Abstract:
In at least one embodiment, the present invention provides a frame, a cushion supported on the frame, with the cushion having a surface area comprising a major portion and a minor portion, and a trim material secured over the cushion to cover the major portion of the surface area. The minor portion of the surface area is uncovered by the trim material and a colored coating is disposed on the minor portion of the surface area of the cushion.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a vehicle seat assembly having a cushion with a colored coating and method of making the same. More specifically, in at least certain embodiments, the present invention relates to a vehicle seat assembly having localized regions of an in-mold coatings to inhibit cushion show through and method of making the same. 
         [0003]    2. Background Art 
         [0004]    Generally speaking, a vehicle seat assembly includes three fundamental components: (a) a frame to support the seat assembly and to mount it to a vehicle; (b) a foam cushion to cover the frame; and (c) trim material to cover the foam cushion and provide a durable surface for contact with a vehicle occupant. Typically, the foam cushion is made from an expandable foam material, such as polyurethane, and is molded to a predetermined shape during a molded process. The resulting molded cushion is typically a relatively light color such as white or yellow and has a grey scale rating of less than 30%, and in particular less than 20%. 
         [0005]    The trim material may include any number of materials, such as cloth, polymers, or leather. Often, the selection of trim material is governed by the sale price of the vehicle. For example, leather trim material may be used for luxury vehicles while cloth and polymeric materials may be used for less expensive vehicles. The trim material is secured over the cushion to cover the cushion however, often times there remains certain areas where the trim material does not completely cover the cushion. In these uncovered areas, because of the contrast of color between the trim material and the cushion, there can be cushion show through that is noticeable to vehicle occupants. 
         [0006]    These areas of show through can occur in any number of areas, depending on a variety of factors such as, the design of the cushion, the trim material, and the trim material attachment scheme. Certain examples of some relatively likely show through areas are at the trim close out, i.e., in the corners or edges of the cushion where the trim material is wrapped, or places where clips and/or seat belt components are present. 
         [0007]    Depending upon the relative colors of the trim material and the cushion, cushion show through may be visible at these uncovered locations. These uncovered areas are especially noticeable when the trim material is relatively dark, such as those having a grey scale rating of more than 30%, and in particular greater than 50%, such as the case for blue, black and brown trim. 
         [0008]    Accordingly, there is a need to provide a vehicle seat assembly which has a seat cushion and trim material of relative contrast that inhibits cushion show through which can be manufactured easily and relatively economically. Moreover, even in situations with light colored trim, it may be desirable to provide a vehicle seat assembly that masks the appearance of the light colored foam cushion. 
       SUMMARY OF THE INVENTION 
       [0009]    According to at least one aspect of the present invention, a vehicle seat assembly is provided. In at least one embodiment, the vehicle seat assembly comprises a vehicle seat assembly comprising a frame, a cushion supported on the frame, the cushion having a surface area comprising a major portion and a minor portion, a trim material secured over the cushion to cover the major portion of the surface area, the minor portion of the surface area being uncovered by the trim material, and a colored coating disposed on the minor portion of the surface area of the cushion. 
         [0010]    According to at least another aspect of the present invention, a method of making a vehicle seat assembly is provided. In at least one embodiment, the method comprises providing a cushion assembly having an average thickness of 0.5 to 4 cm and having a colored coating disposed at a predetermined location on the cushion, supporting the cushion on a frame, and securing a trim material over the cushion assembly supported on the frame, the trim material not covering at least a portion of the colored coating on the cushion. 
         [0011]    In at least another embodiment, the method comprises providing a cushion assembly having an average thickness of 0.5 to 4 cm and having a colored coating disposed at a predetermined location on the cushion. The method further comprises supporting the cushion on a frame, and securing a trim material over the cushion assembly supported on the frame. The trim material is sized such that the trim material, when secured over the cushion assembly, does not cover at least a portion of the coating, wherein the colored coating forms a first colored region on the cushion adjacent a second colored region such that the first colored region is darker in color than the second colored region, and wherein the color of the trim material is at least substantially similar to the first color. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a cut-away environmental view of a vehicle seat assembly; 
           [0013]      FIG. 2  is a cut-away perspective view of a vehicle seat assembly in accordance with an embodiment of the present invention; 
           [0014]      FIG. 3  is a cut-away perspective view of another vehicle seat assembly in accordance with an embodiment of the present invention; 
           [0015]      FIG. 4  is a schematic illustration of a method of making the vehicle seat assembly illustrated in  FIG. 1 ; 
           [0016]      FIG. 5  is a flow diagram illustrating a portion of the method illustrated in  FIG. 4 ; and 
           [0017]      FIG. 6  is a view similar to  FIG. 4  illustrating another method. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0018]    As required, detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention. 
         [0019]    Moreover, except where otherwise expressly indicated, all numerical quantities in this description and in the claims are to be understood as modified by the word “about” in describing the broader scope of this invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary, the description of a group or class of materials by suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more members of the group or class may be equally suitable or preferred. 
         [0020]    Referring now to the figures, where like numerals are used to designate like structure throughout the drawings, an illustrative schematic vehicle seat assembly is generally shown at  10  in  FIG. 1 . While the vehicle seat assembly  10  is illustrated in  FIG. 1  to be a bucket seat assembly, it should be understood that the principles of the present invention are applicable to other types of seat assemblies, such as bench, captain, and other types of seat assemblies. It should also be understood that the principles of the present invention are applicable to other applications where foam and/or trim are components, such as back rests, back support pads, arm rests, and head restraints. 
         [0021]    As shown in  FIG. 1 , the vehicle seat assembly  10  includes a seat frame, generally indicated at  14  having a plurality of mounting brackets (not shown) adapted to operatively secure the seat frame within a vehicle. The seat frame  14  may be constructed from any material suitable for application within a vehicle seat assembly  10 , such as aluminum, steel or other metal alloy or a suitable polymer. Further, the seat frame  14  may be manufactured using a technique commonly known in the art, relative to the type of material employed. By way of example, manufacturing techniques may include stamping, welding, fastening or molding a suitable material to form a seat frame  14 . 
         [0022]    The vehicle seat assembly  10  comprises a seat back, generally indicated at  16 , and a lower seat assembly, generally indicated at  18 . In at least the illustrated embodiment, the seat back  16  includes a central back support pad  20  and side bolsters  22  on opposite sides of the pad  20 . In at least the illustrated embodiment, the lower seat assembly  18  includes a central seating pad  26  and a plurality of bolsters  30  and  31  substantially surrounding at least two opposing sides, and as shown here, three sides, of the central seating pad  26 . In the illustrated embodiment, bolsters  30  are located at opposite sides (i.e., inboard and outboard) of the lower seat assembly  18  and the bolster  31  is located at the front of the lower seat assembly  18  and extends between and connects the front portions of the bolsters  30 . 
         [0023]    The vehicle seat assembly  12  further includes a back foam cushion (not shown) and a seat foam cushion generally indicated at  34 . The back foam cushion and the seat foam cushion  34  are similar in construction and as such, only the seat foam cushion  34  will be discussed. The seat foam cushion  34  is conventionally secured to the seat frame  14  and/or a seat assembly infrastructure (not shown). The foam cushion  34  may be secured to the seat frame  14  and/or infrastructure by any method generally known in the art, such as by an adhesive. While the foam cushion  34  is illustrated to be a bucket-seat bottom cushion, it should be understood that the principles of the present invention can be applicable to any type of seat cushion, such as a seat back cushion for a bucket-seat and seat back and bottom cushion for bench seats, as well as other types of seats. 
         [0024]    The cushion  34  can have any suitable size, shape and configuration, however in at least one embodiment, has an average thickness of 0.25 to 8 cm, in at least another embodiment of 0.5 to 4 cm, and in at least yet another embodiment of 1 to 3 cm. The cushion  34  can comprise any suitable cushion material, such as a suitable resilient polymer. In at least one embodiment, suitable cushion materials will have a density of 1.5 to 5 pcf, in another embodiment of 2 to 3.75 pcf, and in yet other embodiments of 2.7 to 3 pcf. Density of the cushion material can be measured by ASTM test method No. D3574. 
         [0025]    In at least one embodiment, suitable cushion materials will have a hardness of 175 N (Newtons) to 400 N, in other embodiments of 225 to 350 N, and in yet other embodiments of 275 to 325 N. Hardness of the cushion material can be measured by ASTM test method No. D3574. In at least one embodiment, suitable cushion materials will have a hysteresis of 18 to 30 KPa, in another embodiments of 20 to 28 KPa, and in yet other embodiments of 23 to 26 KPa. Hysteresis of the cushion material can be measured by ASTM test method No. D3574. 
         [0026]    In at least certain embodiments, the cushion material comprises a soft flexible foam, such as conventional polyurethane foam, soy-based foam, silicone, thermoplastic olefins, thermoplastic urethanes, and/or natural oil-based expanded polyurethanes and the like. In at least one embodiment, because of its environmentally friendly nature, soy-based polyurethane is preferred. Soy-based polyurethane can be made with any suitable soy-based polyols, such as those available, but not necessarily limited to, from Bayer, Urethane Soy Systems Corporation, and Dow Chemical. Any suitable soy-based polyurethane may be used, however in at least one embodiment, suitable soy-based polyurethanes include, but are not necessarily limited to those available from Renosol. 
         [0027]    The vehicle seat assembly  12  also includes a trim material  36  adapted to engage the foam cushion  34  (or cushions) in a covering relationship. The trim material  36  may include any suitable cover material. By way of example, some of the known materials include cloth, leather, or polymers of sufficient quality and thickness for use in seat trim applications. Polymer trim materials may include a flexible closed cell polymer skin material such as polyvinyl, polyvinyl chloride (PVC), thermoplastic olefin (TPO), or thermoplastic urethane (TPU). 
         [0028]    Additionally, materials for use as trim material  36  may include a foam backing (not shown, but generally known in the art) which may be manufactured from a variety of polymer foam materials. By way of example, the foam backing may be polyethylene, polypropylene, polyurethane, or a polystyrene foam. Optionally, a mesh or reinforcing material (not shown, but generally known in the art) such as fiberglass or nylon may be applied to the foam backing or back of the trim material  36  for increasing strength without increasing rigidity. 
         [0029]    The trim material  36 , by the manner in which it is secured to the cushion  34  and/or the frame  14  and/or other part of the seat assembly  10 , while essentially covering the cushion  34  may not completely cover the cushion  34  and can result in uncovered areas  37  of the cushion  34 . The uncovered areas  37  of the cushion  34  are most likely to be present in the corners  35  of the seat assembly  10  ( FIG. 2 ) and areas  33  ( FIG. 3 ) adjacent latches  37  or other attachment devices, like seat belts, that extend from or adjacent the cushion  34 , however it is to be understood that uncovered areas  37  could be present at any number of locations on the cushion  34 . 
         [0030]    Certain examples of likely occurrences of uncovered area  37  are shown in  FIGS. 2 and 3 . In  FIG. 2 , the lower seat assembly  18  has a bottom surface  27  that connects to a vehicle floor (not shown). The bottom surface  27 , at the lower corners, has portions  37  adjacent a trim connector (not shown) that are uncovered. In  FIG. 3 , the back surface  25  of the seat back  16  has clips  21  having a housing  19  surrounding the clip  21 . The clips  21  can be any type of attachment clip, such as a child seat clip. Between the clips  21  and the housing  19  are uncovered areas  37  of the cushion  34 . For illustrative purposes, in  FIGS. 2 and 3 , the left side uncovered areas  37  are shown as they may appear in the prior art, while the right side uncovered areas  37  are shown as they may appear when coated in accordance with the principles of the present invention. Again for illustrative purposes, the trim material  36  adjacent the left side uncovered areas  37  have been cut-away to help show certain aspects of the principles of the present invention. 
         [0031]    The uncovered areas  37  of the cushion  34  are such that if the color of the trim material  36  is appreciably different than the color of the foam cushion  34 , cushion see through or show through can be appreciated by a passenger occupant. These uncovered areas  37  are especially noticeable when the trim material is relatively dark, such as those having a grey scale rating of more than 30%, and in particular greater than 50%, such as the case for blue, black and brown trim. In certain instances, the difference in grey scale ratings of the trim material and the cushion  34  can be 5 to 80%, in other embodiments 25 to 70%, and in yet other embodiments 30 to 60%. 
         [0032]    In accordance with the present invention, portions of the foam cushion  34  are colored to reduce or alleviate foam cushion show through. In at least certain embodiments, the uncovered areas  37  of the seat cushion  34  are colored to form colored portions  38 . As can be seen in the Figures, the colored portions  38  are adjacent to non-colored portions  15  of the surface of the foam cushion  34 . While various examples of colored portions  38  are shown and described herein, the exact number and location of the colored portions  38  are expected to vary as needed. In at least one embodiment, the colored portions comprise 0.5 to 20% of the surface area of cushion  34 , in another embodiment, 1 to 15%, and in yet other embodiments, 2 to 10%, based on the total surface area of the cushion  34 . 
         [0033]    The colored surface portions  38  of the cushion  34  can be provided in any suitable manner. In at least one embodiment, paint or other colored coating, such as IMC (in-mold coating), are provided on selected portions, i.e., anticipated uncovered areas  37 , of the surface of the foam cushion  34 . The colored coating is illustrated as  39 . While any suitable paint or other colored coatings could be used, in at least one embodiment, the colored coating is a polyurethane in-mold coating. 
         [0034]    In at least one embodiment, suitable polyurethane in-mold coatings are formed from suitable colored polyurethane coating compositions that comprise liquid isocyante, liquid polyol and liquid colorant. In at least a further embodiment, the polyurethane composition is an aromatic composition. 
         [0035]    Any suitable liquid isocyanate, such as an aromatic isocyanate, can be used. Examples of suitable aromatic liquid isocyanates include, but are not necessarily limited to, MDI and TDI. Alternatively, liquid aliphatic isocyanate could also be used. The liquid isocyanate could have suitable additives, such as UV inhibitors/stabilizers, especially if the isocyanate is aromatic. Suitable suppliers of suitable liquid isocyanates include Huntsman of Auburn Hills, Mich.; Bayer Polymers of Pittsburgh, Pa.; and Dow Chemical of Freeport, Tex. 
         [0036]    Any suitable liquid polyol can be used. In at least one embodiment, the polyol employed is a polyether polyol. Examples of suitable liquid polyols include, but are not necessarily limited to, graft polyols, PhD polyols, Polymer Polyols, and PIPA polyols. Suitable suppliers of suitable liquid polyols include Dow Chemical of Freeport, Tex.; BASF Corporation of Wyandotte, Mich.; and Bayer Polymer of Pittsburgh, Pa. The liquid polyol could have suitable additives, especially if aliphatic, such as UV and antioxidant inhibitors/stabilizers, such as Irganox 1175, Tinuvin 765 and TIN B-75, from Ciba Specialty Chemicals of Terrytown, N.Y., and Cyasorb®. Family UV stabilizers and antioxidants from Cytec Polymers of Stamford, Conn. 
         [0037]    Any suitable liquid colorant can be used. Examples of suitable liquid colorants include, but are not necessarily limited to, finely ground pigment dispersed in a liquid component useable in the formation of polyurethane, such as polyol and/or isocyanate. Other suitable colorants, such as liquid dyes, can also be used. Suppliers of suitable colorants include Rite Systems of West Chicago, Ill. and PolyOne of North Baltimore, Ohio. In certain embodiments, the liquid colorant includes a UV stabilizer, such as zinc, benzophones, benzotriazole, and benzoxazione to inhibit UV degradation should the resultant polyurethane skin be exposed to UV light. Other suitable additives could be included, such as, but not necessarily limited to, triazines and radical scavengers, as are available from Ciba Specialty Chemicals and Cytec Polymers. 
         [0038]    In at least one embodiment, the colorant (i.e., dye or pigment) is provided in an amount of 1 to 20 wt. %, based on the total weight of the colored coating composition, and in other embodiments an amount of 3 to 10 wt. %, based on the total weight of the colored coating composition. 
         [0039]    While any suitable thickness of colored coating  39  can be used, in at least one embodiment, the colored coating is provided in an amount of an average thickness of 0.1 to 3 mm, in another embodiment of 0.5 to 2.25 mm, and in yet another embodiment, 0.75 to 1.25 mm. 
         [0040]    In at least one embodiment, the colored coating  39  has a length of 0.25 to 400 cm and an average width of 5 to 150 mm. In at least another embodiment, the colored coating  39  has a length of 2 to 150 cm and an average width of 10 to 100 mm. The coating  39  is applied so as to match an area on the foam that is likely to be exposed by trim openings, i.e., uncovered areas  37 , for closure, clip pass-through, and at the base of the trimmed foam cushion  34  when the seat is folded. 
         [0041]    In at least one embodiment, the colored coatings  39  are such a color that they are substantially similar to the color of the trim material  36 . In other embodiments, the colored coatings  39  and such a color that they are identical to the color of the trim material  36 . In yet other embodiments, the colored coatings  39  are such a color that the color contrast between the trim material  36  and the cushion  34  is substantially alleviated, relative to the uncoated cushion portions  15 . For instance, the color of the colored coating  39  can be close to the color of the trim material  36  such that the difference in grey scale between the coating(s)  39  and the trim material  36  is less than 25%, in other embodiments from 1 to 15%, and in yet other embodiments from 1 to 10%. 
         [0042]    However, it should be understood that in some instances where the trim material  36  is light in color, it may be desirable to provide dark colored coatings  39  so that a dark color coating shows through instead of the foam material. This can result in a more “finished” appearance, and as such there may be instances where the difference in grey scale between the coatings  39  and the trim material  36  can be greater than 25%, in some embodiments from 50 to 80%, and in other embodiments from 60 to 95%. 
         [0043]    The colored coating  39  can be provided in any suitable manner. In at least the embodiment illustrated in  FIG. 4 , the colored coating  39  is deposited onto a cushion mold  40  at selected locations  42  via spraying. The desired colored coating composition is sprayed via a spray nozzle  46  which is in communication with a colored coating composition source  48 . After the colored coating composition is sprayed onto the selected areas  42  of the mold  40  that would correspond to anticipated and/or actual uncovered areas  37  of the seat cushion  34 , the mold  40  is then closed and foam forming materials from foam source  52  is introduced into the cavity  54  of the mold  40 . The coating composition  56  within the cavity  54  is still uncured at this point. The foam forming material and the coating composition  56  are then cured to form a seat cushion  34  having colored coatings  39  at selected portions. The cushions  34  are then secured to a metal frame  14  with the trim cover  36  being secured thereon to form a seat assembly  10 . 
         [0044]      FIG. 5  illustrates a schematic representation of the foam molding process. First the mold is cleaned  1  and then optional mold release application is applied  3  to the mold surfaces. An in-mold paint or other colored coating composition is applied to selected portions of the mold. If necessary, inserts provided within the mold cavity  7  and then foam forming material such as urethane are dispensed  9  within the cavity of the mold. The foam and the in-mold paints or colored coating composition are then cured  11  and the resulting cured foam cushion having selected colored portions is then de-molded  13 . 
         [0045]    In another embodiment, as best shown in  FIG. 6 , the seat cushion  34  is first formed and then the coatings  56  are sprayed at selected portions of the seat cushion  34 . The coatings  56  are then cured on the cushion  34  to form the colored portion  38  of the cushion  34 . The cushions are then secured to the frame member  14  with the trim material  36  secured thereon to provide a seat assembly  10 . 
         [0046]    While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Moreover, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from spirit and scope of the invention.