GB2597808A

GB2597808A - Method for shaping flexible material and products produced thereby

Info

Publication number: GB2597808A
Application number: GB2012735.3A
Authority: GB
Inventors: Corneloues Andrew; Silk David; Liles Joshua; Sassi Amira
Original assignee: Bayerische Motoren Werke AG
Current assignee: Bayerische Motoren Werke AG
Priority date: 2020-08-06
Filing date: 2020-08-14
Publication date: 2022-02-09
Also published as: GB2598212B; GB2598212A; GB202012735D0; GB202012287D0

Abstract

A product comprising a flexible material having opposite sides, the material comprising bends, a flexible, elongate and inextensible strand passing through the material from one side to the other and back again through the material, the bend in the material is formed by passage of the strand through the material and engagement between the strand and material such that movement of the strand and the material with respect to one another is prevented; the termini of the strand are unsecured with respect to the material. Also claimed is a method for shaping flexible material. The material may have uniform thickness and may be leather or textile. The material may be pre-perforated with regularly spaced holes. The holes may define vertices of polygons. Multiple strands may be used. The strands may be arranged in a flat or planar array. The strand may be a wire monofilament thread or fibre optic. The product may be used in vehicle, furniture clothing or part of a building.

Description

Method for Shaping Flexible Material and Products Produced Thereby The present application relates to methods for shaping materials, such as leather or textiles, so that the material has a predetermined pattern defined by raising or depressing defined areas or zones of the material above or below the plane of the flat material. The zones of the material that are raised or lowered in this way are defined by the passage of substantially inextensible elongate strands, such as monofilament fibres, metal wires or fibre optic filaments, through the material. Accordingly, the invention relates to methods for producing such products and the products themselves.

Manipulation of animal hides and other leathers are one of the oldest technologies known to mankind. Accordingly, shaping, cutting and embellishing such leathers are one of the oldest known human decorative activities. Stitching leathers in order to join and otherwise shape them has been known for millennia. Similarly, shaping leather by embossing or debossing leather by the application of a form or mould and pressure to the leather to cause the leather to conform to the shape of the mould has also been known for millennium.

Similarly, leather has been decorated by embroidering with thread since prehistoric times. Usually, embroidery is carried out by passing a filament, normally a thread, from back to front through the piece of leather being embroidered and then from the front to the back leaving a length of thread (a stitch) displayed on the front surface of the leather wherein the stitch is held in place by friction from the passage of the thread through the leather at either end of the stitch. A multiplicity of stitches can be built up into a decorative design and this design can be enhanced by the use of different coloured filaments or threads to yield different coloured stitches and thus multicoloured designs.

In addition, known techniques for changing the shape of leather and/or textiles by passing elongate strands or other fibres through the material of the leather or textile are known. However, these rely on tension generated in the elongate strands by the sewing process and this tension is normally maintained by securing the termini of the -2 -elongate strands with respect to the material by way of a knot or other stopper system.

However, such manipulations of leathers and other materials, such as textiles, and especially thick textiles, have the disadvantage of necessarily compressing and/or stretching, and thus potentially damaging the materials manipulated in this way. However, these techniques have persisted because of the requirement for complex shapes and decorations in these highly versatile materials.

Examples of the versatility of known techniques and their use can be seen in the textile galleries and archaeological collections in many museums worldwide.

Hence, there is a need for an alternative means of shaping leather, textiles or other materials wherein these materials are made to conform to or with specific three dimensional designs while providing reduced compression and/or stretching of the leather or textile during shaping that potentially damage the leather, textile or other material. Materials shaped in such a way are particularly suited to interior decoration of automobiles.

Accordingly, the object of the invention is to provide a method by which leather or a textile material, e.g. a woven, or non-woven textile, e.g. knitted textile, may be shaped according to a pre-determined pattern of raised and/or depressed zones in the shaped material without embossing or debossing the material of the leather or textile against a tool shaped to reflect the desired form of the embossed or debossed product.

Leather is a material created by tanning animal or cattle hide or skin. A textile is a flexible material consisting of a network of natural or artificial fibres (yarn or thread). Yarn is produced by spinning raw fibres of wool, flax, cotton, hemp, or other materials to produce long strands. Textiles are formed by weaving, knitting, crocheting, knotting, tatting, felting, or braiding yarns and/or threads.

There are known techniques for changing the shape of leather and/or textiles by passing elongate strands, such as yarn or thread, or other fibres, through the -3 -material of the leather or textile, but these rely on tension generated in the elongate strands and securing portions of the material with respect to the elongate strands so that the elastic force generated by deforming the material and/or the strands so that the material bears against and is maintained by tension in the elongate strands, which is maintained by way of a knot or other 'stopper' system which prevents movement of the termini of the elongate strands by securing the termini of the elongate strands with respect to the material.

The use of knots and/or other stopping systems causes weakness in the elongate strand, especially at the termini, and necessarily renders replacement of such elongate strands in such products difficult or impossible.

The present invention aims to overcome each of these problems.

Accordingly, the invention provides a product comprising a flexible material having two substantially opposite sides, wherein the material comprises one or more bends in pre-determined positions, wherein a flexible, elongate and substantially inextensible strand passes through the material from one side to the other and thence back again through the material, and wherein the bend in the material is formed by passage of the strand through the material and engagement between the strand and material such that movement of the strand and the material with respect to one another is prevented: and wherein the termini of the strand are unsecured with respect to the material.

The path of the flexible, elongate and substantially inextensible strand may be substantially linear or straight and the bends in the material of the product may be arranged to lie on one or both sides of this straight path, preferably both sides of this linear or straight path.

The invention also provides a method of shaping a piece of flexible material having two substantially opposite sides according to a pre-determined pattern, comprising the steps of: -4 - (a) passing a flexible, elongate and substantially inextensible strand through the material from one side to the other; and (b) thence passing the strand back through the material, thereby bringing the strand and material into contact such that movement of the strand and the material with respect to one another is prevented and thus a bend is formed in the material.

wherein the termini of the strand are unsecured with respect to the material.

In the context of the present invention shaping includes the acts of introducing bends and/or partial or complete folds into the flexible material. Thus, also in the context of the present invention, bending the flexible material, in order to make a bend therein, is to manipulate the flexible material by applying forces thereto so that the shape of the flexible material is changed. The original form of the flexible material is preferably straight, flat and/or planar. The effect of bending the flexible material may be to change the flexible material from a straight form into a curved or angular one, or from a curved or angular form into some different form, which may be a straight form.

The product formed by the method of the invention may be shaped such that the path of the flexible, elongate and substantially inextensible strand is substantially linear or straight and the bends in the material of the product may be formed to lie on one or both sides of this straight path, preferably on both sides of this linear or straight path.

Engagement in the context of the invention means that the elongate strand and material are in contact at particular and/or pre-defined locations and this contact prevents movement of the material with respect to the strand and vice versa. The force preventing or acting against such relative movement is preferably yielded by friction between the strands and the material at one or more, preferably all, of the contact points.

The flexible material may be engaged with the elongate strand such that the strand and material are substantially immobile with respect to one another. -5 -

In this context a terminus of the strand being unsecured with respect to the material of the product means that it is not essential for the stability of the shape of the product of the invention that the termini be secured via any additional stopping means, e.g. knots or repeated stitches in one location securing a strand terminus, in order to maintain tension along the length of the strand between the termini. It is sufficient for formation and/or maintenance of the structure of the product of the invention that tension forces borne within the strand are caused by engagement of the strand with the flexible material at their points of contact rather than by force applied at or near a terminus of the strand or the termini of the strand.

It was unexpected to the inventors that the form of the product of the invention would have such a stable form without the use of stopping means to secure one or both of the termini of the elongate strand. However, the interaction of the substantially inextensible strands with the flexible material has the synergistic effect of a stable interaction and thus produces a product with a substantially stable shape without the use of such means.

A pattern may be an individual or repeating pattern and therefore the term pattern also encompasses the pattern being a design for the form of the product produced or 20 being made.

The object of the invention is achieved by provision of the product of the invention defined above or by producing a product according to the method of the invention. In these products, or products produced according to the method the termini of the strand are unsecured with respect to the material and are shaped according to a predetermined pattern of raised and/or depressed zones in the shaped material without embossing or debossing the material of the leather or textile against a tool shaped to reflect the desired form of the embossed or debossed product.

Preferably the flexible material may be of substantially uniform or identical thickness.

The flexible material may be leather or a textile material according to the definitions given above. Preferably the flexible material is leather. -6 -

The flexible material may have a pre-perforated array of regularly spaced holes The array of pre-perforated holes comprises three or more lines of holes in the flexible material. Preferably the array comprises at least: four lines of holes; five lines of holes; six lines of holes; seven lines of holes; eight lines of holes; nine lines of holes; or ten lines of holes. Thus the array is two dimensional and is distinct from a one dimensional line of holes or two parallel lines of holes.

The regularly spaced holes may define the vertices of an array of polygons. This array may define the vertices of an array of rectangles and/or an array of triangles.

Further the regularly spaced holes may define the vertices of an array of regular polygons and this array might define the vertices of an array of squares or equilateral triangles.

Preferably the holes in the flexible material sit 5mm apart in a square grid.

The holes in the flexible material may be of any size suitable for allowing passage of the filament through them. The holes in the perforated flexible material may thus be circular, oval, rounded, square, polygonal or star shaped. Preferably the holes in the perforated flexible material are circular or oval. The holes in the perforated flexible material may be 0.1 to 3 mm across. The holes in the perforated flexible material may be 0.1, 0.25, 0.5, 0.75, 1, 2, or 3 mm across. Preferably the holes are 1 mm across.

All known types of perforated leather that are suitable to pass filament through may be used in the context of the present invention. The present invention has the advantage of not being limited to using leathers or materials that can be machine sewn. Preferably upholstery leather from bulls is used as this has the advantage of being the type of leather most commonly used in the automobile upholstery.

Accordingly, this type of leather is readily available and use of this type of leather minimises the adaptations required to use the present invention in the context of producing vehicle upholstery. Saddle leather can also be hand sewn through when perforated and thus can be used in the context of the present invention. Leathers -7 -from other sources may also be used: in particular, goat, ox, elk, kangaroo and deer leathers are suitable.

Preferably, the pre-perforated leather is that produced by HEWA with the pre-perforated holes in the leather located 5mm apart in a square grid.

The elongate strand is preferably substantially inextensible or significantly less extensible than known textile or embroidery threads. In practical terms the elongate strands do no stretch appreciably under normal loading. Preferably the filament is a metal wire, monofilament thread, fibre optic filament or acrylic wire. The filament may be coloured. The elongate strand may be of a single colour or multiple colours. Most preferably the elongate strand is a fibre optic filament. Preferably the fibre optic filament can transmit light along its length. Most preferably the fibre optic filament can emit light from all or a portion of the filament transmitting the light.

The fibre optic filaments may be gathered at the side or remove from the product of the invention to be illuminated by one or more light sources. This can be advantageously achieved because no knot or other structural change need be introduced into the elongate strand in order to maintain the structure of the product of the invention and thus the fibre optic strands may be illuminated efficiently without knots or other securing means being required.

The elongate strands are threads or flexible elongate members that are substantially inextensible. The cross section of these strands may vary significantly as long as the cross section provides for maintaining engagement between the material and the surface of the strand, preferably by friction, so that movement of the material with respect to the strand in the product of the invention is substantially prevented.

The flexible elongate and substantially inextensible strand may make at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, or 50 passes through the material. Preferably at least 5 passes through the material. Most preferably at least 10 passes through the material. Preferably the number of bends introduced into the flexible material will equal the number of passages of the elongate strand through the material minus 1. -8 -

An increased or greater number of passes through the material has the advantage of providing a greater number of points of contact between the strand and the material. Consequently there are additional friction forces preventing movement of the strand with respect to the material. Accordingly, a greater number of passes through the material yields a more stable engagement between the strand and the material and contributes to the product having greater structural stability.

Multiple flexible, substantially inextensible strands may be used. Preferably these multiple strands are arranged in a substantially flat or planar array. Preferably the strands are arranged to be substantially parallel Without wishing to be bound by theory, the array of inextensible monomer filament fibres defining a substantially laminar or planar structure that, in the context of the products of the invention, is sufficiently resilient that then the flexible material may be bent around and/or through in order to produce the 3D aspect of the design of the leather without substantially deforming the substantially laminar or planar structure of the array of inextensible monomer filament fibres. Thus, also not wishing to be bound by theory, the 3D deformation of the flexible material is due to the physical properties of the elongate strands and, particularly, that they are substantially inextensible.

Thus, again not wishing to be bound by theory, the fibres define a lamina shape, which is preferably flat, that effectively penetrates the three-dimensional shape of the flexible material being shaped as the inextensible strands pass therethrough. Thus the bending of the flexible material toward and away from the plane of this lamina is achieved by causing specific portions of the flexible material to be located on one 'face' of the lamina or another depending on the location of the elongate strands.

In addition, the elongate strands are not secured at their termini and no tethering of the elongate strands at their termini is required. The shape of the products are formed because the elongate strands penetrate the flexible material. That is the elongate strands do not have to be secured at their termini in order to have the effect of changing the 3D shape of the flexible material. -9 -

The elongate strand may be partially or completely incorporated into the product of the invention or according to the method of the invention by passing the flexible, elongate and substantially inextensible strand through the flexible material by hand.

Such a process may be closely akin to hand embroidery, however the use of a needle to guide the passage and course of the elongate strand is optional.

Accordingly, in the context of the present invention, passing the elongate strand through the material may include the acts of carrying and/or guiding the strand through the material on a tool for this purpose (e.g. on a sewing needle) or passing the strand through a perforation, hole or gap in the material using a tool for carrying and/or guiding the strand through the material on a tool for this purpose or otherwise. Thus methods of the present invention may comprise hand embroidery or machine sewing steps and/or processes.

Hand embroidery is advantageous in the context of the present invention because producing an embroidery in pre-perforated leather by machine requires exceedingly tight and consistent mechanical tolerances to stich through the pre-made holes without puncturing the leather elsewhere. A single failure would produce an extra hole and thus alter the mechanical properties of the embroidered leather piece and might compromise the usefulness of the pieces of embroidery in the methods of the invention. Thus hand embroidery according to the invention is advantageous over machine embroidery as there is less likelihood of damage to the embroidery piece during creation.

As noted above, the formation of such a structurally stable 'composite material' by combining a flexible material with inextensible elongate strands with untethered termini, i.e. the product of the invention, was unexpected. The resulting product of the invention is a synergistic combination of the contrasting properties of the flexible material and inextensible strands comprised in the product whereby it is flexible enough, strong enough and adaptable enough to be used in a variety of locations, including the cabin of an automobile.

-10 -In addition, a sound absorbing or deadening material may be selected for the flexible material of the product of the invention. Softer leathers and textiles are examples of such materials. Such materials are not generally structurally resilient of themselves but, notwithstanding this, and as noted above, products of the invention comprising such materials can be made to be structurally resilient. In addition, products of the invention can be shaped to comprise noise absorbing surfaces or baffles formed by folds in the flexible material that are secured in place by the elongate strands. Thus products of the invention are particularly well suited to being mounted in locations where a degree of noise abatement is desirable, e.g. in vehicles or buildings.

Accordingly, the products and products produced according to the methods described may be comprised in a vehicle, furniture, clothing or part of a building. Thus the products and products produced according to the methods described may be comprised in a headliner, ceiling panel, door, seat, wall, wall panel, flooring, floor panel, dashboard, instrument panel or parcel shelf.

The products and products produced according to the methods described herein are preferably for use in a vehicle, for example an automobile or car, an aeroplane, train or boat, preferably an automobile. Advantageously, apparatus of the invention can be conveniently incorporated into items of furniture in the cabin.

The three dimensional object may be an automotive part and may be within the cabin of an automobile. That is a product of the invention can be mounted in the cabin of a vehicle.

The automotive part may be a panel in the interior of the cabin of an automobile. In addition, some internal panels are low wear areas and thus are particularly suitable locations for mounting a product of the invention.

Thus, the invention also provides: A headliner comprising an product described herein.

A door panel or insert comprising a product described herein. A seat back comprising a product described herein.

A seat panel comprising a product described herein, preferably the waterfall area of the seat of an automobile.

An instrument panel comprising a product described herein.

A dashboard or insert thereof comprising a product described herein.

A parcel shelf or insert thereof comprising an apparatus described herein.

The waterfall area of the seat of the automobile is the area between the two rear seats. It often has the shape of a waterfall and is thus so named. This is an area of the automobile upholstery that is normally subject to low wear.

Examples and Description of the Drawings

The invention is now illustrated in the following specific embodiments with reference to the accompanying drawings showing:-Fig. 1 a diagrammatic representation of an isometric view of a strip of flexible material with a regular array of round perforations/holes arranged in a grid pattern wherein the vertices of the grid form squares through which run a series of parallel elongate inextensible strands in order to provide the 3D structure of the product illustrated.

Fig. 2 is a side view of the product illustrated in Fig. 1.

Fig. 3 is a photograph of a perspective view of an example of a product of the invention. The inextensible elongate strands in this example are fibre optic fibres located in the zig-zag valleys of the product. The embroidery threads the run orthogonally to the fibre optic fibres are decorative only.

Fig. 4 is a photograph of a top view of the example of a product of the invention shown in Fig 3.

Example

In a specific embodiment of the invention as shown in Figures 3 and 4, a piece of substantially flat leather of substantially uniform thickness is pre-perforated with an array of circular perforations ("holes") arranged at the vertices of a regular grid of squares with a separation between vertices of 5mm is shaped by inserting monofilament strands.

-12 -Specifically, a predetermined pattern is decided upon and then monofilament strands are threaded through the holes/perforations in the pre-perforated leather in order to bend/warp the leather out of the original plane of the leather piece in order to yield a predetermined 3D structure to the leather (wherein the first and second dimensions are the height and width of the plane of the substantially flat leather and the third dimension is orthogonal to the first and second dimensions).

The monofilament strands are inserted by hand in a manner akin to stitching or embroidery. That is, they are passed through the holes/perforations by hand according to the predetermined pattern.

Thus, the passage of the monofilament fibre through the leather and its transit above the plane of the leather causes the leather to be depressed below the natural (resting or relaxed) plane. Conversely passage of the monofilament strand through the leather and its transit below the plane of the leather causes the leather to be raised above its natural plane. Accordingly, the portions of raised and lowered leather can be produced according to a predetermined pattern or plan.

The monofilament strands are held in place by friction with the leather as the strands pass through the perforations. This friction is also increased by pressure on the monofilament strand by the leather relaxing towards its natural flat state. As a consequence of this friction and pressure, the monofilament is secured within the leather and need not be additionally secured. That is, the three-dimensional shape of the leather is created and maintained without having to knot or otherwise secure the termini of the stands.

Thus, the strands of monofilament are single pieces passing through the leather according to a predetermined path.

In this example, multiple strands of monofilament are passed through the leather in parallel lines and the passage above or below the plane of the leather is varied.

-13 -Thus, the strength and inextensibility of the monofilaments act together in the array of parallel monofilaments to provide a substantially planar array around which the flexible leather is passed/arranged in order to provide the three dimensional pattern.

In this particular specific example, the monofilament is passed through the holes of the square grid in a diagonal direction and the passage of the monofilaments yield a pattern of repeated chevrons/arrow heads.

Monofilament is also suitable for transmitting and emitting light in the manner of a fibre optic cable or filament. Thus, the monofilament strands can act as fibre optic cables to provide illumination. Such illuminated fibre optic cables are incorporated within the product and are visible as the filament transits above or below the plane of the leather.

Leather shaped in this way is used for elements of the interior of automobiles, especially motorcars. In particular, leather shaped in this way is suitable for lower-wear areas of the interior of a motorcar such as interior door panels, headliners, dashboard sections and seat backs.

Thus, the invention provides a means of incorporating substantially inextensible elongate strands into a substantially planar piece of flexible material (such as leather or fabric) so that the piece of flexible material is bent so that one or more portions of the flexible material are made to protrude above or below the previous plane of the unshaped flexible material. Furthermore, the substantially inextensible fibres may be visible when the leather or fabric is bent so that the apex of the bend points away from the viewer and thus the visible fibres can provide additional decoration or illumination. The invention also provides products for use in automobiles, especially motorcars.

Claims

-14 -Claims: 1. A product comprising a flexible material having two substantially opposite sides, wherein the material comprises one or more bends in pre-determined positions, wherein a flexible, elongate and substantially inextensible strand passes through the material from one side to the other and thence back again through the material, and wherein the bend in the material is formed by passage of the strand through the material and engagement between the strand and material such that movement of the strand and the material with respect to one another is prevented; and wherein the termini of the strand are unsecured with respect to the material.
2. A product according to claim 1, wherein the path of the flexible, elongate and substantially inextensible strand is substantially linear or straight and the bends in the material of the product are arranged to lie on one or both sides of this path.
3. A method of shaping a piece of flexible material having two substantially opposite sides according to a pre-determined pattern, comprising the steps of: (a) passing a flexible, elongate and substantially inextensible strand through the material from one side to the other; and (b) thence passing the strand back through the material, thereby bringing the strand and material into contact such that movement of the strand and the material with respect to one another is prevented and thus a bend is formed in the material, wherein the termini of the strand are unsecured with respect to the flexible material.
4. A method according to claim 3, wherein the step of (a) passing a flexible, elongate and substantially inextensible strand through the flexible material is carried out by hand.
-15 - 5. A product or method according to any preceding claim wherein the flexible material is engaged with the strand such that the strand and material are substantially immobile with respect to one another.
6. A product or method according to any preceding claim, wherein the flexible material is of substantially uniform or identical thickness.
A product or method according to any preceding claim, wherein the flexible material is leather or a textile.
8. A product or method according to any preceding claim, wherein the flexible material is leather
9. A product or method according to any preceding claim, wherein the flexible material has a pre-perforated array of regularly spaced holes.
10. A product or method according to claim 9, wherein the regularly spaced holes define the vertices of an array of polygons.
11. A product or method according to claim 10, wherein the polygons are squares.
12. A product or method according to claim 11, wherein the squares have 5 mm sides.
13. A product or method according to any of claims 9 to 12, wherein the holes are 0.1 to 3 mm across.
14. A product or method according to claim 13, wherein the holes are 1 mm across.
15 A product or method according to any preceding claim, wherein a multiplicity of flexible, substantially inextensible strands are used.
16 A product or method according to claim 15, wherein the multiplicity of flexible, substantially inextensible strands are arranged in a substantially flat or planar array.-16 -
17 A product or method according to any preceding claim, wherein the flexible, substantially inextensible strand is a fibre optic filament, acrylic wire, monofilament thread, or metal wire.
18. A product or method according to claim 17, wherein the flexible, substantially inextensible strand is a fibre optic filament.
19. A product according to any of claims 1, 2 or 5 to 18, wherein the product is for use in a vehicle, furniture, clothing or part of a building.
20. A product according to claim 19, wherein the product is for use in a vehicle.
21 A product according to any of claims 1, 2 or 5 to 20, comprised in a headliner, ceiling panel, door, seat, wall, wall panel, flooring, floor panel, dashboard, instrument panel or parcel shelf.
22. A vehicle comprising a product of any of claims 1, 2 or 5 to 21.
23. A vehicle according to claim 22, wherein the vehicle is an automobile.