composite structure. It is also contemplated that the cushioning material may be attached to the outer skin layer18in a preliminary cladding operation so as to form a preliminary layered composite which may thereafter be applied across any substrate panel17as may be utilized.

Of course and in other embodiments, the outer skin layer15can be anyone of a single layer of material such as leather, vinyl, TPO, cloth, combinations thereof etc.) that are cut from a pattern and sewn together (cut-n-sew) prior to being wrapped around a component such as a seat cushion, head rest, arm rest, console lid, instrument panel substrate, etc. or any other component wherein illuminated stitches or seams are desired.FIGS. 1-3illustrate some non-limiting possible methods of encapsulating a light conducting medium and/or generator10in a trim piece12between two parallel join seams14of outer skin layer15. In one embodiment, the light conducting and/or generating medium10is a side emitting fiber optic cable or any other suitable elongated light conducting device capable of being used as the light conducting and/or generating medium10or a stitch in accordance with various embodiments of the present invention. For example, the side emitting fiber optic cable can be anyone of poly(methyl methacrylate) (PMMA) (e.g., transparent thermoplastic) material, jacketed glass fibers, polytetrafluoroethylene (PTFE), and equivalents thereof etc.

In one non-limiting embodiment the light conducting and/or generating medium10is replaced by an electroluminescent wire (E-wire). In this embodiment, the electroluminescent wire may in some instances create radio frequency (RF) interference and is thus applicable to components wherein RF interference would not be an issue or wherein the RF interference from the electroluminescent wire is of a non-interfering frequency.

FIGS. 1-3illustrate various embodiments, with a light conducting medium is retained between two join seams (14,14′). In particular,FIG. 1illustrates, a deck seam with two join seams14and14′ enveloping a side emitting fiber optic cable10. Here tension control on the join seam14′ (e.g., tension controlled join seam) controls the design gap11. Accordingly, light from the side emitting fiber optic cable10shows through the design gap11. In one embodiment, the threads for the seams can be clear multi-strand or monofilament or can be pigmented depending on the desired effect. InFIG. 1, a 3rd (decorative) stitch16is provided to create a deck seam fold.

FIG. 2illustrates an illuminated join seam14with join seam cross stitching serving to separate the light as desired. Here a deck seam with two join seams enveloping a side emitting fiber optic cable10is illustrated. Once again, tension control on the join seams controls the design gap11and light from the side emitting fiber optic cable10shows through the design gap11. As previously mentioned, the threads can be clear multi-strand or monofilament or can be pigmented depending on the desired effect.

FIG. 3is similar toFIG. 2with the addition of a double needle (French) seam18stitch to secure the selvage to the backside of the material. Once again, tension control on the join seams controls the design gap11and light from the side emitting fiber optic cable shows through the design gap. As mentioned above, the threads can be clear multi-strand or monofilament or can be pigmented depending on the desired effect.

FIGS. 4-6illustrate still other possible methods of securing a light conducting and/or generating medium10to the show surface22of a join seam20or material surface22. Here the light conducting medium is retained by a functional stitch24or a tape26. Alternatively, both a functional stitch24and a tape26may be used. A cross stitch24is used to secure the light conducting medium to the top of the join seam inFIG. 4while a tape26is used to secure the light conduction medium to the backside as shown inFIG. 5. InFIG. 6a cross-stitch24is used to secure a light conducting medium to the surface of the material at non-join areas. InFIG. 4, a join seam with a decorative/functional hold down stitch24retains the side emitting fiber optic cable10in a trench21of the join seam.

FIG. 4illustrates a join seam with a retainer tape26that holds the side emitting fiber optic cable10in the trench21of the join seam. As in any of the previous embodiments, the threads can be clear multi-strand or monofilament or can be pigmented depending on the desired effect. InFIG. 6a decorative/functional hold down stitch24retains the side emitting fiber optic10on the surface23of the material15. As in any of the previous embodiments, the threads used for the stitch or stitches can be clear multi-strand or monofilament or can be pigmented depending on the desired effect.

FIGS. 7-10illustrate still other additional methods of securing a light conducting and/or generating medium10to the surface of a join seam or material surface using a functional stitch24or a tape or retainer tape26. Still further both a functional stitch24and tape26may be employed.FIGS. 7 and 8are comparable toFIGS. 4 and 5, with the addition of a double needle stitch (French seam)30which also secures the selvage to the backside of the material.FIGS. 9 and 10utilize a light conducting and/or generating medium10behind the double needle stitching with or without join seam20illumination as an option. Also illustrated is that multiple or numerous light conducting and/or generating mediums10are employed in various locations proximate to the seams and/or the related threads.

In the attached FIGS. some but not all multiple combinations of side emitting fiber optic cable10are illustrated. Accordingly, numerous configurations are possible and are not limited to the specific examples described herein. As mentioned, herein the threads used for the seams (functional or non-functional) can be clear multi-strand or monofilament or can be pigmented depending on the desired effect. Moreover, multiple colors are possible as are lighting from both ends of the cable10(same color or different). Still further, the colors can be dynamically changed through lensing arrangements, redundant (different) light sources, and by the use of different lenses (fixed or moving).

FIGS. 11 and 12illustrate the possibility of illuminating a double and single needle non-functional stitch33using a light conducting and/or generating medium10which is attached directly behind the stitch seam on the backside of the part by for example, a retainer tape26. Tape or retainer tape26being sufficient to secure the light conducting and/or generating medium10in the appropriate location. Also shown is a non-functional stitch33. Accordingly, the seams do not have to be functional to be used with side emitting fiber optic cable10.FIG. 11illustrates a simulated French seam33with dual fiber optic cables10andFIG. 12illustrates a simple stitch33′ with a fiber optic cable10.

Still further and in an alternative embodiment (See at leastFIG. 13), actual stitching is not required. In this embodiment or in combination with any of the previous embodiments the material15is provided with perforations35extending therethrough and the light conducting and/or generating medium10is located to illuminate the perforations35.FIG. 13illustrates the use of light conducting and/or generating medium10to illuminate a perforation or numerous perforations35introduced to the material15and in this embodiment no stitch or join seam is present. Of course, perforations35may be used in combination with any of the aforementioned seams and stitches. Still further and as mentioned, the threads used for the seams (functional or non-functional) can be clear multi-strand or monofilament or can be pigmented depending on the desired effect.

As mentioned above and where applicable, the light conducting medium10can be stitched into the seam, or inserted into a previously stitched seam or comprise the materials (e.g., thread) that is used to form the seam or any combination thereof to provide an interior portion12of a vehicle or any other component manufactured wherein an illuminated stitch or portion is desired. Variations in the thickness of the light conducting medium especially when used in a non-stitching application can vary the desired effect of the same.

FIG. 14is a view of a show surface of an interior portion of a component formed in accordance with an exemplary embodiment of the present invention, wherein a deck seam similar to the embodiment illustrated inFIG. 1is employed with a 3 mm side emitting light pipe inserted into the join seam.

Referring now toFIGS. 15A and 15Ba cross-sectional view of an illuminated component12in accordance with one alternative exemplary embodiment is illustrated. Here the light conducting medium10is positioned adjacent or below the cover material15such that the light conducting medium10is located on an opposite side of the show surface22of the illuminated component12and is arranged to coincide with the threads of the seam to be illuminated. In this embodiment, translucent threads30are utilized and the light conducting medium10(e.g., light conductor or light generator) is located adjacent to the translucent threads such that light can be passed through them to the show surface or front22by applying a light source to the back32of the illuminated component12. In one non-limiting embodiment, the light conducting or generating medium10is a light conducting medium coupled to a light generator34such as an LED or any other equivalent structure. Alternatively, the entire cable36is a light generator or light producing device.

FIG. 15Billustrates the illumination of the light conducting or light generating medium10wherein the color of the conductor/generator is passed through the translucent threads30indicated by arrows38.

Referring now toFIGS. 16A and 16Bwelting with a side emitting fiber optic cable10or any other suitable elongated light conducting device10is shown as being co-extruded with a sewable material40that provides a coextruded jacket42located around the light conducting device10and also provides a portion44capable of being sewn into a component12. In one non-limiting embodiment, the co-extruded jacket42can be clear, or translucent.

Accordingly and in this embodiment, the side emitting fiber optic cable10can be co-extruded with a sew-able material creating piping, or welting. When this coextruded item is sewn into a seam and illuminated, it can create dramatic effects on many different products.

Referring now toFIGS. 17A and 17Bwelting with a side emitting fiber optic cable10or any other suitable elongated light conducting device10is shown as being wrapped with a sewable material40that provides a jacket42located around the light conducting device10and also provides a portion44capable of being sewn into a component12. In this embodiment, the jacket42is also provided with a perforated covering46that can provide interesting light effects when illuminated. Covering46also includes a sewable portion45located proximate to portion44. As with the previous embodiments, this design can be sewn into numerous seams the way any piping or welting material could be. Also, the perforations48can be numerous shapes for added impact or effect. In addition, perforated covering46may also be translucent and/or opaque to provide still other lighting effects when illuminated by the light conducting or generating medium10.

Accordingly and in this embodiment, the side emitting fiber optic cable10can be wrapped with a sew-able material creating piping, or welting. When this item is sewn into a seam and illuminated, it can create dramatic effects on many different products.

Referring now toFIGS. 18A-18Canother alternative embodiment is illustrated. Here the light conducting or generating medium10(e.g., side emitting fiber optic cable or any other equivalent device) is coextruded with a material50that can be positioned within a seam52located between two materials15that are sewn together at seam52. In this embodiment, the shape of the coextruded material (e.g., light conducting or generating medium10and material50) can be designed to affect the shape of the sewn seam52. Still further numerous fiber optic shapes of the light conducting or generating medium10can be used to provide different lighting effects as well as facilitating co-extrusion. Non-limiting configurations of such shapes are illustrated inFIGS. 18A-18C.

In addition, material50can comprise a softer material in order to facilitate sewing of seam52by passing threads54therethrough.

Referring now toFIG. 19yet another alternative embodiment is illustrated. Here the light conducting/generating medium10(e.g., side emitting fiber optic cable or any other equivalent device) is coextruded or assembled with a supporting structure17. In this embodiment the supporting structure with the coextruded or integrally placed light conducting/generating medium10helps facilitate securement of the same to materials15during the forming of a seam56, which in the illustrated embodiment is a French seam formed with stitches58.

As illustrated inFIGS. 20A-20Cand in yet another embodiment, the light conducting or light generating medium10can also be applied to or integrated with the substrate material17being wrapped by a cover material15.

For example and as illustrated inFIG. 20A, the light conducting or light generating medium10is located on a substrate17wherein numerous attachment methods are employed ranging from directly assembled to molded in place. Moreover and in one embodiment wherein the stitch is decorative only, the stitching is applied through the cover material15and the substrate17. Accordingly and when translucent threads are used, light can be passed through them to the front by applying a light source to the back of the part.

As mentioned above, the light source10can be fixed to layers15with a separately molded (or extruded piece)17, or with another component57(extruded or assembled,FIG. 20B) or with simple tape59(FIG. 20C).

Referring now toFIGS. 21A and 21Ba cross-sectional view of an illuminated component12in accordance with yet another alternative exemplary embodiment is illustrated. Here the light generator34is directly coupled to the translucent threads30such that light can be passed through them to the show surface or front22. Accordingly and as mentioned above and in this embodiment, the threads themselves are the light conducting medium. This may be particularly useful in short runs or lengths of stitching wherein the light can be directly transmitted to the sewn stitch without a separate light conductor10. In one non-limiting embodiment, the light generator34is an LED or any other equivalent structure. One non-limiting example of translucent threads30is a mono-filament material.FIG. 15Billustrates the illumination of the translucent threads30indicated by arrows38. Still further, this embodiment may be combined with embodiments employing the light conducting medium10thus numerous combinations are possible.

FIG. 22illustrates a deck seam illuminated with a 3 mm side emitting light pipe.