阅读说明：本技术 包括一体编织背衬材料的车辆座椅装饰罩及其制造方法 (Vehicle seat trim cover including integrally woven backing material and method of making same ) 是由 D·W·布斯 P·W·亚力山大 N·L·约翰逊 H·H·麦卡杜-威尔逊 J·C·罗宾切克 于 2019-05-31 设计创作，主要内容包括：提供了一种用于附接至车辆座椅的装饰部件,装饰部件包括第一部分和第二部分。第一部分设置在装饰部件的第一侧面上并且限定第一编织物。第二部分设置在装饰部件的第二侧面上并且限定与第一编织物不同的第二编织物。第一部分和第二部分一体编织。装饰部件配置为安装在座椅的一个或多个支承构件上。第一侧面配置为面向支承构件。第二部分配置为与座椅的乘员接触。在各个方面,第一部分包括第一纱线,并且第二部分包括第二纱线,第二纱线在密度、厚度和材料中一项或多项不同于第一纱线。在各个方面,第一纱线是热活化纱线。(A trim component for attachment to a vehicle seat is provided, the trim component including a first portion and a second portion. The first portion is disposed on the first side of the trim component and defines a first braid. The second portion is disposed on the second side of the trim component and defines a second braid that is different from the first braid. The first portion and the second portion are integrally woven. The trim component is configured to be mounted on one or more support members of the seat. The first side is configured to face the support member. The second portion is configured to contact an occupant of the seat. In various aspects, the first portion includes a first yarn and the second portion includes a second yarn that differs from the first yarn in one or more of density, thickness, and material. In various aspects, the first yarn is a heat activated yarn.)

1. A trim component for attachment to a seat of a vehicle, the trim component comprising:

a first portion disposed on a first side of the trim component, the first portion being woven and comprising a first yarn, the first yarn being a heat activated yarn; and

a second portion disposed on a second side of the trim component, the second portion integrally woven with the first portion and comprising a second yarn, the second yarn being different from the first yarn, wherein,

the trim component is configured to be mounted on a support member of the seat;

the first side is configured to face the support member; and is

The second portion is configured to contact an occupant of the seat.

2. The trim component of claim 1, wherein the heat activated yarn is a binder yarn configured to stiffen upon application of heat to the binder yarn.

3. The trim component of claim 2, wherein the binder yarn comprises a thermoplastic polymer selected from the group consisting of: polyamides, copolyamides, polyesters, copolyesters, and combinations thereof.

4. The trim component of claim 2, further comprising:

an outer component comprising the first portion and the second portion; and

an inner component directly engaging the first portion and configured to engage the support member, wherein the inner component is bonded to the first portion by the bonding yarn.

5. The decorative member of claim 2 wherein the first portion defines a plurality of perforations through which the second portion of the decorative member is visible from the first side of the decorative member.

6. The decorative member according to claim 1,

the heat activated yarn comprises a core and a shell at least partially enclosing the core;

the core comprises a first composition;

the shell comprises a second composition configured to melt when the heat activated yarn is heated above a predetermined temperature;

the first composition is released from the shell when the second composition melts; and

the first composition is configured to react with a third composition to form a thermoset polymer.

7. The trim component of claim 6, further comprising a third portion disposed between the first portion and the second portion, the third portion comprising a third yarn and integrally woven with the first portion and the second portion, wherein the third yarn comprises the third composition.

8. The trim component of claim 6, further comprising:

an outer component comprising the first portion and the second portion; and

an inner component comprising a third yarn comprising the third composition, the inner component directly engaging the first portion of the outer component.

9. The decorative member according to claim 8,

the inner member includes a third portion and a fourth portion;

the third portion includes the third yarn and is disposed on a third side of the inner member, the third side being joined with the first side of the first portion; and

the fourth portion is disposed on a fourth side of the inner component, the fourth portion integrally woven with the third portion and comprising a fourth yarn, the fourth yarn different from the third yarn.

10. The decorative member according to claim 6, wherein one of the first composition and the third composition comprises a resin, and the other comprises a curing agent.

Technical Field

The present disclosure relates to a vehicle seat trim cover including an integrally woven backing material and a method of manufacturing a vehicle seat trim cover.

Background

The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this specification as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

A seat trim cover for a vehicle seat may be made of a braid. Such seat trim covers are installed to cover the interior structure and structural foam of the vehicle seat, thereby achieving an aesthetically pleasing and comfortable seating surface. The seat trim cover may include a backing material, such as a scrim, film, or foam, to improve the appearance, durability, performance, or feel of the vehicle seat.

Disclosure of Invention

In various aspects, the present disclosure provides a trim component for attachment to a seat of a vehicle. The trim component includes a first portion and a second portion. The first portion is disposed on the first side of the trim component. The first portion is braided. The first portion includes a first yarn. The first yarn is a heat activated yarn. The second portion is disposed on the second side of the trim component. The second portion is integrally woven with the first portion. The second portion includes a second yarn. The second yarn is different from the first yarn. The trim component is configured to be mounted on a support member of the seat. The first side is configured to face the support member. The second portion is configured to contact an occupant of the seat.

In one aspect, the heat activated yarn is a binder yarn configured to stiffen upon application of heat to the binder yarn.

In one aspect, the binder yarn comprises a thermoplastic polymer selected from the group consisting of: polyamides, copolyamides, polyesters, copolyesters, and combinations thereof.

In one aspect, the trim component further comprises an outer component and an inner component. The outer member includes a first portion and a second portion. The inner member directly engages the first portion. The inner component is configured to engage with the support member. The inner member is bonded to the first portion by a bonding yarn.

In one aspect, the first portion defines a plurality of perforations through which the second portion of the decorative member is visible from the first side of the decorative member.

In one aspect, a heat activated yarn includes a core and a shell at least partially encapsulating the core. The core includes a first composition. The shell includes a second composition. The second composition is configured to melt when the heat activated yarn is heated above a predetermined temperature. When the second composition melts, the first composition is released from the shell. The first composition is configured to react with the third composition to form a thermoset polymer.

In one aspect, the trim component further includes a third portion disposed between the first portion and the second portion. The third portion includes a third yarn. The third portion is integrally woven with the first and second portions. The third yarn comprises a third composition.

In one aspect, the trim component further comprises an outer component and an inner component. The outer member includes a first portion and a second portion. The inner component includes a third yarn including a third composition. The inner component directly engages the first portion of the outer component.

In one aspect, the inner component includes a third portion and a fourth portion. The third portion includes a third yarn and is disposed on a third side of the inner member. The third side engages the first side of the first portion. The fourth portion is disposed on the fourth side of the inner member. The fourth portion is integrally woven with the third portion and includes a fourth yarn. The fourth yarn is different from the third yarn.

In one aspect, one of the first and third compositions comprises a resin and the other comprises a curing agent.

In various aspects, the present disclosure provides another trim component for attachment to a seat of a vehicle. The trim component includes a first portion and a second portion. The first portion is disposed on the first side of the trim component. The first portion defines a first braid. The second portion is disposed on the second side of the trim component. The second portion is integrally woven with the first portion. The second portion defines a second braid that is different from the first braid. The trim component is configured to be mounted on one or more support members of the seat. The first side is configured to face the support member. The second portion is configured to contact an occupant of the seat.

In one aspect, the first portion includes a first yarn and the second portion includes a second yarn, the second yarn being different from the first yarn in one or more of density, thickness, and material.

In one aspect, the second portion includes a first region and a second region. The first region includes a second yarn. The second region includes a third yarn that is different from the second yarn and the first yarn.

In one aspect, the second yarn is an air-textured yarn.

In one aspect, the trim component further includes a third portion. The third portion is disposed between the first portion and the second portion. The third portion includes a third yarn and is integrally woven with the first portion and the second portion. The first yarn is a heat activated yarn.

In one aspect, the first braid and the second braid differ in one or more of structure, stitch, density, and thickness.

In various aspects, the present disclosure provides a method of assembling a contoured trim component for attachment to a seat of a vehicle. The method includes heating a first material to a first predetermined temperature. The first material includes a heat activated polymer. The method also includes disposing a first material on the forming surface of the fixture. The forming surface defines a plurality of apertures. The first side of the first material is in communication with the forming surface and the second side of the first material is in communication with the second material. The second material is woven and profiled. The method also includes heating the first material to a second predetermined temperature. The method also includes drawing a vacuum within the interior volume of the fixture. The vacuum is drawn to cause the first material to adhere to the second material and conform to the contoured surface to form the contoured trim component.

In one aspect, the method further includes disposing a third material comprising foam on the forming surface prior to disposing the first material on the forming surface. The first material is disposed between the third material and the second material.

In one aspect, the first material is knitted with yarns comprising a heat activated material and the second material is integrally knitted with the first material.

In one aspect, the first material is a sheet comprising a heat activated material.

Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective partial cut-away view of a vehicle seat according to certain aspects of the present disclosure;

FIG. 2 is a perspective view of a trim component for a vehicle seat according to certain aspects of the present disclosure;

FIG. 3 is a schematic view of the trim component of FIG. 2;

FIG. 4 is a cross-sectional view of the trim component of FIG. 2 after heating to form a film;

FIG. 5 is a perspective view of another trim component according to certain aspects of the present disclosure;

FIG. 6 is a cross-sectional view of the trim component of FIG. 5 after heating to form a film;

FIG. 7 is a partially exploded perspective view of yet another trim component according to certain aspects of the present disclosure;

FIG. 8 is a schematic view of the trim component of FIG. 7;

FIG. 9 is a cross-sectional view of the trim component of FIG. 7 after heating to form an adhesive film;

FIG. 10 is a perspective view of yet another trim component according to certain aspects of the present disclosure;

FIG. 11 is a cross-sectional view of the first yarn of the trim component of FIG. 10;

FIG. 12 is a schematic view of the trim component of FIG. 10;

FIG. 13 is a cross-sectional view of the trim component of FIG. 10 after heating to form a film;

FIG. 14 is a partially exploded perspective view of yet another trim component according to certain aspects of the present disclosure;

FIG. 15 is a schematic view of an outer component of the trim component of FIG. 14;

FIG. 16 is a schematic view of an interior component of the trim component of FIG. 14;

FIG. 17 is a cross-sectional view of the trim component of FIG. 14 after heating to form an adhesive film;

FIG. 18 is a schematic view of yet another trim component according to certain aspects of the present disclosure;

FIG. 19 is a flow diagram depicting an exemplary method of thermoforming a contoured trim component;

FIG. 20 is an exemplary trim component formed according to the method of FIG. 19, according to certain aspects of the present disclosure; and

fig. 21 is another exemplary trim component formed according to the method of fig. 19, according to certain aspects of the present disclosure.

In the drawings, reference numbers may be repeated to identify similar and/or identical elements.

Detailed Description

As discussed above, seat trim covers typically include a backing material to improve the appearance, durability, performance, and/or feel of the seat. The portion of the trim cover that faces outward for contact with an occupant of the seat may be referred to as the "a-side". The a-side may comprise a durable, stain resistant, aesthetically pleasing, and tactilely pleasing woven material. The inner portion of the trim cover facing the interior structure of the seat may be referred to as the "B-side". The a-side and B-side materials are typically joined together in large flat pieces by sewing, lamination (e.g., flame lamination), or adhesives. The resulting trim material is a large flat piece that is placed on a roll for storage or transport. The material is then cut to the desired shape and size for the particular seat application and/or seat and joined to one another.

Foam, such as padded (plus pad), is commonly used as the B-side material. Different areas of the vehicle seat may include foam having different characteristics. In one example, the trim panel for the side areas of the seat includes a thinner foam padding and the trim panel for the cushion insert of the seat includes a thicker foam padding. In another example, a trim panel having a lower density foam is used on the seat back insert and a trim panel having a higher density foam is used on the seat cushion insert.

A scrim or film is typically used as the B-side material to protect the support foam of the seat from abrasion due to frictional engagement with the a-side material. The scrim is a thin sheet material that may be woven or knitted. Exemplary scrim materials include lightweight textiles such as polyester, cotton, and linen. Nonwoven scrims are particularly useful in non-seating applications such as instrument panels and door inserts. The film comprises a thin polymer-based material.

The a-side material is typically provided in the form of a large flat sheet of joined material that is joined to the B-side material to create a large flat sheet. When the a-side material is a woven material, three-dimensional weaving ("3D weaving") can be used to directly form the a-side material in the desired shape and size. 3D weaving can produce woven materials with contours, depths, and variable thicknesses. However, it is difficult to join B-side materials (e.g., foams, scrims, or films) to contoured a-side materials because typical joining methods are not feasible or time consuming. Furthermore, joining a flat B-side material with a contoured a-side material may result in undesirable folds, creases, and/or seams that may reduce occupant comfort, create potential wear points, and reduce the aesthetic appeal of the seat cover.

In various aspects, the present disclosure provides a trim panel or cover for a vehicle seat that includes an a-side and a B-side that are integrally woven with one another. The a-side includes yarns having desirable characteristics for interaction with the occupant, such as durability, stain resistance, and/or visual and tactile appeal. The B-side includes one or more yarns that have beneficial properties themselves or can be heated to produce beneficial properties. By way of non-limiting example, the inherent beneficial properties include thickness, density, and elasticity. Certain yarns, known as "heat activated yarns," may be heated to form a scrim-like surface. Some heat activated yarns may be heated and used as an adhesive to attach another backing material.

The integrally woven trim panel may include an a-side having a different texture, color, or pattern in different areas of the seat. The B-side can be customized to the desired properties in each zone by varying the thickness and type of yarn. The B-side may provide protection for the structural foam of the seat, for texture sufficient to hide defects in the structural foam, and for performance characteristics (e.g., variable density) in specific areas of the seat. Accordingly, the integrally woven trim panel of the present disclosure may improve occupant comfort, improve wear performance of the seat, and enhance the appearance of the seat.

The integrally woven trim panel may be contoured and configured to be coupled to a vehicle seat without the need for additional manufacturing steps such as stitching. Thus, the trim panel of the present disclosure requires less labor intensive secondary processing than other trim covers. The trim panel is not limited to use on a vehicle seat. Trim panels may also be used, for example, in other vehicle trim components (e.g., instrument panels, interior door covers, storage compartments, steering wheels) or in non-vehicle applications, such as furniture, apparel, architectural applications, and other consumer products.

Referring to fig. 1, a vehicle seat 10 is illustrated in accordance with certain aspects of the present disclosure. The vehicle seat 10 includes a cushion portion 12, a backrest portion 14, and a headrest 16. The cushion portion 12 is configured to support an occupant seated on the vehicle seat 10, and the backrest portion 14 is configured to support the back of the occupant. The seat generally includes an interior structure or frame (not shown), one or more support members 18, and a trim cover 20. One example of a support member 18 is a foam bun.

The trim cover 20 is pulled taut against the support member 18 to prevent the trim cover 20 from wrinkling, bulging, or otherwise separating from the support member 18. The trim cover 20 includes one or more contoured trim panels 22. The trim panel 22 is 3D woven to have an integrally formed profile. The trim panel 22 may also define an overall surface texture, variable thickness, and/or variable density.

Referring to fig. 2-4, a trim component 30 for a vehicle seat is provided according to various aspects of the present disclosure. The trim component 30 can be all or a portion of a trim cover (see, e.g., trim cover 20 of fig. 1). An example of a portion of a trim cover is a panel (see, e.g., trim panel 22 of fig. 1).

The trim component 30 includes a first side 32 and a second side 34 disposed opposite the first side 32. When the trim component 30 is fixed to a vehicle seat (see, for example, the vehicle seat 10 of fig. 1), the first side surface 32 is a lower side and is configured to be disposed toward a support member of the seat (see, for example, the support member 18 of fig. 1). In some aspects, the first side 32 directly engages the support member. The second side 34 faces outwardly and is configured to engage an occupant of the seat.

First side 32 includes a first knitted portion 36. The first knitted portion 36 is knitted with a first yarn 38. The second side 34 includes a second braided portion 40. The second knitted portion 40 is knitted with a second yarn 42. The second braided portion 40 is integrally braided with the first braided portion 36, for example, by 3D braiding. Thus, the trim component 30 can include an integral profile to match the profile of the support member of the seat.

The first yarn 38 is a heat activated yarn. The heat activated yarns may be binder yarns comprising a material that melts and hardens at a predetermined temperature to fuse to surrounding elements (e.g., adjacent yarns, fibers, or structures). The binder yarn may be composed of a plurality of threads. All or a portion of the strands may comprise a thermoplastic polymer. Examples of suitable thermoplastic polymers include low melting polyamides, copolyamides, low melting polyesters, copolyesters, and the like. In various aspects, the thermoplastic polymer is selected from the group consisting of: low melting polyamides, copolyamides, low melting polyesters, copolyesters, and combinations thereof. The binder yarns formed from the thermoplastic strands may be heated and reformed.

The second yarn 42 is different from the first yarn 38. Because the occupant of the seat directly engages the second woven portion 40, the second woven portion 40 may desirably be durable, stain resistant, aesthetically pleasing, and/or tactilely pleasing. The second yarn 42 may comprise polyester, polyester blends, polyamide blends, wool, or any other suitable yarn known to those skilled in the art. When second yarns 42 comprise a thermoplastic polymer, the melting point of the thermoplastic polymer is higher than the melting point of first yarns 38.

The second woven portion 40 is configured to completely conceal the first woven portion 36 when the trim component 30 is mounted on the vehicle seat. Second braided portion 40 may optionally define a variable thickness. For example, a first region intended to directly engage an occupant defines a higher thickness, while a second region intended to engage an occupant less frequently defines a lower thickness. The woven portion 40 may also define an integrally woven surface texture or pattern to enhance the look or feel of the trim component 30. The surface texture or pattern may be present on all or part of the seat cover, depending on the desired appearance of the seat. The second side 34 may include other integrally woven yarns (not shown) in addition to the second yarn 42. The yarns may vary in color, pattern, density and/or diameter.

The decorative member 30 can be heated to change the decorative member 30 from the first configuration shown in figures 2-3 to the second configuration 30' as shown in figure 4. More specifically, heat may be applied to first side 32 of trim component 30 to melt or soften the polymer of first yarns 38. Any suitable heat source may be used to melt first yarn 38 in the first knitted portion. In one example, trim component 30 is placed inside an oven and subjected to a suitable elevated temperature. In another example, the trim component 30 is heated by flame lamination. In other examples, the trim cover 30 is heated by using a heat gun, steam wand, or other heating device.

Upon cooling, the polymer of the first yarns 38 is hardened to form a film 38' on the first side 32 of the trim component 30. In one embodiment, the film 38' is discontinuous. However, in alternative embodiments, the membrane 38' may be continuous. During heating, the polymer of the first yarns 38 may penetrate the void spaces between the threads of the second yarns. However, the polymer does leak to the second side 34 of the trim component 30'. The joint 44 between the first braided portion 36 and the second braided portion 40 may be particularly strong due to the combination of the integral braided and adhesive properties of the first yarn 38. In certain aspects, only a portion of the first braided portion 36 is melted (not shown).

In various aspects, the second woven portion 40 is the a side of the trim component 30 'and the film 38' is the B side of the trim component. When the trim component 30 'is coupled to the vehicle seat, the film 38' is disposed between the second woven portion 40 and the support member. The membrane 38 'is relatively stiff compared to the second braided portion 40, and thus the membrane 38' may conceal imperfections in the support member. The membrane 38' may also be relatively smooth compared to the second knitted portion 40. The smooth texture of the film enables it to slide over the support member without significant scratching, thereby reducing wear at the outer surface of the support member. Reduced wear may advantageously contribute to extended vehicle seat life and appearance. Decorative member 30' has no distinct scrim (i.e., a scrim that is attached by a secondary process such as sewing).

Referring to fig. 5, another trim component 60 in accordance with various aspects of the present disclosure is provided. The decorative member 60 includes a first side 62 and a second side 64 disposed opposite the first side 64. The trim component 60 includes a first woven portion 66 woven with a first yarn 68. First yarn 68 is similar to first yarn 68 of trim component 30 (fig. 2-4). The trim component 60 also includes a second woven portion 70 woven with a second yarn 72. Second yarn 72 is similar to second yarn 42 of trim component 30 (fig. 2-4). The first braided portion 66 and the second braided portion 70 are integrally braided.

First braided portion 66 defines a plurality of perforations 74. The second woven portion 70 is visible from the first side 64 of the decorative member 60 through the perforation 74. Similar to the trim component 30 of fig. 2-4, the first woven portion 66 can be heated to form a trim component 60 'having a film 68' disposed on the first side 62, as shown in fig. 6. The film 68' extends around the perimeter of the perforations but does not close the perforations 74. Perforations 74 allow airflow between the support member (e.g., foam bun) and the second braided portion 70 (i.e., side a). In various aspects, the decorative member 60' can be referred to as a "perforated decorative member".

With continued reference to fig. 6, the film 68 'defines a first surface 78 as viewed from the first side 62 of the trim component 60'. The second woven portion 70 defines a second surface 80 as viewed from the first side 62 of the decorative member 60'. The second surface 80 is offset from the first surface 78 by a depth 82. That is, perforations 74 have a depth 82. The depth 82 is measured in a direction orthogonal to the surface of the decorative member 60'. In various aspects, the depth 82 is greater than 0.5mm and less than 5mm, optionally greater than 1mm and less than 3mm, and optionally about 2 mm. The depth or offset 82 reduces or eliminates direct contact between the second braided portion 70 and the support member, which may cause wear of the support member.

Although perforations 74 are depicted as being circular, one skilled in the art will appreciate that any other shape that allows sufficient ventilation while minimizing contact between the support member and second braided portion 70 is possible. The porosity (total area of perforations 76 divided by total surface area of first side 62) of the trim component 60' can also be varied, as long as the area of the first surface 78 is large enough to maintain the function as a film/scrim. The perforations 74 need not be evenly distributed on the first side 62 of the trim member 60. For example, high contact areas, such as adjacent the seat cushion insert, may have a lower porosity, while lower contact areas, such as adjacent the side of the seat, have a higher porosity.

Referring to fig. 7-9, another decorative member 90 is provided according to various aspects of the present disclosure. The decorative member 90 includes a first or outer member 92 and a second or inner member 94. The first member 92 is similar to the trim panel 30 of fig. 2-4. Accordingly, first component 92 includes a first knitted portion 96 and a second knitted portion 100, first knitted portion 96 including a first yarn 98 that is a heat activated yarn, and second knitted portion 100 including a second yarn 102. First portion 96 and second portion 100 are integrally woven with one another. The outer member 92 may be contoured and formed by a 3D knitting process. The first woven portion 96 is disposed on a first side 104 of the decorative member 90 and the second woven portion 100 is disposed on a second side 106 of the decorative member 90.

The inner member 94 is a scrim. By way of example, the scrim is a thin material that may be knitted or woven. The scrim may be made of or include a lightweight textile such as polyester, cotton or linen. The inner member 94 includes a third side 108.

The first or heat activated yarn 98 is a binder yarn. Thus, when heated to a predetermined temperature, first yarn 98 melts. When the first yarn 98 melts, the third side 108 of the inner component 94 directly engages the first side 104 of the outer component 92. The melted first yarns 98 harden and cool to form a film 98' that acts as an adhesive to bond the inner component 94 to the outer component 92.

As shown in fig. 9, a membrane 98' is disposed between the inner member 94 and the outer member 92. The first side 104 of the outer member 92 is directly joined to the third side 108 of the inner member 94. Similar to the film 38' of the trim component 30' of fig. 4, the interior component 94 can conceal imperfections and reduce wear on the support member (see, e.g., the support member 18 of fig. 1) when the trim component 90' is installed on a vehicle seat (see, e.g., the vehicle seat 10 of fig. 1).

Referring to fig. 10-13, yet another trim component 120 is illustrated in accordance with various aspects of the present disclosure. The decorative member 120 includes a first side 122 and a second side 124 disposed opposite the first side 122. The trim component 120 includes a first woven portion 126 woven with a first yarn 128. The first woven portion 126 is disposed on the first side 122 of the decorative member 120. The trim component 120 also includes a second woven portion 130 woven with a second yarn 132. The second woven portion 130 is disposed on the second side 124 of the decorative member 120. The trim component 120 also includes a third woven portion 134 woven with a third yarn 136. First braided portion 126, second braided portion 130, and third braided portion 134 are integrally braided with one another. The decorative member 120 can include a contour.

Second yarn 132 is similar to second yarn 42 of trim component 30 (fig. 2-4). First yarn 128 and third yarn 136 are heat activated yarns. The heat-activated yarn is a core-shell yarn comprising an elongate core or base and comprising a shell or carrier at least partially enclosing or enveloping the core. The first yarn 128 includes a first core 138 and a first sheath 140 (fig. 11) surrounding the first core 138. The first core comprises a first composition and the first shell comprises a second composition. Third yarn 136 includes a second core (not shown) and a second shell (not shown). The second core comprises a third composition and the second shell comprises a fourth composition.

The first composition and the third composition are different. More particularly, the first composition is configured to react with the third composition to form a thermoset polymer. The second and fourth compositions may be the same or different. The second composition is configured to melt upon heating to a first predetermined temperature. The fourth composition is configured to melt upon heating to a second predetermined temperature. When the second and fourth compositions are heated, the first and second shells melt, releasing the first and third compositions of the first and second cores, respectively. In various aspects, the first predetermined temperature and the second predetermined temperature are the same or similar such that the first composition and the third composition are released simultaneously during heating. In other aspects, the first predetermined temperature and the second predetermined temperature are different such that the first composition and the third composition are released at different points during heating. First yarn 129 and third yarn 136 may include any other suitable structure that allows for the controlled release of the first and third compositions that form the reactive system.

The first and third compositions may together be a two-part adhesive system. In various aspects, one of the first and third compositions is a resin and the other is a curing agent. In one example, the first composition includes an epoxy resin and the third composition includes a hardener. In another example, the first composition and the third composition are polyurethane reactants. Examples of suitable second and fourth compositions include polyester and nylon.

The respective shells isolate the first and third compositions of the core until the trim component 90 is heated. When the decorative member 90 is heated, the second and fourth compositions are at least partially melted to expose the first and third compositions. The first composition and the third composition react to form a thermoset polymer, thereby forming the trim component 120' having a film 142 comprising a thermoset polymer.

Similar to the film 38' of the trim component 30' of fig. 4, the interior component 94 can conceal imperfections and reduce wear on the support member (see, e.g., the support member 18 of fig. 1) when the trim component 90' is installed on a vehicle seat (see, e.g., the vehicle seat 10 of fig. 1). The use of two different yarns having different components that react to form a film allows a large degree of control over the location where the film 142 is formed on the first side 122 of the trim component 120. In various aspects, the first woven portion 126 and/or the third woven portion 134 are woven to define perforations similar to the perforations 74 of the trim component 60 of fig. 6. Unlike the thermoplastic polymers described above, the thermoset polymer of the film 142 cannot be heated and reshaped. Thus, the film 142 may be more permanent than a thermoplastic film that may be heated and reshaped.

Referring to fig. 14-17, yet another trim component 150 for a vehicle seat according to various aspects of the present disclosure is provided. The decorative member 150 includes an outer member 152 and an inner member 154. The outer component 152 is configured to be disposed on an outboard side of the vehicle seat, and the inner component 154 is configured to be disposed toward a support member of the vehicle seat (see, e.g., support member 18 of fig. 1).

Outer member 152 includes a first knitted portion 156 knitted with a first yarn 158 and a second knitted portion 160 knitted with a second yarn 162. The first braided portion 156 and the second braided portion 160 are integrally braided with one another. First braided portion 156 is disposed on a first side 164 of outer member 152 and second braided portion 160 is disposed on a second side 166 of outer member 152 opposite first side 164 of outer member 152.

Inner member 154 includes a third knitted portion 168 knitted with a third yarn 170 and a fourth knitted portion 172 knitted with a fourth yarn 174. The third braided portion 168 and the fourth braided portion 172 are integrally braided with one another. Third braided portion 168 is disposed on third side 176 of inner member 154. The fourth braided portion is disposed on a fourth side 178 of inner member 154 opposite third side 176 of inner member 152.

The second yarn 162 is similar to the second yarn 132 of the trim component 120 of fig. 10-13. Fourth yarn 174 may be a non-heat reactive yarn. The fourth yarn may have a size or density characteristic suitable for the interior of the trim cover. For example, the fourth yarn 174 may be a bulky yarn, such as an air textured yarn, to provide additional padding and enhance occupant comfort on the vehicle seat.

The first yarn 158 is similar to the first yarn 128 of the trim component 120 of fig. 10-13. The third yarn 170 is similar to the third yarn 136 of fig. 10-13. Accordingly, first yarn 128 includes a first component and a second component, and third yarn 170 includes a third component and a fourth component, the first component and the third component being configured to react to form a thermoset polymer.

The outer part 152 and the inner part 154 are directly engaged with each other. More specifically, the first side 164 of the outer member 152 is in contact with the third side 176 of the inner member 154. The outer and inner components 152, 154 may be heated to melt the respective second and fourth components and release the first and third components. The first component and the third component react to form a thermoset polymer. Thus, the decoration member 150' having the film 180 is formed.

Membrane 180 is disposed between second braided portion 160 and fourth braided portion 172. The first side 164 can be the a side of the decorative member 150 'and the fourth surface 178 can be the B side of the second woven portion 150'. As described above, fourth knitted portion 172 may include a yarn suitable for use in a seat. The fourth yarn 174 may be selected to enhance passenger comfort, for example, by using a bulky or light yarn that simulates foam plus padding. Such yarns may also hide imperfections in the support structure, thereby improving the appearance of the vehicle seat.

The trim component 150 is particularly suited for shipping because the outer component 152 and the inner component 154 can be stored separately until the outer component 152 and the inner component 154 are intentionally joined by heat. Thus, the effect of inadvertent leakage of the core material is minimized because it does not cause a reaction to form the thermosetting polymer. Those skilled in the art will appreciate that the trim component of the present disclosure may include more than two components (i.e., the outer component 154 and the inner component 152).

Referring to fig. 18, a portion 190 of another decorative member in accordance with various aspects of the present disclosure is provided. The decorative member 190 includes a first side and a second side opposite the first side. The decorative member 190 includes a first braided portion 192 defining a first braid 193 and a second braided portion 194 defining a second braid 195 different from the first braid 195. The first and second braided portions 192 and 194 are integrally braided with one another. In various aspects, first braid 193 and second braid 195 differ in structure, yarn (e.g., yarn having different thicknesses, densities, or materials), stitch, density (e.g., weight of part/volume of part), and thickness. In one example, the first portion drops or omits a ring to make it soft or ventilated as compared to the second portion (not shown). In another example, the first portion defines a soft or ventilated first stitch and the second portion defines an aesthetically pleasing stitch (not shown). In yet another example, the first portion and the second portion define the same stitches, and the loops of the second portion are pulled tighter than the loops of the first portion, making the first portion more durable and the first portion more ventilated (not shown). In yet another example, the first portion is thicker than the second portion to provide cushioning and thereby increase occupant comfort.

In the example shown in fig. 18, first braid 193 includes first yarns 196 and second braid 195 includes second yarns 198. First yarn 196 is similar to fourth yarn 174 of fig. 14-17. The second yarn 198 is similar to the first yarn 158 of the trim component 150 of figures 14-17. Thus, the first woven portion 192 is configured to form the B side of the decorative member 190 and the second woven portion 194 is configured to form the a side of the decorative member 190.

The first knitted portion 192 may comprise a bulky or plush yarn and be knitted to a suitable thickness to function similarly to padding in a vehicle seat. One example of a suitable first yarn 196 is an air textured yarn. The first braided portion 192 provides cushioning to enhance occupant comfort. First braided portion 192 also protects the support member from scratching by second braided portion 194 because first yarn 196 is softer than second braided portion 198. Finally, the first braided portion 192 advantageously minimizes the appearance of imperfections in the support member, thereby improving the aesthetic appearance of the vehicle seat. Those skilled in the art will appreciate that the trim component 190 may include additional integrally woven portions, such as portions including thermally reactive yarns (not shown).

In various aspects, the first knitted portion includes a plurality of regions having different characteristics. In one example, the first knitted portion includes a first region and a second region integrally knitted with the first region. The first region and the second region are both disposed on the first side of the trim component. The first region defines a first thickness and the second region defines a second thickness different from the first thickness. In another example, the first portion includes a first region and a second region. The first region and the second region are both disposed on the first side of the trim component. The first region is knitted with a first yarn having a first density. The second region is integrally knitted with a second yarn having a second density. The first density and the second density are different. In both examples described above, different regions may be provided on different regions of the vehicle seat, for example, the seat cushion having a greater thickness and/or a higher density, or the seat side having a lesser thickness/lower density.

Referring to fig. 19-21, a method for forming a contoured trim component for a vehicle seat according to various aspects of the present disclosure is provided. The method starts at 220. At 220, the first material 222 is heated to a first predetermined temperature. The first material 222 comprises a heat-activated polymer such as those described above. The first material 222 may be in the form of a different thin polymer sheet. First material 222 may alternatively be in the form of a first yarn integrally knitted with second contoured knit material 224. The first predetermined temperature may be above the glass transition temperature of the polymer film but below the melting temperature of the polymer. In certain aspects, this step is referred to as a preheat step. The method continues at 226.

At 226, a third material 228 is optionally placed on a forming surface 230 of a fixture 232 (fig. 21). The forming surface 230 defines a plurality of apertures 334, the plurality of apertures 334 opening into the interior volume 236 of the fixture 232. The contoured surface 230 is configured to match the contour of the vehicle seat to which the trim cover will be mounted. The third material 228 comprises a foam, such as those described above. In various alternative aspects, the third material 228 can comprise a woven material similar to the fourth woven portion 172 of the inner member 154 of the trim component 150 of fig. 14-17. The third material 228 may be in direct contact with the forming surface 230. The third material 228 (fig. 20) may be omitted. The method continues at 238.

At 238, the first material 222 is disposed on the forming surface 230 of the fixture 232. The first material 222 may be stretched around the forming surface 230 while at the first predetermined temperature to eliminate wrinkles, folds, and folds. If step 226 is performed, the first material 222 is placed on the third material 228. If step 226 is omitted, the first material 222 is placed in direct contact with the forming surface 230. The method continues at 240.

At 240, a second material 224 is optionally disposed on the first material 222. If the first material 222 is in the form of a thin polymer sheet, the second material 224 is a 3D woven structure having one or more contours. If the first material 222 and the second material 224 are integrally woven with one another (see, e.g., trim component 30 of fig. 2-3), step 240 is omitted because the second material 224 is already disposed on the first material 222. The method continues at 242.

At 242, the first material 222 is heated to a second predetermined temperature. The second predetermined temperature is above the glass transition temperature of the polymer but below the melting temperature of the polymer. The second predetermined temperature may be the same as or different from the first predetermined temperature. Heating the first material 222 to the second predetermined temperature causes softening such that the first material 222 can conform to the forming surface 230 of the mold. The method continues at 244.

At 244, a vacuum 246 is drawn within the interior volume 236 of the fixture 232. The vacuum pressure may be in the range of 20inH-27 inHg. The method continues at 248. Step 244 and step 242 may be performed simultaneously.

At 248, additional pressure is optionally applied to the materials 222, 224, 238 on the fixture 232. Step 248 may be omitted. The method ends. The resulting profile of the trim cover may be that of a vehicle seat. The trim cover is then installed on the vehicle seat.

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps of the method may be performed in a different order (or simultaneously) without altering the principles of the present disclosure. Furthermore, although each embodiment is described above as having certain features, any one or more of those features described in relation to any embodiment in the present disclosure may be implemented with and/or in combination with features of any other embodiment, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive and a permutation and combination of one or more embodiments is still within the scope of the present disclosure.

Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms including "connected," joined, "" coupled, "" adjacent, "" immediately adjacent, "" on top, "" above, "" below, "and" disposed. Unless explicitly described as "direct," when a relationship between a first element and a second element is described in the above disclosure, the relationship may be a direct relationship in which no other intermediate element exists between the first element and the second element, but may also be an indirect relationship in which one or more intermediate elements exist (spatially or functionally) between the first element and the second element. As used herein, at least one of the phrases A, B and C should be construed to mean logic (a or B or C) using a non-exclusive logical "or" and should not be construed to mean "at least one of a, at least one of B, and at least one of C.