Patent Publication Number: US-2011053448-A1

Title: Trim cover assembly and a method of manufacture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to DE 10 2009 039 178.9, filed Aug. 28, 2009, which is hereby incorporated by reference in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a trim cover assembly and a method of manufacture. 
     SUMMARY OF THE INVENTION 
     In at least one embodiment, a trim cover assembly is provided. The trim cover assembly includes a first layer and a second layer. The first layer has a first surface and a second surface disposed opposite the first surface. The second layer is bonded against the second surface. The second layer inhibits plastic deformation of the first layer. 
     In at least one embodiment, a method of making trim cover assembly is provided. The method includes the steps of providing a first layer, a first bonding layer, and a second layer having a polymeric material, positioning the first bonding layer between the first and second layers, and, applying heat and pressure to activate the polymeric material to adhere the first bonding layer to the first and second layers. The second layer and the first bonding layer cooperate to permit elastic deformation of the first layer while inhibiting plastic deformation of the first layer. 
     In at least one other embodiment a trim cover assembly is provided. The trim cover assembly includes a first layer. A first bonding layer is bonded to the first layer. A second layer is bonded to the first bonding layer. A second bonding layer is bonded to the second layer. A third layer is bonded to the second bonding layer. A third bonding layer is bonded to the third layer. A fourth layer is bonded to the third bonding layer. The second layer and first bonding layer cooperate to inhibit plastic deformation of the first layer. The third and fourth layers provide cushioning. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective section view of a trim cover assembly. 
         FIG. 2  is a magnified view of a layer of the trim cover assembly. 
         FIG. 3  is a flowchart of a method of manufacture of the trim cover assembly. 
     
    
    
     DETAILED DESCRIPTION 
     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. In addition, any or all features from one embodiment may be combined with any other embodiment. 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. 
     Referring to  FIG. 1 , a portion of an exemplary trim cover assembly  10  is shown. The trim cover assembly  10  may be configured for use in vehicular or non-vehicular applications. For example, in a vehicular application like for a car or truck, the trim cover assembly  10  may be provided on an interior trim component, such as a seat, door panel, instrument panel, or console. Examples of non-vehicular applications include seats, furniture, accessory bags, and clothing. In the discussion below, the trim cover assembly  10  will primarily be described in the context of a seat. 
     The trim cover assembly  10  may comprise at least a portion of an exterior surface of an article of manufacture. As such, the trim cover assembly  10  may provide a visible surface. A visible surface of the trim cover assembly  10  may include one or more decorative features, such as a groove, logo, or contoured surface. In various applications, a load force may be placed on the trim cover assembly  10 , such as may occur when a seat occupant sits on a seat having a trim cover. It may be desirable to inhibit plastic deformation of a visible surface of the trim cover assembly (or other deformation from which the visible surface cannot recover) to inhibit creasing, wrinkling and/or bulging that may degrade aesthetic appearance and/or reduce seating comfort. Plastic deformation may result from a sufficiently high load force exerted against a surface of a trim cover that does not have sufficient plastic deformation inhibiting characteristics. 
     Referring to  FIG. 1 , a portion of the trim cover assembly  10  is shown in more detail. The trim cover assembly  10  may include a plurality of layers. The layers may be superimposed over each other; however, a layer may or may not completely separate two adjacent layers from each other. 
     The trim cover assembly  10  may include a first layer  20 , a first bonding layer  22 , a second layer  24 , a second bonding layer  26 , a third layer  28 , a third bonding layer  30 , and a fourth layer  32 . The trim cover assembly  10  may be provided as a laminate in which the first, second, and third bonding layers  22 ,  26 ,  30  adhere or bond one or more layers  20 ,  24 ,  28 ,  32  together as will be discussed in more detail below. In addition, one or more of the layers may be omitted or repositioned in alternate embodiments. 
     The first layer  20  may provide at least a portion of an exterior or visible surface of the trim cover assembly  10 . As such, the first layer  20  may include an exterior or first surface  40  and a second surface  42  disposed opposite the first surface. The first layer  20  may be made of any suitable material or materials, such as leather, vinyl, or fabric. In the discussion below, the first layer  20  is generally described in the context of a tanned leather skin. 
     The first bonding layer  22  may be disposed against or in direct physical contact with at least a portion of the first and second layers  20 ,  24 . For instance, a first region or surface of the first bonding layer  22  may contact the second surface  42  and a second region or surface may contact the second layer  24 . The first bonding layer  22  may attach, adhere, or bond the first layer  20  and the second layer  24  together. The first bonding layer  22  may be heat activated and may be configured as a heat activated adhesive web or resin. In addition, the first bonding layer  22  may be high frequency weldable and may be provided without bodying modifiers or blowing agents in one or more embodiments. The first bonding layer  22  may be configured to reach a softening, melting, and “stick points” above room temperature. For example, the first bonding layer  22  may be configured with a stick point in the range of about 60-90° C. and a melting point of about 80-110° C. The first bonding layer  22  may be made of any suitable material, such as a polymeric material like a copolyester thermoadhesive or a copolyamide. Examples of suitable first bonding layers  22  are Spunfab Ltd. product number PA1801 and Protechnic product number WEB 9L8. 
     Referring to  FIGS. 1 and 2 , the second layer  24  may be disposed between the first and third layers  20 ,  28 , presuming that a third layer  28  is provided. For instance, the second layer  24  may include a first surface  50  that faces toward the first layer  20  and a second surface  52  disposed opposite the first surface  50 . At least a portion of the first surface  50  may be in direct physical contact with the first bonding layer  22 . Moreover, a portion of the first surface  50  may contact a portion of the first layer  20  in one or more embodiments. The second layer  24  may inhibit stretching of the first layer  20  while providing a desired level of flexibility. More specifically, the second layer  24  may help inhibit plastic deformation of the first layer  20  in cooperation with the first bonding layer  22  while permitting elastic deformation of the first layer  20 . In at least one embodiment, plastic deformation of the first layer  20  may also be inhibited by placing the second layer in close physical proximity with the first layer rather than via separation by multiple intermediate layers. 
     The second layer  24  may be have a different configuration and/or may be made of one or more materials that differ from the first layer  20 . For example, the second layer  24  may be provided as a cloth, fabric or woven material that may include a plurality of fibers and/or a plurality of materials. The second layer  24  may include a first material  60  and a second material  62  that differs from the first material  60 . The first and second materials  60 ,  62  may be provided with different melting points to facilitate limited bonding of fibers during manufacture. In at least one embodiment, the first material  60  may be a polymeric material, such as polyester, and the second material  62  may be an organic material, such as cotton. Moreover, the second layer  24  may be composed of a greater quantity of the first material  60  or one or more materials having a lower melting point than the second material  62  to provide the opportunity to create physical bonds  64  in the first material  60  that may not be present before manufacture of the trim cover assembly  10 . Such bonds may be provided in a majority of the composition of the second layer  24 . For instance, the second layer  24  may include more than 50% of a polymeric material, such as polyester, and the remainder may be cotton. As such, the polymeric material may be melted or bonded together during manufacture while the cotton fibers do not melt together, thereby helping to maintain a desired level of flexibility. In another embodiment, the second layer  24  may be provided with different polymeric materials, such as polyester or PESF and viscose or CV. Such materials or fibers may have dissimilar or non-overlapping softening or melting temperature ranges. In at least one embodiment, at least one material may soften or melt in a temperature range that overlaps the activation temperature of one or more bonding layers  22 ,  26 ,  30 . 
     The reinforcement qualities of the second layer  24  that may help inhibit plastic deformation of the first layer may also be affected by the type or “tightness” of the weave of the fabric. For instance, a tighter weave or greater thread density may help provide more load bearing fibers and/or more melting or bonding points between fibers than a looser weave or lower thread density. Resistance to tensile axial elongation, such as along a line or surface that does not intersect another layer, may be proportional to the tightness of the weave. An example of a suitable “tight weave” fabric is Greve &amp; Co. KG product no. 50000 1983 0689/1500. An example of a suitable “loose weave” fabric is Kufner International product no. R171G46. 
     Referring again to  FIG. 1 , the second bonding layer  26  may be disposed in direct physical contact with at least a portion of the second and third layers  24 ,  28 , presuming that a third layer  28  is provided. For instance, a first region or surface of the second bonding layer  26  may contact a region or surface of the second layer  24  that faces away from the first layer  20 . The second bonding layer  26  may attach, adhere, or bond the second layer  24  and the third layer  28  together. The second bonding layer  26  may have the same configuration as the first bonding layer  22  and may be heat activated or may be configured as a heat activated adhesive web or resin. In addition, the second bonding layer  26  may be high frequency weldable and may be provided without bodying modifiers or blowing agents in one or more embodiments. The second bonding layer  26  may activate or adhere at similar temperatures and pressures as the first bonding layer  22 . 
     The third layer  28  may be disposed between the second and fourth layers  24 ,  28 , if provided. For instance, the third layer  28  may include a first surface  70  that faces toward the second layer  24  and a second surface  72  disposed opposite the first surface  70 . At least a portion of the first surface  70  may be in direct physical contact with the second bonding layer  26 . Moreover, a portion of the first surface  70  may contact a portion of the second layer  24  in one or more embodiments. The third layer  28  may be have a different configuration and/or may be made of a material that differs from that of the first and second layers  20 ,  24 . The third layer  28  may be made of one or more materials that provide cushioning, such as foam. 
     The third bonding layer  30  may be disposed in direct physical contact with at least a portion of the third and fourth layers  28 ,  32 , if provided. For instance a first region or surface of the third bonding layer  30  may contact a region or surface of the third layer  28  that faces away from the first layer  20 . In addition, the third bonding layer  30  may attach, adhere, or bond the third layer  28  and the fourth layer  32  together. The third bonding layer  28  may have the same or similar configuration as the first and second bonding layers  22 ,  26  and may be heat activated or may be configured as a heat activated adhesive web or resin. In the embodiment shown, the third bonding layer  30  is shown with a different configuration than the first and second bonding layers  22 ,  26  to illustrate a bonding layer that may be provided with voids or gaps, such as may occur when a bonding layer is provided at discrete points or along different lines or areas that may or may not intersect. The third bonding layer  30  may activate or adhere at similar temperatures and pressures as the first and/or second bonding layers  22 ,  26 . 
     The fourth layer  32 , if provided, may be disposed proximate the third layer  28 . For instance, the fourth layer  32  may include a first surface  80  that faces toward the third layer  28  and a second surface  82  disposed opposite the first surface  80 . At least a portion of the first surface  80  may be in direct physical contact with the third bonding layer  30 . Moreover, a portion of the first surface  80  may contact a portion of the third layer  28 . In the embodiment shown, the second surface  82  is disposed opposite the first surface  40  of the first layer  20 . 
     The fourth layer  32  may be have a different configuration and/or may be made of a material that differs from that of the first, second, and third layers  20 ,  24 ,  28 . For example, the fourth layer  32  may be a woven or unwoven material, such as fleece, that helps provides cushioning. In at least one embodiment, the third and fourth layers  28 ,  32  may be preassembled or attached to each other before attachment to the second layer  24 . Alternatively, the fourth layer  32  may be a coating or fabric layer that may help provide wear resistance. In a seating application, the second surface  82  may be disposed proximate or against a cushion that may be directly or indirectly supported by a support structure or frame. Alternatively, additional layers may be provided on the second surface  82  in one or more embodiments. 
     Referring to  FIG. 3 , a flowchart depicting an exemplary method of manufacture of the trim cover assembly  10  is provided. 
     At block  100 , the components to be assembled may be provided. The components to be assembled may include the first layer  20 , the first bonding layer  22  and the second layer  24 . The second bonding layer  26  and third layer  28  may be provided in embodiments having a third layer  28 . Similarly, the third bonding layer  30  and fourth layer  32  may be provided in embodiments having a fourth layer  32 . The layers may be provided separately or one or more layers may be preassembled in any suitable combination. For example, the third layer  28 , third bonding layer  30 , and fourth layer  32  may be preassembled and provided as a subassembly laminate. One or more layers may be provided as a sheet and may be provided on a roll to facilitate high volume production. In addition, one or more bonding layers  22 ,  26 ,  30  may be provided with or as part of another material or layer. For instance, the first or second bonding layers  22 ,  26  may be preassembled or provided as part of the second layer  24 . 
     At block  102 , the components may be configured to a predetermined size and/or shape. For instance, a first layer  20 , such as a leather layer, may be cut to a desired shape or attached to other leather or non-leather pieces in any suitable manner to preassemble the first layer  20 . Similarly, one or more of the other layers  22 ,  24 ,  26 ,  28 ,  30 ,  32  may be cut, shaped, or formed to a desired configuration. This step may be omitted or performed later in the process, such as after block  104  or  106  in one or more embodiments. 
     At block  104 , the components may be positioned with respect to each other. The layers may be placed in a predetermined sequence. For instance, the first bonding layer  22  may be positioned adjacent to the first layer  20 , the second layer  24  may be positioned adjacent to the first bonding layer  22 , the second bonding layer  26  may be placed adjacent to the second layer  24 , and so on. One or more layers may be manually positioned or positioned via automation. For instance, one or more layers may be unrolled and routed in close physical proximity to each other in a continuous flow assembly process. 
     At block  106 , the components may be joined (e.g., attached, adhered, bonded together). In at least one embodiment, heat and pressure may be provided to activate the bonding layers  22 ,  26 ,  30  at approximately the same time. The amount of heat and pressure applied may be configured to active one or more bonding layers  22 ,  26 ,  30 . The heat and/or pressure that activate the bonding layers may also melt or fuse together fibers in the second layer  24 . As such, the tensile strength of the second layer  24  may increase from its original condition when the materials are joined due to the attachment or fusing together of individual fibers. 
     Heat and pressure may be provided in any suitable manner. For instance, the components may be positioned in a press having first and second dies or contact surfaces. The first and second contact surfaces may be heated. In addition, the first and second contact surfaces may be heated to different temperatures. In an embodiment having a leather first layer  20 , the contact surface that contacts the first layer  20  may be heated to a lower temperature than the other contact surface to prevent heat damage to the first layer  20 . In a continuous flow assembly process, the components may pass one or more sets of rollers help position and apply pressure to the layers. A set of rollers may be heated to apply the desired level of thermal energy. In addition, different rollers may be heated to different temperatures similar to the press embodiment described above. 
     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. Rather, 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 the spirit and scope of the invention.