CN102001199B - 装饰覆盖物组件及制造方法 - Google Patents

装饰覆盖物组件及制造方法 Download PDF

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Publication number
CN102001199B
CN102001199B CN201010244730.8A CN201010244730A CN102001199B CN 102001199 B CN102001199 B CN 102001199B CN 201010244730 A CN201010244730 A CN 201010244730A CN 102001199 B CN102001199 B CN 102001199B
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China
Prior art keywords
layer
binder course
ground floor
decorative cover
cover assembly
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Expired - Fee Related
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CN201010244730.8A
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CN102001199A (zh
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拉尔夫·霍布尔
凯文·约翰·威瑟斯
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Lear Corp
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Lear Corp
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
    • A47C31/10—Loose or removable furniture covers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Textile Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)

Abstract

本发明涉及装饰覆盖物组件及制造方法。公开了一种装饰覆盖物组件及制造方法。该装饰覆盖物组件具有第一层和第二层。第一层具有第一表面和布置成对置于该第一表面的第二表面。第二层布置成靠着第二表面。第二层阻止第一层的塑性变形。

Description

装饰覆盖物组件及制造方法
相关申请的交叉引用 
本申请根据35U.S.C.§119(a)-(d)要求于2009年8月28日提交的DE 102009039178.9的外国优先权权益，其通过引用全文合并于此。 
技术领域
本发明涉及装饰覆盖物组件及制造方法。 
发明内容
在至少一个实施方式中，提供装饰覆盖物组件。该装饰覆盖物组件包括第一层和第二层。该第一层具有第一表面以及布置成对置于第一表面的第二表面。第二层靠着第二表面结合。第二层阻止第一层的塑性变形。 
在至少一个实施方式中，提供制造装饰覆盖物组件的方法。该方法包括步骤：提供第一层、第一结合层以及具有聚合物材料的第二层；将第一结合层定位在第一层和第二层之间；以及施加热和压力以活化聚合物材料，以使第一结合层附着于第一层和第二层。第二层和第一结合层配合，以允许第一层的弹性变形，同时阻止第一层的塑性变形。 
在至少一个另外的实施方式中，提供装饰覆盖物组件。该装饰覆盖物组件包括第一层。第一结合层结合到第一层。第二层结合到第一结合层。第二结合层结合到第二层。第三层结合到第二结合层。第三结合层结合到第三层。第四层结合到第三结合层。第二层和第一结合层配合，以阻止第一层的塑性变形。第三层和第四层提供缓冲。 
附图说明
图1为装饰覆盖物组件的透视截面图。 
图2为装饰覆盖物组件的层的放大视图。 
图3为装饰覆盖物组件的制造方法的流程图。 
具体实施方式
本文公开了本发明的详细实施方式；然而，应理解，公开的实施方式仅为可以体现在各种以及可选择的形式中的本发明的示范。附图未必按照比例绘制，一些特征可能被扩大或缩小以示出特定部件的细节。另外，来自一个实施方式的任何或全部特征可以与任何其他的实施方式结合。因此，本文公开的具体结构和功能的细节不应被解释成限制性的，而仅仅是作为权利要求的代表性基础和/或作为教授本领域技术人员以各种形式使用本发明的代表性基础。 
参照图1，示出了示范性的装饰覆盖物组件10的一部分。装饰覆盖物组件10可以配置成在交通工具或非交通工具的应用中使用。例如，在比如汽车或卡车的交通工具应用中，装饰覆盖物组件10可以设置在内部装饰部件上，比如座椅、门板、仪表板或控制台。非交通工具应用的例子包括座椅、家具、配件袋子以及衣服。在下文的讨论中，装饰覆盖物组件10将主要以座椅的角度来描述。 
装饰覆盖物组件10可以包括制造物品的外表面的至少一部分。因此，装饰覆盖物组件10可以提供可视表面。装饰覆盖物组件10的可视表面可以包括一个或多个装饰特征，比如沟槽、标志或带轮廓的表面。在各种用途中，负载力可能被设置在装饰覆盖物组件10上，例如可能在座椅乘坐者坐在具有装饰覆盖物的座椅上时发生。期望阻止装饰覆盖物组件10的可视表面的塑性变形(或可视表面不能从其恢复的其他变形)，以便阻止可能降低美观和/或降低座位舒适感的折缝、起皱和/或鼓起。塑性变形可能由抵着没有足够塑性变形阻止特性的装饰覆盖物的表面来施加的足够高的负载力而引起。 
参照图1，更详细地示出了装饰覆盖物组件10的一部分。装饰覆盖物 组件10可以包括多个层。这些层可以彼此叠加，然而，一层可以完全地将两个邻近的层彼此分开，也可以不完全地将两个邻近的层彼此分开。 
装饰覆盖物10可以包括第一层20、第一结合层22、第二层24、第二结合层26、第三层28、第三结合层30以及第四层32。装饰覆盖物组件10可以设置成层压板，其中第一结合层、第二结合层以及第三结合层22、26、30像下文将要更详细地讨论的那样将一个或多个层20、24、28、32附着或结合在一起。另外，在可选择的实施方式中，这些层中的一个或多个可以被省略或重定位。 
第一层20可以提供装饰覆盖物组件10的外表面或可视表面的至少一部分。因此，第一层20可以包括外表面或第一表面40和布置成对置于第一表面的第二表面42。第一层20可以由任何合适的材料制成，比如皮革、乙烯树脂或织物。在下文的讨论中，第一层20大致上以鞣革皮(tannedleather skin)的角度来描述。 
第一结合层22可以布置成靠着第一层20和第二层24的至少一部分，或者与第一层20和第二层24的至少一部分直接物理接触。例如，第一结合层22的第一区域或表面可以接触第二表面42，并且第二区域或表面可以接触第二层24。第一结合层22可以将第一层20和第二层24连接、附着或结合在一起。第一结合层22可以为热活化的，并且可以配置成热活化的粘合剂网(heat activated adhesive web)或树脂。另外，在一个或多个实施方式中，第一结合层22可以为可高频焊接的，并且可以在没有稠化改性剂(bodying modifier)或发泡剂的情况下提供。第一结合层22可以配置成在室温以上达到软化、熔化以及“发粘点”。例如，第一结合层22可以配置成具有在大约60℃到90℃的范围内的发粘点以及大约80℃到110℃的熔化点。第一结合层22可以由任何合适的材料制成，比如类似于共聚多酯热粘合剂(copolyester thermoadhesive)或共聚酰胺的聚合物材料。合适的第一结合层22的例子为Spunfab Ltd.产品编号PA1801以及Protechnic产品编号WEB 9L8。 
参照图1和2，假设提供了第三层28，第二层24可以布置在第一层20和第三层28之间。例如，第二层24可以包括面向第一层20的第一表 面50和布置成对置于第一表面50的第二表面52。第一表面50的至少一部分可以与第一结合层22直接物理接触。此外，在一个或多个实施方式中，第一表面50的一部分可以接触第一层20的一部分。第二层24可以阻止第一层20的拉伸，同时提供期望程度的柔韧性。更具体地，第二层24可以与第一结合层22配合帮助阻止第一层20的塑性变形，同时允许第一层20的弹性变形。在至少一个实施方式中，第一层20的塑性变形也可以通过将第二层放置成紧密物理靠近第一层而不是经过由多个中间层分开来阻止。 
第二层24可以具有不同的构造和/或可以由区别于第一层20的一种或多种材料制成。例如，第二层24可以提供为布、织物或可包括多种纤维和/或多种材料的纺织材料。第二层24可以包括第一材料60和区别于第一材料60的第二材料62。第一材料和第二材料60、62可以设置成具有不同的熔点，以在制造过程中促进纤维的有限的结合。在至少一个实施方式中，第一材料60可以为聚合物材料，比如聚酯，并且第二材料62可以为有机材料，比如棉。此外，第二层24可以包括更大数量的第一材料60或者具有比第二材料62低的熔点的一种或多种材料，以便提供在第一材料60中产生在制造装饰覆盖物组件10之前可能不存在的物理结合64的机会。这些结合可以提供在第二层24的大多数的组成中。例如，第二层24可以包括多于50％的聚合物材料，比如聚酯，并且剩余部分可以为棉。就这点而论，在制造过程中，聚合物材料可以熔合或结合在一起，而棉纤维不会熔合到一起，从而帮助保持期望程度的柔韧性。在另一个实施方式中，第二层24可以提供有不同的聚合物材料，比如聚酯或PESF以及纤维胶或CV。这些材料或纤维可以具有不同的或不重合的软化或熔化温度范围。在至少一个实施方式中，至少一种材料可以在叠加了一个或多个结合层22、26、30的活化温度的温度范围内软化或熔化。 
可以帮助阻止第一层的塑性变形的第二层24的强化质量也可能受织物编织的类型或“紧密度”影响。例如，较紧密的编织或较大的线密度可以比较松散的编织或较小的线密度帮助提供更多的承载纤维和/或在纤维之间的更多的熔化或结合点。对于张力轴向拉伸(tensile axial elongation)，比如沿着不与另一层相交的线或表面，的阻力可能与编织的紧密度成比例。合适的“紧密编织”织物的一个例子是Greve & Co.KG产品编号S00001983 0689/1500。合适的“松散编织”织物的一个例子是Kufner International产品编号R171G46。
再次参照图1，假设提供了第三层28，第二结合层26可以布置成与第二层和第三层24、28的至少一部分直接物理接触。例如，第二结合层26的第一区域或表面可以接触第二层24的背离第一层20的区域或表面。第二结合层26可以将第二层24和第三层28连接、附着或结合在一起。第二结合层26可以具有与第一结合层22相同的构造，并且可以为热活化的或者可以配置成热活化的粘合剂网或树脂。另外，在一个或多个实施方式中，第二结合层26可以为可高频焊接的，并且可以在没有稠化改性剂或发泡剂的情况下提供。第二结合层26可以在与第一结合层22类似的温度和压力时活化或附着。 
第三层28可以布置在第二层24和第四层32之间，如果提供的话。例如，第三层28可以包括面向第二层24的第一表面70和布置成对置于第一表面70的第二表面72。第一表面70的至少一部分可以与第二结合层26直接物理接触。此外，在一个或多个实施方式中，第一表面70的一部分可以接触第二层24的一部分。第三层28可以具有不同的构造和/或可以由不同于第一层20和第二层24的材料制成。第三层28可以由提供缓冲的一种或多种材料制成，比如泡沫。 
如果提供了第三结合层30，则第三结合层30可以布置成与第三层28和第四层32的至少一部分直接物理接触。例如，第三结合层30的第一区域或表面可以接触第三层28的背离第一层20的区域或表面。另外，第三结合层30可以将第三层28和第四层32连接、附着或结合在一起。第三结合层30可以具有与第一结合层22和第二结合层26相同或类似的构造，并且可以为热活化的或者可以配置成热活化的粘合剂网或树脂。在示出的实施方式中，第三结合层30表示为具有与第一结合层22和第二结合层26不同的构造，以说明可设置有空洞或间隙的结合层，比如可能在结合层被提供在离散的点处或者沿着可能相交或可能不相交的不同的线或区域处 时发生。第三结合层30可以在与第一结合层22和/或第二结合层26类似的温度和压力时活化或附着。 
如果提供有第四层32，则第四层32可以布置成邻近于第三层28。例如，第四层32可以包括面向第三层28的第一表面80和布置成对置于第一表面80的第二表面82。第一表面80的至少一部分可以与第三结合层30直接物理接触。此外，第一表面80的一部分可以接触第三层28的一部分。在示出的实施方式中，第二表面82布置成对置于第一层20的第一表面40。 
第四层32可以具有不同的构造和/或可以由不同于第一层20、第二层24和第三层28的材料制成。例如，第四层32可以为帮助提供缓冲的纺织或非纺织材料，比如羊毛。在至少一个实施方式中，第三层和第四层28、32在连接到第二层24之前可以彼此预先组装或者连接。可选择地，第四层32可以为可帮助提供耐磨性的涂层或织物层。在座位应用中，第二表面82可以布置成靠近或抵住可直接地或间接地由支撑结构或框架支撑的垫子。可选择地，在一个或多个实施方式中，附加的层可以设置在第二表面82上。 
参照图3，提供了描绘制造装饰覆盖物组件10的示范性方法的流程。 
在方框100处，可提供将要被组装的部件。将要被组装的部件可以包括第一层20、第一结合层22和第二层24。在具有第三层28的实施方式中，可提供第二结合层26和第三层28。类似地，在具有第四层32的实施方式中，可提供第三结合层30和第四层32。这些层可以单独地提供，或者一个或多个层可以以任何合适的组合被预先组装。例如，第三层28、第三结合层30以及第四层32可以被预先组装并且提供为子组件层压板。一个或多个层可以设置为板，并且可以设置在卷上以促进大量生产。另外，一个或多个结合层22、26、30可以设置有或者设置为另外的材料或层的一部分。例如，第一结合层22或第二结合层26可以被预先组装为或者设置为第二层24的一部分。 
在方框102处，部件可以配置成预先确定的尺寸和/或形状。例如，第一层20，比如皮革层，可以以任何合适的方式切割成想要的形状或者连接 到其他皮革或非皮革件，以便预先组装第一层20。类似地，其他层22、24、26、28、30、32中的一个或多个可以被切割、成形或形成为想要的构造。该步骤可以在过程中被省略或以后执行，比如在一个或多个实施方式中在方框104或106之后。 
在方框104处，部件可以关于彼此定位。这些层可以以预定的次序放置。例如，第一结合层22可被定位成靠近第一层20，第二层24可被定位成邻近第一结合层22，第二结合层26可以被放置成邻近第二层24，等等。一个或多个层可以手动地定位或者利用自动化定位。例如，在连续的流水组装作业中，可将一个或多个层铺开并布置成彼此紧密物理接近。 
在方框106处，部件可以被接合(例如，连接、附着、结合在一起)。在至少一个实施方式中，可以提供热和压力，以便在近似相同的时间上活化结合层22、26、30。可配置施加的热和压力的量以活化一个或多个结合层22、26、30。活化结合层的热和/或压力也可以使第二层24中的纤维熔化或熔合在一起。因此，当材料由于单独的纤维连接或熔合在一起而接合时，第二层24的抗拉强度可以从其初始状态增加。 
可以以任何合适的方式提供热和压力。例如，部件可以定位在具有第一模具和第二模具或接触表面的压力机中。第一接触表面和第二接触表面可以被加热。另外，第一接触表面和第二接触表面可以被加热到不同的温度。在具有皮革第一层20的实施方式中，接触第一层20的接触表面可以被加热到和另一接触表面相比较低的温度，以便防止对第一层20的热损坏。在连续的流水装配作业中，部件可以经过一组或多组辊子以帮助定位这些层和对这些层施加压力。可以将一组辊子加热，以便施加期望程度的热能。另外，不同的辊子可以被加热到类似于上文描述的压力机实施方式的不同的温度。 
虽然已经阐明和描述了本发明的实施方式，但是这些实施方式并不能用来阐明和描述本发明所有可能的形式。更确切地说，说明书中所使用的词汇为描述性的词汇而非限制性的词汇，并且应理解到，可以做出各种改变而不背离于本发明的精神和范围。 

Claims (20)

1.一种装饰覆盖物组件，包括：
第一层，其具有第一表面和布置成对置于所述第一表面的第二表面；以及
第二层，其靠着所述第二表面结合；
第二结合层，其结合到所述第二层；
第三层，其结合到所述第二结合层；
第三结合层，其结合到所述第三层；以及
第四层，其结合到所述第三结合层，其中所述第四层具有布置成对置于所述第一层的所述第一表面的表面，该表面是所述装饰覆盖物组件的另一外表面；
其中，所述第二层阻止所述第一层的塑性变形；并且
其中，所述第二层包括由第一材料制成的第一组纤维和由不同于所述第一材料的第二材料制成的第二组纤维，其中，所述第一组纤维的组成部分的至少一部分彼此结合，以便形成阻止所述第一层的张力拉伸的至少一个连接点。
2.如权利要求1所述的装饰覆盖物组件，其中，所述第一层为皮革。
3.如权利要求1所述的装饰覆盖物组件，还包括第一结合层，所述第一结合层靠着所述第二表面和所述第二层布置，其中，所述第二层为织物，并且所述第一结合层为热活化的结合剂。
4.如权利要求3所述的装饰覆盖物组件，其中，所述第二层包括第一材料和区别于所述第一材料的第二材料，其中，所述第一材料配置成当所述热活化的结合剂被活化时熔化，以便将所述第一层和所述第二层附着在一起。
5.如权利要求3所述的装饰覆盖物组件，其中，所述第二层包括第一材料和第二材料，所述第一材料为有机纤维，所述第二材料为聚合物。
6.如权利要求5所述的装饰覆盖物组件，其中，所述第一材料为棉，并且所述第二材料为聚酯。
7.如权利要求3所述的装饰覆盖物组件，其中，所述第一结合层配置成具有在60℃到90℃的范围内的发粘点以及80℃到110℃的熔化点。
8.如权利要求1所述的装饰覆盖物组件，其中所述第三层通过所述第二结合层叠压到所述第二层。
9.如权利要求8所述的装饰覆盖物组件，其中，所述第三层为泡沫。
10.如权利要求8所述的装饰覆盖物组件，其中所述第四层通过所述第三结合层叠压到所述第三层。
11.如权利要求10所述的装饰覆盖物组件，其中，所述第四层为羊毛材料。
12.如权利要求8所述的装饰覆盖物组件，其中，所述第一层为皮革，所述第二结合层为热活化的粘合剂树脂，并且所述第三层为织物，其中，所述第二结合层和所述第三层配合以允许所述第一层的弹性变形，并阻止所述第一层的塑性变形，并且其中，对张力轴向拉伸的阻力与织物的编织的紧密度成比例。
13.一种制造装饰覆盖物组件的方法，包括：
提供第一层、第一结合层以及具有聚合物材料的第二层；
将所述第一结合层定位在所述第一层和所述第二层之间；以及
施加热和压力以活化聚合物材料，以便使所述第一结合层附着于所述第一层和所述第二层；
其中，所述第二层和所述第一结合层配合，以允许所述第一层的弹性变形，同时阻止所述第一层的塑性变形，并且所述第一结合层配置成具有在60℃到90℃的范围内的发粘点以及80℃到110℃的熔化点。
14.如权利要求13所述的方法，其中，施加热和压力的步骤包括：对所述第一层的第一表面施加第一程度的热，以及对所述装饰覆盖物组件的布置成对置于所述第一表面的表面施加第二程度的热，其中，所述第一程度的热小于所述第二程度的热。
15.如权利要求13所述的方法，其中，提供第一层的步骤包括：将所述第一层切割到预定的形状。
16.如权利要求13所述的方法，其中，所述第二层包括第一材料和不同于所述第一材料的第二材料，并且其中，施加热和压力的步骤还包括：将所述第一材料的至少一部分熔合在一起。
17.如权利要求13所述的方法，其中，所述第二层包括第一纤维材料和不同于所述第一纤维材料的第二纤维材料，并且其中，施加热和压力的步骤还包括：将所述第一纤维材料的纤维的至少一部分熔化在一起，而没有将所述第二纤维材料的纤维熔化在一起。
18.如权利要求13所述的方法，其中，在施加热和压力之后，所述第二层的抗拉强度增加。
19.如权利要求13所述的方法，还包括：提供邻近于所述第二层的第二结合层、邻近于所述第二结合层的第三层、邻近于所述第三层的第三结合层，以及第四层，其中，热和压力被施加到所述第一层和所述第四层，以便将所述第一层、第一结合层、第二层、第二结合层、第三层、第三结合层和第四层结合在一起。
20.一种装饰覆盖物组件，包括：
第一层，其具有第一表面，所述第一表面为所述装饰覆盖物组件的外表面；
第一结合层，其结合到所述第一层；
第二层，其结合到所述第一结合层；
第二结合层，其结合到所述第二层；
第三层，其结合到所述第二结合层；
第三结合层，其结合到所述第三层；以及
第四层，其结合到所述第三结合层，其中所述第四层具有接触所述第三结合层的第一表面和布置成对置于所述第一层的所述第一表面的第二表面；
其中，所述第二层和所述第一结合层配合，以阻止所述第一层的塑性变形，并且其中，所述第三层和所述第四层提供缓冲。
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