Method for forming motor vehicle seat uphosltery

Patent metadata

Field	Value
Publication number	US-10137615-B2
Application number	US-201414907950-A
Country	US
Kind code	B2
Filing date	Aug 1, 2014
Priority date	Aug 2, 2013
Publication date	Nov 27, 2018
Grant date	Nov 27, 2018

Abstract

A method for producing a cover element for upholstery of a motor vehicle seat element, includes at least one layer of foam and a cap made at least from a covering material. The forming of the cover element includes the steps of: placing the cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix; holding the cap pressed against the matrix by suction; placing the at least one layer of foam against a back of the covering material; and applying a forming punch defining a rear face of the cover element.

First claim

The invention claimed is:

1. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:
placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;
maintaining the cap pressed against the matrix by suction;
placing said at least one layer of foam against a back of said covering material; and
applying a forming punch defining a rear surface of the cover element;
wherein a foam thickness of the at least one layer of foam is obtained by spraying foam on a substrate supported by a suction plate.

2. The method of claim 1 , wherein said substrate is a polyethylene film.

3. The method of claim 1 , wherein said substrate comprises a slit foam layer.

4. The method of claim 1 , wherein said substrate comprises a woven or nonwoven textile.

5. The method of claim 1 , wherein the cap has a permeability to air smaller than 300 liters/m 2 per second.

6. The method of claim 1 , wherein the cap further comprises a barrier layer made of polyurethane.

7. The method of claim 6 , wherein the covering material is assembled with the barrier layer by sewing along style feature lines.

8. The method of claim 1 , wherein the covering material is skin.

9. The method of claim 1 , wherein a thickness of the cover element is in the range from 5 to 40 mm.

10. The method of claim 1 , wherein elements for fastening the cover element to a support block are embedded in the at least one layer of foam.

11. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:
placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;
maintaining the cap pressed against the matrix by suction;
placing said at least one layer of foam against a back of said covering material; and
applying a forming punch defining a rear surface of the cover element;
wherein the cap has a permeability to air smaller than 300 liters/m 2 per second.

12. A method of forming a cover element for upholstery of an element of a motor vehicle seat, comprising at least one layer of foam and a cap comprising at least a covering material, wherein the forming of the cover element comprises the steps of:
placing said cap against a matrix defining the visible shape of the cover element, with the covering material on a side of the matrix;
maintaining the cap pressed against the matrix by suction;
placing said at least one layer of foam against a back of said covering material; and
applying a forming punch defining a rear surface of the cover element;
wherein the cap further comprises a barrier layer made of polyurethane.

Assignees

• Faurecia Sieges Dautomobile

Inventors

• Thomas Julie
• Etienne Fabrice
• Lemarchand Robert

Classifications

• B32B2605/003

  Interior finishings · CPC title

• B29L2031/58

  Upholstery or cushions, e.g. vehicle upholstery or interior padding {(mattresses, cushions B29L2031/751)} · CPC title

• B32B27/065

  of foam · CPC title

• B29D99/0092

  Producing upholstery articles, e.g. cushions, seats (B29C63/025 takes precedence) · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title