WO2023081331A1

WO2023081331A1 - Panel assembly with soft touch outer surface

Info

Publication number: WO2023081331A1
Application number: PCT/US2022/048923
Authority: WO
Inventors: Andrew M. VIVIAN
Original assignee: Magna Seating Inc.
Priority date: 2021-11-04
Filing date: 2022-11-04
Publication date: 2023-05-11

Abstract

A panel assembly for an automotive seat assembly includes a laminate assembly of a trim cover and a soft-touch foam coated on the trim cover. The soft-touch foam includes a densified layer formed on a surface facing away from the trim cover. The laminate assembly also includes a rigid foam adhered to the densified layer. A portion of the densified layer around a periphery of the laminate assembly extends beyond the rigid foam.

Description

PANEL ASSEMBLY WITH SOFT TOUCH OUTER SURFACE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63/275,531, filed on November 4, 2021, the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] The present invention relates to a panel assembly for use in an automotive seat assembly. More particularly, the invention relates to a method for forming a panel assembly having a soft-touch outer surface and automotive seat panel assemblies formed by this method.

Description of Related Art

[0003] Automotive seat assemblies typically include a seat cushion and a seat back for supporting a passenger above a vehicle floor. Certain seat assemblies include a panel assembly covering a portion of the seat back or the seat cushion. One example of a known method for forming a panel assembly is described in Japan Publication JP 2015-205424A, wherein a cushion layer is formed by discharging liquid polyurethane foam material processed by a mechanical froth method onto a surface layer to form a skin material. The skin material is cut into a desired shape and placed into a mold. A resin base material is injection molded onto the skin material to form the panel assembly.

[0004] However, the known panel assembly lacks localized surface contours with defined lines resulting in a styled appearance that is desired in a seat back panel. In addition, the known panel assembly lacks a flexible peripheral rim that can be sewn or otherwise attached to additional seat trim components. It is desirable, therefore, to form panel assemblies having localized contour with defined lines while maintaining a soft-touch outer surface and having a rigid inner polyurethane layer and a flexible peripheral rim.

[0005] Figure 1 shows one method for forming a panel assembly for a seat back. Initially, slab stock foam is flame laminated to the trim cover (step 2). A polyurethane barrier film is then laminated to the slab stock foam to form a laminate assembly of the trim cover, the slab stock foam, and the barrier film (step 4). The laminate assembly is cut into pieces, sewn together to create a trim cover assembly and vacuum-formed into the desired shape for the seat back panel (step 6). Liquid polyurethane foam is poured directly onto the trim cover assembly to form a rigid foam on the barrier film (step 8). The barrier film prevents migration of the liquid polyurethane foam through the slab stock foam. This method is undesirable, however, since the barrier film adversely affects breathability of the trim cover.

SUMMARY OF THE INVENTION

[0006] According to one embodiment, there is provided a panel assembly for an automotive seat assembly. The panel assembly comprises a laminate assembly of a trim cover and a soft- touch foam coated on the trim cover. The soft-touch foam includes a densified layer formed on a surface facing away from the trim cover. The laminate assembly also includes a rigid foam adhered to the densified layer. A portion of the densified layer around a periphery of the laminate assembly extends beyond the rigid foam.

[0007] According to another embodiment, there is provided a method of forming a panel assembly for an automotive seat assembly. The method comprises mechanically frothing liquid components to form a mechanically frothed foam, coating a trim cover with the mechanically frothed foam to form a laminate assembly, cutting the laminate assembly to form a laminate blank, vacuum-forming the laminate blank into a 3 -dimensional shape having one or more of a molded feature, a molded line, a molded surface concavity, and forming a rigid foam on the vacuum-formed laminate blank, wherein a portion of the mechanically frothed foam around a periphery of the laminate blank extends beyond the rigid foam.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0009] Figure l is a flow chart of a conventional method for forming a panel assembly;

[0010] Figure 2 is a perspective view of a seat assembly having a panel assembly, according to one embodiment of the present invention;

[0011] Figure 3 is a front view of the panel assembly of Figure 2;

[0012] Figure 4 is a rear view of the panel assembly of Figure 3; [0013] Figures 5A-5D are cross-sectional views of portions of panel assemblies according to alternate embodiments of the present invention;

[0014] Figure 6 is a chart showing Shore A hardness of exemplary foams according to embodiments of the present invention;

[0015] Figure 7 is a flow chart of a method of forming the panel assembly of Figure 3;

[0016] Figure 8 is a cross-sectional view of a process of coating a trim cover with mechanically frothed foam to form a laminate assembly, according to one embodiment of the present invention;

[0017] Figure 9 is a rear view of a laminate blank cut from the laminate assembly of Figure 8;

[0018] Figure 10 is cross-sectional view of the laminate blank of Figure 9 inserted between a mold lid and a mold base and showing vacuum-forming and molding processes;

[0019] Figure 11 is a rear view of the laminate blank of Figure 10 after a vacuum-forming process; and

[0020] Figure 12 is a cross-sectional view of a panel assembly formed from the laminate blank of Figure 11 prior to removing the panel assembly from the mold lid and the mold base.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] Figures 2-12 illustrate a panel assembly 10 for use in an automotive seat assembly 12 and a method for producing the panel assembly 10 according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0022] As depicted in Figure 2, the seat assembly 12 includes a seat back 14 and a seat cushion 16. The panel assembly 10 covers a rear portion of the seat back 14. It will be appreciated that the panel assembly 10 may be configured to cover other surfaces of the seat assembly 12 without altering the scope of the present invention. Figures 3 and 4 show the outer surface 18 (i.e., front side) and the inner surface 20 (i.e., rear side), respectively, of the panel assembly 10.

Figures 5A-5D show cross-sectional views of a portion of the panel assembly 10.

[0023] Referring to Figures 2-5, the panel assembly 10 is a trilaminate panel comprising a layered assembly of a trim cover 22, a soft-touch foam 24, and a rigid foam 26. The soft-touch foam 24 is adhered to both the trim cover 22 and the rigid foam 26. The Shore A hardness of the soft-touch foam 24 is less than the Shore A hardness of the rigid foam 26. More specifically, the soft-touch foam 24 reduces the perceived hardness of the panel assembly 10 from about 95 Shore A hardness of the rigid foam 26 to about 55 Shore A hardness or less of the soft-touch foam 24. The outer surface 18 reduces knee load and creates a luxury hand feel when touching the panel assembly 10 due to the inclusion of the soft-touch foam 24.

[0024] Referring to Figures 5A-5D, the trim cover 22 of panel assemblies 10A-10D is a vinyl material. However, other materials, such as cloth or leather as non-limiting examples, may be used as the trim cover 22 without varying the scope of the present invention.

[0025] The rigid foam 26 in the panel assembly 10 is a high density polyurethane foam having a density of about 400 kg/m³ and a Shore A hardness of about 95. The rigid foam 26 preferably has a Shore A hardness of about 90 to about 100 to provide a hard surface as part of the panel assembly 10. However, it will be appreciated that the density, thickness, and Shore A hardness of the rigid foam 26 may vary without altering the scope of the present invention. In addition, the rigid foam 26 optionally contains recycled and/or renewable content, up to about 45% by volume, as a non-limiting example. The rigid foam 26 preferably has strong adhesion to the soft-touch foam 24.

[0026] The soft-touch foam 24 is a mechanically frothed latex or polyurethane foam with a Shore A hardness of preferably about 55 or less. Preferably, the soft-touch foam 24 also has a foam thickness of about 2 mm or less.

[0027] Cross-sectional views of panel assemblies 10A-10D having different formulations of soft-touch foam 24A-24D are shown in Figures 5A-5D, respectively, according to alternate embodiments of the present invention. Figure 6 is a chart showing the Shore A hardness of the rigid foam 26 and exemplary soft-touch foams 24A-24D. The soft-touch foam 24A in panel assembly 10A comprises a mechanically frothed latex foam having a Shore A hardness of about 30, a latex foam density of about 14 pounds per cubic foot (pcf) (about 224 kg/m³) or higher, and a thickness of about 2 mm. The soft-touch foam 24B in panel assembly 10B comprises a mechanically frothed polyurethane foam having a Shore A hardness of about 40, a polyurethane foam density of about 18 pcf (about 288 kg/m³) or higher, and a thickness of about 1.2 mm. The soft-touch foam 24C in panel assembly 10C comprises a mechanically frothed polyurethane foam having a Shore A hardness of about 43, a polyurethane foam density of about 18 pcf (about 288 kg/m³) or higher, and a thickness of about 1.2 mm. The soft-touch foam 24D in panel assembly 10D comprises a mechanically frothed polyurethane foam having a Shore A hardness of about 55, a polyurethane foam density of about 18 pcf (about 288 kg/m³) or higher, and a thickness of about 1.5 mm. Latex foam density of at least 14 pcf (224 kg/m³) or polyurethane foam density of at least 18 pcf (288 kg/m³) is preferred in order to withstand the reaction pressures in the high-pressure closed pour (HPCP) production process 28 described below. It will be appreciated that the Shore A hardness, density, foam formulation, and thickness of the soft-touch foam 24 may vary without altering the scope of the present invention. In addition, the soft-touch foam 24 optionally contains recycled and/or renewable content, up to about 75% by volume, as a non-limiting example.

[0028] Depicted in Figure 3, the outer surface 18 includes molded features 30, molded lines 32 having the appearance of sew seams, surface concavity 34, and a 3-dimensional shape. Shown in Figure 4, one or more mounting components 36 are optionally adhered to the inner surface 20 of the panel assembly 10. Alternatively, mounting components 36 and other components may be assembled with the panel assembly 10 using an insert molding process. Also shown in Figure 4, the panel assembly 10 includes a flexible peripheral rim 38 that extends beyond the rigid foam 26. Referring to Figure 2, additional seat trim components, such as side facings 40, may be sewn to or otherwise attached to the peripheral rim 38.

[0029] Figures 7-12 illustrate a method 42 of forming the panel assembly 10 according to one embodiment of the present invention. Referring to Figures 7 and 8, liquid components are mechanically frothed to form mechanically frothed liquid components 50 (step 45). Depicted in Figure 8, the mechanically frothed liquid components 50 are sprayed onto or otherwise applied to coat the inner surface 44 (i.e., the rear side) of the automotive trim cover 22 to form mechanically frothed foam 24 (step 46). The mechanically frothed foam 24 adheres to the trim cover 22 to form a laminate assembly 48. The mechanically frothed foam 24 has a desired thickness of preferably about 2 mm or less. However, the thickness of the mechanically frothed foam 24 may vary without altering the scope of the present invention. [0030] The mechanically frothed foam 24 creates a self-skinning densified layer 52 on the surface of the mechanically frothed foam 24 during the curing process. The densified layer 52 allows the laminate assembly 48 to be vacuum-formed without requiring a barrier film during the HPCP production process 28. In addition, the densified layer 52 prevents the rigid foam 26 from migrating into the soft-touch foam 24 during the HPCP production process 28.

[0031] As shown in Figures 7 and 9, the laminate assembly 48 is cut into a laminate blank 54 using a Gerber cutting process (step 56) after the mechanically frothed foam 24 has cured. One or more locating holes 58 may be formed in the laminate blank 54. Next, the panel assembly 10 is produced from the laminate blank 54 using the HPCP production process 28 (step 60 of Figure 7).

[0032] The HPCP production process 28 is described in greater detail in reference to Figures 10-12. In addition, the HPCP process is described in PCT publication WO/2022/076024A1, the disclosure of which is incorporated herein in its entirety. As shown in Figure 10, the laminate blank 54 is inserted into a mold bowl 62 formed in a mold base 64 with the trim cover 22 adjacent the mold bowl 62. A ledge 66 extends from an upper edge of the mold bowl 62 and one or more locating pins 68 project from the ledge 66. The peripheral rim 38 of the laminate blank 54 is placed on the ledge 66 with the locating pins 68 extending through respective locating holes 58 in the laminate blank 54. A mold lid 70 is placed on top of the mold base 64 to form a cavity 72 between the mold bowl 62 and the mold lid 70.

[0033] Also shown in Figure 10, a plurality of vacuum holes 74 is distributed across a lower surface of the mold bowl 62. The laminate blank 54 is vacuum-formed to conform to the contour of the mold bowl 62 by drawing air (arrow 76) through the vacuum holes 74. The vacuum-formed laminate blank 54 is illustrated in Figure 11. Molded features 30, molded lines 32, and surface concavity 34 are formed in the laminate blank 54 during the vacuum-forming process.

[0034] After the laminate blank 54 is vacuum-formed against the mold bowl 62, liquid components 78 are injected through an inlet channel 80 in the mold lid 70 and into the cavity 72 between the laminate blank 54 and the mold lid 70. Referring to Figure 12, the liquid components 78 foam and form the rigid foam 26 adhered to the soft-touch foam 24, resulting in the panel assembly 10. Rigid foam 26 does not coat the peripheral rim 38 of the laminate blank 54 since a seal is formed along the peripheral rim 38 between the mold lid 70 and the mold base 64. After the rigid foam 26 has cured, the mold lid 70 is removed and the panel assembly 10 is removed from the mold base 64.

[0035] The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:

1. A panel assembly for an automotive seat assembly, the panel assembly comprising: a laminate assembly comprising: a trim cover; and a soft-touch foam coated on the trim cover, wherein the soft-touch foam includes a densified layer formed on a surface facing away from the trim cover; and a rigid foam adhered to the densified layer, wherein a portion of the densified layer around a periphery of the laminate assembly extends beyond the rigid foam.

2. The panel assembly as set forth in claim 1, further comprising one or more of a molded feature, a molded line, or a molded surface concavity formed in the laminate assembly.

3. The panel assembly as set forth in claim 2, wherein the rigid foam comprises a high density polyurethane foam having a Shore A hardness of about 90 to about 100.

4. The panel assembly as set forth in claim 3, wherein the soft-touch foam has a Shore A hardness of about 55 or less.

5. The panel assembly as set forth in claim 4, wherein the soft-touch foam comprises a mechanically frothed latex foam having a density of about 14 pcf or higher.

6. The panel assembly as set forth in claim 4, wherein the soft-touch foam comprises a mechanically frothed polyurethane foam having a density of about 18 pcf or higher.

7. The panel assembly as set forth in claim 4, further comprising one or more mounting components fixedly coupled to the rigid foam.

8. The panel assembly as set forth in claim 4, wherein the soft-touch foam has a thickness of about 2 mm or less.

9. A method of forming a panel assembly for an automotive seat assembly, the method comprising: mechanically frothing liquid components to form a mechanically frothed foam; coating a trim cover with the mechanically frothed foam to form a laminate assembly; cutting the laminate assembly to form a laminate blank;

8 vacuum -forming the laminate blank into a 3 -dimensional shape having one or more of a molded feature, a molded line, or a molded surface concavity; and forming a rigid foam on the vacuum-formed laminate blank, wherein a portion of the mechanically frothed foam around a periphery of the laminate blank extends beyond the rigid foam.

10. The method as set forth in claim 9, further comprising curing the mechanically frothed foam to form a densified layer in the mechanically frothed foam, wherein the densified layer prevents migration of the rigid foam into the mechanically frothed foam.

11. The method as set forth in claim 10, further comprising: adhering one or more mounting components to the rigid foam.

12. The method as set forth in claim 11, wherein the rigid foam comprises a high density polyurethane foam having a Shore A hardness of about 90 to about 100.

13. The method as set forth in claim 12, wherein the mechanically frothed foam has a thickness of about 2 mm or less.

14. The method as set forth in claim 13, wherein the mechanically frothed foam comprises a mechanically frothed latex foam having a density of about 14 pcf or higher and a Shore A hardness of about 55 or less.

15. The method as set forth in claim 13, wherein the mechanically frothed foam comprises a mechanically frothed polyurethane foam having a density of about 18 pcf or higher and a Shore A hardness of about 55 or less.

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