US20110101557A1 - Vehicle seat with improved craftsmanship - Google Patents
Vehicle seat with improved craftsmanship Download PDFInfo
- Publication number
- US20110101557A1 US20110101557A1 US12/985,249 US98524911A US2011101557A1 US 20110101557 A1 US20110101557 A1 US 20110101557A1 US 98524911 A US98524911 A US 98524911A US 2011101557 A1 US2011101557 A1 US 2011101557A1
- Authority
- US
- United States
- Prior art keywords
- covering material
- vehicle component
- mold cavity
- vehicle
- receiving surface
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000463 material Substances 0.000 claims abstract description 110
- 239000006260 foam Substances 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 36
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 21
- 239000008367 deionised water Substances 0.000 claims abstract description 11
- 229910021641 deionized water Inorganic materials 0.000 claims abstract description 11
- 238000007711 solidification Methods 0.000 claims abstract description 7
- 230000008023 solidification Effects 0.000 claims abstract description 7
- 238000005507 spraying Methods 0.000 claims abstract description 5
- 239000007921 spray Substances 0.000 claims description 22
- 229920001296 polysiloxane Polymers 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 12
- 229920002635 polyurethane Polymers 0.000 claims description 9
- 239000004814 polyurethane Substances 0.000 claims description 9
- 229920005830 Polyurethane Foam Polymers 0.000 abstract description 3
- 239000011496 polyurethane foam Substances 0.000 abstract description 3
- 239000004744 fabric Substances 0.000 description 9
- 239000003086 colorant Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000003610 charcoal Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000004945 emulsification Methods 0.000 description 1
- 230000001804 emulsifying effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/70—Upholstery springs ; Upholstery
- B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249955—Void-containing component partially impregnated with adjacent component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249955—Void-containing component partially impregnated with adjacent component
- Y10T428/249958—Void-containing component is synthetic resin or natural rubbers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249987—With nonvoid component of specified composition
- Y10T428/24999—Inorganic
Definitions
- the application generally relates to a vehicle component assembly and to a process for improving vehicle craftsmanship.
- the application relates more specifically to nonionic polymeric colorant covering materials for spray application to vehicle components, including foam vehicle components, and an associated process for improving vehicle seat craftsmanship.
- Motor vehicles include a substantial number of assembled components having multiple design considerations. The same holds true for a vehicle seat.
- vehicle seat In the vehicle seat, there are seat portions having foam such as the vehicle seat back and seat cushion.
- the foam typically has a white or substantially yellow colored tone; however, vehicle interiors are commonly gray, black or beige in color. When the light colored foam is visible, it contrasts with darker toned portions of the vehicle interior; the foam can easily be noticed and draw unwanted attention to that area of the vehicle interior.
- One potential solution proposed by some foam manufacturers is to include a dye within the foam mixture.
- the appearance of the colored foam is less noticeable (or at least compliments the other components of the vehicle). While providing colored foam makes the foam less noticeable, it may be costly and potentially complicates the overall production process.
- Marking of the foam has been utilized to color code areas of the foam so as to identify preferred assembly positions.
- the color-coding is typically applied to small areas and in a manner to be identified not concealed.
- a green or red circle may be provided on the surface of the foam to indicate an upward position of mounting a foam seat cushion with respect to the seat frame.
- a red mark on the surface of a foam seat cushion may indicate the corresponding vehicle—in a multi-vehicle assembly line—for the seat cushion.
- flagging a surface of the foam serves to identify and bring attention to certain sections of the vehicle components.
- Another method of covering foam pieces is to provide fabric that is applied to the molding cavity of the foam prior to molding the foam.
- the fabric is placed in the mold cavity and the polyurethane mixture is dispensed therein.
- Such additional parts can prove to be a costly addition to the price of the vehicle component.
- Another method of concealing certain areas of vehicle components is to apply a plastic covering material or plastic insert covering the offending white area of the foam from vehicle occupants as a finishing step before shipment. Again, this may have significant cost implications on the vehicle component due to the need for additional parts.
- One exemplary embodiment a process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a vehicle component, the camouflaging thereby concealing the receiving surface of the vehicle component.
- the process includes designating a receiving surface area on the vehicle component, and providing a covering material having an opaque characteristic.
- the covering material includes deionized water, an opaque dye, and silicone material.
- the process also includes spraying the covering material in a mold cavity at a surface of the mold cavity corresponding to the designated receiving surface area on the vehicle component until the covering material completely covers the surface defined on the mold cavity.
- Another exemplary embodiment relates to a process of making a covering material for camouflaging a vehicle component upon application, the camouflaging thereby concealing the vehicle component from observation and improving overall vehicle craftsmanship.
- the process includes providing a silicone material, adding a deionized water-based solution to the silicone material, adding an opaque dye to the deionized water-based solution and the silicone material, mixing the silicone material, water-based solution and opaque dye in a blend tank, and heating the covering material to a predetermined temperature.
- Another exemplary embodiment relates to a covering material for camouflaging a vehicle component upon application, the camouflaging thereby giving the appearance of concealing the vehicle component from vehicle passengers.
- the covering material comprises a silicone material, a deionized water-based solution, and an opaque dye.
- the covering material is configured to be combined with a polyurethane solution forming a foam seat member upon emulsification.
- Another exemplary embodiment relates to a process for improving vehicle seat craftsmanship by camouflaging a plurality of receiving surfaces on a vehicle component, the camouflaging thereby concealing the plurality of receiving surfaces on the vehicle component.
- the process includes designating the plurality of receiving surfaces on the vehicle component, providing a covering material having an opaque characteristic, and providing a mold cavity.
- the mold cavity defines a plurality of corresponding receiving surfaces, each corresponding receiving surface assigned to one of the plurality of receiving surfaces on the vehicle component.
- the process further includes providing a spray apparatus, applying the covering material to the corresponding receiving surfaces of the mold cavity, and pouring a polyurethane mixture into the mold cavity for solidification.
- FIG. 1 is a perspective view of a vehicle having a vehicle seat therein according to an exemplary embodiment.
- FIG. 2 is a perspective view of a mold cavity according to one exemplary embodiment.
- FIG. 3 is a perspective view of the mold cavity of FIG. 2 with covering material applied thereto according to one exemplary embodiment.
- FIG. 4 is a perspective view of foam with covering material applied thereto according to one exemplary embodiment.
- FIG. 5 is a perspective view of a vehicle component with covering material applied thereto according to one exemplary embodiment.
- FIG. 6 is a perspective view of a vehicle component with covering material applied thereto according to one exemplary embodiment.
- FIG. 7 is a perspective view of a vehicle component with covering materials having different water levels applied thereto according to one exemplary embodiment.
- FIGS. 8 a - d are side and perspective views of a spray apparatus and a mold cavity according to one exemplary embodiment.
- FIGS. 9 a - b are perspective views of a mold cavity with corresponding receiving surfaces indicated according to one exemplary embodiment.
- FIGS. 10 a - c are perspective views of the application of covering material to a mold cavity according to one exemplary embodiment.
- FIG. 11 is a perspective view of a spray apparatus according to one exemplary embodiment.
- a vehicle component assembly (e.g., a vehicle seat assembly 100 ) is provided that is adapted for use in any variety of applications for a vehicle 110 (e.g., automobile, plane, train).
- the vehicle seat assembly 100 may be provided in locations throughout the vehicle other than the location shown in FIG. 1 .
- the vehicle component assembly according to an exemplary embodiment can include a vehicle component of one color and a covering material of another color that is colored to more closely match the surrounding vehicle components.
- the covering material can be a nonionic polymeric colorant covering material for spray application to the vehicle component or to the cavity of a mold configured to form the vehicle component.
- FIGS. 2 and 3 show a mold cavity 120 that can be used to mold a foam vehicle component for a vehicle according to one exemplary embodiment. It will be understood that the following description can apply to mold cavities to create vehicle components for the interior or exterior of a motor vehicle.
- a foam vehicle component can have a bright tone relative to the surroundings components of the vehicle and in certain areas be more noticeable than those surrounding components. To satisfy vehicle craftsmanship concerns, it is desirable to conceal or camouflage the bright tone of the vehicle component so that it is hidden from vehicle users or passengers. To do so, the covering material 16 can be selectively applied to the interior surface of the mold cavity 120 .
- FIG. 2 shows the mold cavity 120 prior to application of the covering material 16
- FIG. 3 shows the mold cavity 120 after application of the covering material 16 .
- the covering material 16 can cover the otherwise bright exterior surface of the foam so that is more closely matches the tone of the surrounding components of the vehicle.
- Application of the covering material 16 to the mold cavity 120 will be explained in more detail in connection with FIGS. 8 a - d , 9 a - b , and 10 a - c.
- the mold cavity 120 can be marked with instructional language such as “CLOTH” or “APPLY HERE.”
- a cloth or upholstery material may be fastened to the interior surface of the mold cavity, and, following curing of the foam vehicle component in the mold, the cloth may adhere to the foam to provide improved foam durability.
- the cloth material might not, however, cover the entire exterior surface of the foam, and so covering material 16 may be applied to the mold cavity in those areas that the cloth does not reach. In this manner, after curing, cloth partially covers the foam vehicle component, and the covering material 16 may cover the remainder so that the otherwise bright tone of the foam is not visible.
- the cloth may be attached to the foam vehicle component after curing in the mold cavity 120 .
- Vehicle component 10 may be covered with a covering material 16 that camouflages the vehicle component as shown in FIGS. 4-7 .
- the covering material 16 is an opaque material that at least partially covers the exterior of vehicle component 10 .
- the vehicle component 10 is composed of a foam member. Upon bonding or reacting with the foam vehicle component, the covering material 16 adheres to the foam vehicle component and gives the appearance of a tinted surface on the vehicle component.
- the covering material 16 can include a black dye that bonds with the polyurethane foam that is poured into a mold (e.g., the mold cavity of FIG. 2-3 ).
- the polyurethane foam can fully react with dye in the covering material upon solidification such that the covering material does not disperse or rub off on other surfaces upon contact.
- Also included in the covering material mixture are deionized water and a silicone dispersing (or mixing) agent.
- a process of making the covering material includes providing a black opaque dye material, adding a deionized water solution to a silicone material, mixing the silicone material, water-based solution and opaque dye in a blend tank, and heating the material to a predetermined temperature.
- the mixing may be performed in an industrial mixing tank configured to blend the water, dye and silicone together.
- the tank may also include a heating unit.
- the material is heated to a temperature between 100 and 120 degrees Fahrenheit.
- the covering material is heated between 80 and 180 degrees Fahrenheit.
- the length of time the mixture is heated is also variable. In one embodiment, the covering material is heated any where from 3 to 60 minutes.
- the ratio of silicone to water to dye may change according to the specified application.
- the covering material consists of an at least 20% water-based solution.
- the amount of water-based solution in the covering material may be altered to increase the viscosity of the covering material according to different vehicle components having different surface characteristics.
- a vehicle component composed of a polymeric material requires a more viscous covering material than a vehicle component composed of a metallic material.
- the covering material can have different material characteristics to accommodate the surface texture of the receiving surface on the vehicle component.
- FIG. 7 shows covering material 16 A and 16 B of different levels of viscosity applied to a metallic receiving surface.
- the covering material 16 A demonstrates an appropriate range of viscosity for application to a metallic receiving surface.
- the viscosity of the covering material 16 B is outside of the appropriate range of viscosity for a metallic surface.
- the covering material 16 B includes too much water.
- the variation in viscosity of the covering material is represented by different gradients or patterns as shown in FIG. 7 .
- the cover weight of the covering material may also change according to the specified application.
- the desirable cover weight is greater for some vehicle components than others.
- the cover weight for the covering material in one exemplary embodiment is between 5 and 15 grams for application to a foam seat member.
- the mixture contains between 0.001 and 75% dye depending upon the overall coverage requirements.
- the covering material consists of at least 0.001% dye.
- the dye is opaque and in one exemplary embodiment configured to match a predetermined color scheme of the vehicle interior.
- the dye color may be black or charcoal so that the covered vehicle component compliments the color scheme of the vehicle interior.
- the vehicle component 10 is a foam insert having a yellow tone.
- the vehicle component is covered with a covering material having a black tone on at least one surface after emulsifying in the mold cavity. Several shades of black may be utilized with the covering material such as REACTINT® products Black 1852, Black 2151, Black 2256, Black X95AB or Black X77.
- a process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a vehicle component, the camouflaging thereby concealing the receiving surface of the vehicle component from observation is also provided.
- the process includes designating a receiving surface area on the vehicle component and providing a covering material having an opaque characteristic.
- the covering material includes deionized water, an opaque dye, and silicone material.
- the process further includes spraying the covering material in a in a mold cavity according to a surface of the mold cavity which corresponds to the designated receiving surface area on the vehicle component until the covering material completely covers a designated receiving surface area defined on the mold cavity.
- the vehicle component is a foam member constructed from polyurethane poured into the mold cavity.
- the designated area is not limited to forming and covering any one of six sides as shown in FIGS. 5-6 .
- the designated area may also form the top surface of a complex component as shown in FIG. 4 or a certain portion of a surface of the vehicle component as shown in FIG. 2 .
- the covering material 16 can be configured for spray application to the mold cavity of the vehicle component 10 .
- the application of the covering material can be with a standard fixed adjustable spray apparatus with pneumatic controls.
- a plurality of spray nozzles are incorporated on the assembly line to enable the water in the covering material to dry off faster so as to not create any surface damage.
- the spray nozzles may be coupled to a controller as a unit or independently.
- the covering material is applied to the vehicle component at a pressure between 15 and 60 psi.
- a process for improving vehicle seat craftsmanship by camouflaging a plurality of receiving surfaces on a vehicle component, the camouflaging thereby concealing the plurality of receiving surfaces on the vehicle component from observation includes designating the plurality of receiving surfaces on the vehicle component and providing a covering material having an opaque characteristic.
- the covering material includes deionized water, an opaque dye, and silicone material.
- the process further includes providing a mold cavity, the mold cavity defining a plurality of corresponding receiving surfaces, each corresponding receiving surface assigned to one of the plurality of receiving surfaces on the vehicle component; providing a spray apparatus; applying the covering material to the corresponding receiving surfaces of the mold cavity; and pouring a polyurethane mixture into the mold cavity for solidification.
- the covering material is applied via a spray apparatus 20 as shown in FIGS. 8 a - d .
- the spray apparatus 20 includes a plurality of spray nozzles (or “guns”)— 22 , 24 , 26 , and 28 —configured to cover a corresponding receiving surface in the mold cavity ( 120 , 30 , 32 , 34 and/or 36 as shown in FIGS. 2-3 , 8 b , 8 d and 9 a - b , respectively).
- the corresponding receiving surfaces are assigned to one of the plurality of receiving surfaces on the vehicle component.
- the corresponding receiving surfaces (“RS”) may be assigned indicators. For example, the corresponding receiving surface labeled “ 7 ” in FIG. 9 a is assigned to a receiving surface on the bottom perimeter of the vehicle component.
- the spray apparatus 20 is configured to include at least one additional nozzle 28 extendable to a position farther outward from the remaining spray nozzles 22 , 24 and 26 , thus enabling the extendable nozzle 28 to reach intricate position of the mold cavities (e.g., 32 ).
- the mold cavities 34 and 36 can define a plurality of receiving areas as shown in FIGS. 9 a - 9 b which correspond to the shape of the vehicle component 10 .
- the mold cavity 34 as shown in FIG. 9 a , is a schematic representation of a mold cavity for an individual passenger seat.
- the mold cavity 36 as shown in FIG. 9 b , is a schematic representation of a mold cavity for a multiple passenger seat such as a seat bench or row.
- the spray apparatus 20 is configured to spray any number of the indicated receiving surfaces for coverage.
- a control module 40 (or panel), such as shown in FIG. 11 , is coupled to the spray apparatus 20 to govern the application of the covering material to the corresponding areas on the mold cavity.
- the spray apparatus 20 and/or mold cavity 34 are configured to move with respect to each other as shown in FIGS. 10 a - c .
- the direction of movement “X” of the mold cavity 34 with respect to the spray apparatus 20 is shown in the exemplary illustrated embodiment.
- the control panel 40 also governs the pressure at which the covering material is applied to the mold cavity as provided by a pump 42 (or pneumatic control) as shown in FIG. 11 .
- the covering material is fed from a tank 44 and into the spray apparatus 20 via the pump 42 .
- the pump 42 may be a high pressure low volume (HVLP) pump or other comparable pneumatic device known to persons of ordinary skill in the art.
- HVLP high pressure low volume
- the control panel 40 and covering material are configured to apply the covering material at a rate of 0.8 seconds per vehicle component.
- the control panel 40 is configured to apply the covering material from 0.1 to 1.5 seconds per vehicle component.
- vehicle component may be any number of different components such as foam cushion (or insulation) pieces, cavities defined by a plurality of other vehicle components, metallic or polymeric surfaces, internal shafts, bonding materials, electronic wiring, fasters, and the like.
Abstract
A process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a predetermined vehicle component (e.g., a foam seat cushion) is described. The camouflaging conceals the vehicle component from observation. One example of the process includes designating a receiving surface area on the vehicle component and providing a covering material having an opaque characteristic. The covering material includes an opaque dye that bonds with the polyurethane foam that is poured into a mold with deionized water for solidification. Another example of the process further includes spraying the covering material according to a surface of the mold cavity which corresponds to the designated receiving surface area on the vehicle component.
Description
- The present application claims the benefit of U.S. Provisional Patent Application No. 60/788,308 (“Vehicle Seat with Improved Craftsmanship”) filed Mar. 31, 2006, which is hereby incorporated by reference it its entirety.
- The application generally relates to a vehicle component assembly and to a process for improving vehicle craftsmanship. The application relates more specifically to nonionic polymeric colorant covering materials for spray application to vehicle components, including foam vehicle components, and an associated process for improving vehicle seat craftsmanship.
- Vehicle craftsmanship directly influences consumer purchasing decisions. Motor vehicles include a substantial number of assembled components having multiple design considerations. The same holds true for a vehicle seat. In the vehicle seat, there are seat portions having foam such as the vehicle seat back and seat cushion. The foam typically has a white or substantially yellow colored tone; however, vehicle interiors are commonly gray, black or beige in color. When the light colored foam is visible, it contrasts with darker toned portions of the vehicle interior; the foam can easily be noticed and draw unwanted attention to that area of the vehicle interior.
- One potential solution proposed by some foam manufacturers is to include a dye within the foam mixture. The appearance of the colored foam is less noticeable (or at least compliments the other components of the vehicle). While providing colored foam makes the foam less noticeable, it may be costly and potentially complicates the overall production process.
- Marking of the foam has been utilized to color code areas of the foam so as to identify preferred assembly positions. However, the color-coding is typically applied to small areas and in a manner to be identified not concealed. For example, a green or red circle may be provided on the surface of the foam to indicate an upward position of mounting a foam seat cushion with respect to the seat frame. Likewise a red mark on the surface of a foam seat cushion may indicate the corresponding vehicle—in a multi-vehicle assembly line—for the seat cushion. Inapposite to camouflaging, flagging a surface of the foam serves to identify and bring attention to certain sections of the vehicle components.
- Another method of covering foam pieces is to provide fabric that is applied to the molding cavity of the foam prior to molding the foam. The fabric is placed in the mold cavity and the polyurethane mixture is dispensed therein. Such additional parts can prove to be a costly addition to the price of the vehicle component.
- Another method of concealing certain areas of vehicle components is to apply a plastic covering material or plastic insert covering the offending white area of the foam from vehicle occupants as a finishing step before shipment. Again, this may have significant cost implications on the vehicle component due to the need for additional parts.
- Despite known methods for marking vehicle components to simplify the manufacturing process, craftsmanship issues persist regarding the visibility of off-colored vehicle components.
- One exemplary embodiment a process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a vehicle component, the camouflaging thereby concealing the receiving surface of the vehicle component. The process includes designating a receiving surface area on the vehicle component, and providing a covering material having an opaque characteristic. The covering material includes deionized water, an opaque dye, and silicone material. The process also includes spraying the covering material in a mold cavity at a surface of the mold cavity corresponding to the designated receiving surface area on the vehicle component until the covering material completely covers the surface defined on the mold cavity.
- Another exemplary embodiment relates to a process of making a covering material for camouflaging a vehicle component upon application, the camouflaging thereby concealing the vehicle component from observation and improving overall vehicle craftsmanship. The process includes providing a silicone material, adding a deionized water-based solution to the silicone material, adding an opaque dye to the deionized water-based solution and the silicone material, mixing the silicone material, water-based solution and opaque dye in a blend tank, and heating the covering material to a predetermined temperature.
- Another exemplary embodiment relates to a covering material for camouflaging a vehicle component upon application, the camouflaging thereby giving the appearance of concealing the vehicle component from vehicle passengers. The covering material comprises a silicone material, a deionized water-based solution, and an opaque dye. The covering material is configured to be combined with a polyurethane solution forming a foam seat member upon emulsification.
- Another exemplary embodiment relates to a process for improving vehicle seat craftsmanship by camouflaging a plurality of receiving surfaces on a vehicle component, the camouflaging thereby concealing the plurality of receiving surfaces on the vehicle component. The process includes designating the plurality of receiving surfaces on the vehicle component, providing a covering material having an opaque characteristic, and providing a mold cavity. The mold cavity defines a plurality of corresponding receiving surfaces, each corresponding receiving surface assigned to one of the plurality of receiving surfaces on the vehicle component. The process further includes providing a spray apparatus, applying the covering material to the corresponding receiving surfaces of the mold cavity, and pouring a polyurethane mixture into the mold cavity for solidification.
-
FIG. 1 is a perspective view of a vehicle having a vehicle seat therein according to an exemplary embodiment. -
FIG. 2 is a perspective view of a mold cavity according to one exemplary embodiment. -
FIG. 3 is a perspective view of the mold cavity ofFIG. 2 with covering material applied thereto according to one exemplary embodiment. -
FIG. 4 is a perspective view of foam with covering material applied thereto according to one exemplary embodiment. -
FIG. 5 is a perspective view of a vehicle component with covering material applied thereto according to one exemplary embodiment. -
FIG. 6 is a perspective view of a vehicle component with covering material applied thereto according to one exemplary embodiment. -
FIG. 7 is a perspective view of a vehicle component with covering materials having different water levels applied thereto according to one exemplary embodiment. -
FIGS. 8 a-d are side and perspective views of a spray apparatus and a mold cavity according to one exemplary embodiment. -
FIGS. 9 a-b are perspective views of a mold cavity with corresponding receiving surfaces indicated according to one exemplary embodiment. -
FIGS. 10 a-c are perspective views of the application of covering material to a mold cavity according to one exemplary embodiment. -
FIG. 11 is a perspective view of a spray apparatus according to one exemplary embodiment. - According to an exemplary embodiment, a vehicle component assembly (e.g., a vehicle seat assembly 100) is provided that is adapted for use in any variety of applications for a vehicle 110 (e.g., automobile, plane, train). The
vehicle seat assembly 100 may be provided in locations throughout the vehicle other than the location shown inFIG. 1 . The vehicle component assembly according to an exemplary embodiment can include a vehicle component of one color and a covering material of another color that is colored to more closely match the surrounding vehicle components. The covering material can be a nonionic polymeric colorant covering material for spray application to the vehicle component or to the cavity of a mold configured to form the vehicle component. -
FIGS. 2 and 3 show amold cavity 120 that can be used to mold a foam vehicle component for a vehicle according to one exemplary embodiment. It will be understood that the following description can apply to mold cavities to create vehicle components for the interior or exterior of a motor vehicle. A foam vehicle component can have a bright tone relative to the surroundings components of the vehicle and in certain areas be more noticeable than those surrounding components. To satisfy vehicle craftsmanship concerns, it is desirable to conceal or camouflage the bright tone of the vehicle component so that it is hidden from vehicle users or passengers. To do so, the coveringmaterial 16 can be selectively applied to the interior surface of themold cavity 120.FIG. 2 shows themold cavity 120 prior to application of the coveringmaterial 16, andFIG. 3 shows themold cavity 120 after application of the coveringmaterial 16. After curing of the foam vehicle component in themold cavity 120, the coveringmaterial 16 can cover the otherwise bright exterior surface of the foam so that is more closely matches the tone of the surrounding components of the vehicle. Application of the coveringmaterial 16 to themold cavity 120 will be explained in more detail in connection withFIGS. 8 a-d, 9 a-b, and 10 a-c. - In the embodiment of
FIGS. 2 and 3 , themold cavity 120 can be marked with instructional language such as “CLOTH” or “APPLY HERE.” A cloth or upholstery material may be fastened to the interior surface of the mold cavity, and, following curing of the foam vehicle component in the mold, the cloth may adhere to the foam to provide improved foam durability. The cloth material might not, however, cover the entire exterior surface of the foam, and so coveringmaterial 16 may be applied to the mold cavity in those areas that the cloth does not reach. In this manner, after curing, cloth partially covers the foam vehicle component, and the coveringmaterial 16 may cover the remainder so that the otherwise bright tone of the foam is not visible. In an alternative embodiment, the cloth may be attached to the foam vehicle component after curing in themold cavity 120. -
Vehicle component 10 may be covered with a coveringmaterial 16 that camouflages the vehicle component as shown inFIGS. 4-7 . The coveringmaterial 16 is an opaque material that at least partially covers the exterior ofvehicle component 10. In one exemplary embodiment, thevehicle component 10 is composed of a foam member. Upon bonding or reacting with the foam vehicle component, the coveringmaterial 16 adheres to the foam vehicle component and gives the appearance of a tinted surface on the vehicle component. - The covering
material 16 can include a black dye that bonds with the polyurethane foam that is poured into a mold (e.g., the mold cavity ofFIG. 2-3 ). The polyurethane foam can fully react with dye in the covering material upon solidification such that the covering material does not disperse or rub off on other surfaces upon contact. Also included in the covering material mixture are deionized water and a silicone dispersing (or mixing) agent. - A process of making the covering material includes providing a black opaque dye material, adding a deionized water solution to a silicone material, mixing the silicone material, water-based solution and opaque dye in a blend tank, and heating the material to a predetermined temperature. The mixing may be performed in an industrial mixing tank configured to blend the water, dye and silicone together. The tank may also include a heating unit. In one exemplary embodiment, the material is heated to a temperature between 100 and 120 degrees Fahrenheit. In another exemplary embodiment, the covering material is heated between 80 and 180 degrees Fahrenheit. The length of time the mixture is heated is also variable. In one embodiment, the covering material is heated any where from 3 to 60 minutes.
- The ratio of silicone to water to dye may change according to the specified application. In one exemplary embodiment, the covering material consists of an at least 20% water-based solution. However, in another exemplary embodiment, the amount of water-based solution in the covering material may be altered to increase the viscosity of the covering material according to different vehicle components having different surface characteristics. For example, a vehicle component composed of a polymeric material requires a more viscous covering material than a vehicle component composed of a metallic material. Accordingly, the covering material can have different material characteristics to accommodate the surface texture of the receiving surface on the vehicle component. The embodiment of
FIG. 7 shows covering material material 16A demonstrates an appropriate range of viscosity for application to a metallic receiving surface. The viscosity of the coveringmaterial 16B is outside of the appropriate range of viscosity for a metallic surface. The coveringmaterial 16B includes too much water. The variation in viscosity of the covering material is represented by different gradients or patterns as shown inFIG. 7 . - The cover weight of the covering material may also change according to the specified application. The desirable cover weight is greater for some vehicle components than others. The cover weight for the covering material in one exemplary embodiment is between 5 and 15 grams for application to a foam seat member. In one exemplary embodiment, the mixture contains between 0.001 and 75% dye depending upon the overall coverage requirements.
- In another exemplary embodiment, the covering material consists of at least 0.001% dye. The dye is opaque and in one exemplary embodiment configured to match a predetermined color scheme of the vehicle interior. For example, where adjacent components are of a darker hue, such as black or gray, the dye color may be black or charcoal so that the covered vehicle component compliments the color scheme of the vehicle interior. In the illustrated embodiments of
FIGS. 4-6 , thevehicle component 10 is a foam insert having a yellow tone. The vehicle component is covered with a covering material having a black tone on at least one surface after emulsifying in the mold cavity. Several shades of black may be utilized with the covering material such as REACTINT® products Black 1852, Black 2151, Black 2256, Black X95AB or Black X77. - A process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a vehicle component, the camouflaging thereby concealing the receiving surface of the vehicle component from observation, is also provided. The process includes designating a receiving surface area on the vehicle component and providing a covering material having an opaque characteristic. The covering material includes deionized water, an opaque dye, and silicone material. The process further includes spraying the covering material in a in a mold cavity according to a surface of the mold cavity which corresponds to the designated receiving surface area on the vehicle component until the covering material completely covers a designated receiving surface area defined on the mold cavity. The vehicle component is a foam member constructed from polyurethane poured into the mold cavity. By designating the receiving surface, the amount of covering material is conserved and is applied only to the needed areas. The designated area is not limited to forming and covering any one of six sides as shown in
FIGS. 5-6 . For example, the designated area may also form the top surface of a complex component as shown inFIG. 4 or a certain portion of a surface of the vehicle component as shown inFIG. 2 . - The covering
material 16 can be configured for spray application to the mold cavity of thevehicle component 10. The application of the covering material can be with a standard fixed adjustable spray apparatus with pneumatic controls. In one exemplary embodiment, a plurality of spray nozzles are incorporated on the assembly line to enable the water in the covering material to dry off faster so as to not create any surface damage. The spray nozzles may be coupled to a controller as a unit or independently. In one exemplary embodiment, the covering material is applied to the vehicle component at a pressure between 15 and 60 psi. - In exemplary embodiment, a process for improving vehicle seat craftsmanship by camouflaging a plurality of receiving surfaces on a vehicle component, the camouflaging thereby concealing the plurality of receiving surfaces on the vehicle component from observation, is provided. The process includes designating the plurality of receiving surfaces on the vehicle component and providing a covering material having an opaque characteristic. The covering material includes deionized water, an opaque dye, and silicone material. The process further includes providing a mold cavity, the mold cavity defining a plurality of corresponding receiving surfaces, each corresponding receiving surface assigned to one of the plurality of receiving surfaces on the vehicle component; providing a spray apparatus; applying the covering material to the corresponding receiving surfaces of the mold cavity; and pouring a polyurethane mixture into the mold cavity for solidification. In one embodiment, the covering material is applied via a
spray apparatus 20 as shown inFIGS. 8 a-d. Thespray apparatus 20 includes a plurality of spray nozzles (or “guns”)—22, 24, 26, and 28—configured to cover a corresponding receiving surface in the mold cavity (120, 30, 32, 34 and/or 36 as shown inFIGS. 2-3 , 8 b, 8 d and 9 a-b, respectively). The corresponding receiving surfaces are assigned to one of the plurality of receiving surfaces on the vehicle component. The corresponding receiving surfaces (“RS”) may be assigned indicators. For example, the corresponding receiving surface labeled “7” inFIG. 9 a is assigned to a receiving surface on the bottom perimeter of the vehicle component. - Where the mold cavity includes a complex surface—e.g., 32 as shown in
FIG. 8 d—thespray apparatus 20 is configured to include at least oneadditional nozzle 28 extendable to a position farther outward from the remainingspray nozzles extendable nozzle 28 to reach intricate position of the mold cavities (e.g., 32). The mold cavities 34 and 36 can define a plurality of receiving areas as shown inFIGS. 9 a-9 b which correspond to the shape of thevehicle component 10. Themold cavity 34, as shown inFIG. 9 a, is a schematic representation of a mold cavity for an individual passenger seat. Themold cavity 36, as shown inFIG. 9 b, is a schematic representation of a mold cavity for a multiple passenger seat such as a seat bench or row. Thespray apparatus 20 is configured to spray any number of the indicated receiving surfaces for coverage. - In one exemplary embodiment, a control module 40 (or panel), such as shown in
FIG. 11 , is coupled to thespray apparatus 20 to govern the application of the covering material to the corresponding areas on the mold cavity. Thespray apparatus 20 and/ormold cavity 34 are configured to move with respect to each other as shown inFIGS. 10 a-c. The direction of movement “X” of themold cavity 34 with respect to thespray apparatus 20 is shown in the exemplary illustrated embodiment. Thecontrol panel 40 also governs the pressure at which the covering material is applied to the mold cavity as provided by a pump 42 (or pneumatic control) as shown inFIG. 11 . The covering material is fed from atank 44 and into thespray apparatus 20 via thepump 42. Thepump 42 may be a high pressure low volume (HVLP) pump or other comparable pneumatic device known to persons of ordinary skill in the art. In one exemplary embodiment, thecontrol panel 40 and covering material are configured to apply the covering material at a rate of 0.8 seconds per vehicle component. In another embodiment, thecontrol panel 40 is configured to apply the covering material from 0.1 to 1.5 seconds per vehicle component. - It will be understood that the vehicle component may be any number of different components such as foam cushion (or insulation) pieces, cavities defined by a plurality of other vehicle components, metallic or polymeric surfaces, internal shafts, bonding materials, electronic wiring, fasters, and the like.
- It should be understood that the construction and arrangement of the elements of the covering material and vehicle component in the exemplary embodiments are illustrative only. Although several embodiments of the covering material and vehicle component have been described in detail in this disclosure, many modifications are possible (e.g., variations in size, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of the elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. Unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and/or omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.
Claims (11)
1. A process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a vehicle component, the camouflaging thereby concealing the receiving surface of the vehicle component, the process comprising:
designating a receiving surface area on the vehicle component;
providing a covering material having an opaque characteristic, wherein the covering material includes deionized water, an opaque dye, and silicone material; and
spraying the covering material in a mold cavity at a surface of the mold cavity corresponding to the designated receiving surface area on the vehicle component until the covering material completely covers the surface defined on the mold cavity.
2. The process of claim 1 wherein the vehicle component is a foam member constructed from a polyurethane mixture.
3. The process of claim 2 , further comprising:
pouring the polyurethane mixture into the mold cavity for solidification
4. The process of claim 3 wherein the polyurethane fully reacts with the dye during solidification thereby preventing the covering material from moving upon contact.
5. The process of claim 1 , further comprising:
calibrating the provided covering material so that a water level of the covering material corresponds to the predetermined viscosity requirements for the designated receiving surface.
6. The process of claim 1 wherein the spraying of the covering material on the designated surface is conducted at a pressure level between 5 and 100 psi.
7-17. (canceled)
18. A process for improving vehicle seat craftsmanship by camouflaging a plurality of receiving surfaces on a vehicle component, the camouflaging thereby concealing the plurality of receiving surfaces on the vehicle component from observation, the process comprising:
designating the plurality of receiving surfaces on the vehicle component;
providing a covering material having an opaque characteristic;
providing a mold cavity, the mold cavity defining a plurality of corresponding receiving surfaces each corresponding receiving surface assigned to one of the plurality of receiving surfaces on the vehicle component;
providing a spray apparatus;
applying the covering material to the corresponding receiving surfaces of the mold cavity; and
pouring a polyurethane mixture into the mold cavity for solidification.
19. The process of claim 18 wherein the covering material includes deionized water, an opaque dye, and silicone material.
20. The process of claim 18 wherein the vehicle component is a foam member.
21-23. (canceled)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/985,249 US20110101557A1 (en) | 2006-03-31 | 2011-01-05 | Vehicle seat with improved craftsmanship |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US78830806P | 2006-03-31 | 2006-03-31 | |
US11/730,346 US7883770B2 (en) | 2006-03-31 | 2007-03-30 | Vehicle seat with improved craftsmanship |
US12/985,249 US20110101557A1 (en) | 2006-03-31 | 2011-01-05 | Vehicle seat with improved craftsmanship |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/730,346 Division US7883770B2 (en) | 2006-03-31 | 2007-03-30 | Vehicle seat with improved craftsmanship |
Publications (1)
Publication Number | Publication Date |
---|---|
US20110101557A1 true US20110101557A1 (en) | 2011-05-05 |
Family
ID=38712295
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/730,346 Expired - Fee Related US7883770B2 (en) | 2006-03-31 | 2007-03-30 | Vehicle seat with improved craftsmanship |
US12/985,249 Abandoned US20110101557A1 (en) | 2006-03-31 | 2011-01-05 | Vehicle seat with improved craftsmanship |
US12/985,270 Abandoned US20110105679A1 (en) | 2006-03-31 | 2011-01-05 | Vehicle seat with improved craftsmanship |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/730,346 Expired - Fee Related US7883770B2 (en) | 2006-03-31 | 2007-03-30 | Vehicle seat with improved craftsmanship |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/985,270 Abandoned US20110105679A1 (en) | 2006-03-31 | 2011-01-05 | Vehicle seat with improved craftsmanship |
Country Status (1)
Country | Link |
---|---|
US (3) | US7883770B2 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090127912A1 (en) * | 2007-11-19 | 2009-05-21 | Lear Corporation | Vehicle seat assembly having a cushion with a colored coating and method of making the same |
US8998309B2 (en) * | 2013-01-10 | 2015-04-07 | Lear Corporation | Vehicle seat assembly having a permeable cushion with a colored coating and method of making the same |
CN103331233A (en) * | 2013-06-24 | 2013-10-02 | 苏州快吉刀片制造有限公司 | Device for oiling blade |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4113677A (en) * | 1976-01-14 | 1978-09-12 | Turtle Wax, Inc. | Polished composition containing microcrystalline wax |
US4784844A (en) * | 1979-12-03 | 1988-11-15 | General Electric Company | Volatile silicone-water emulsions and methods of preparation and use |
US4814230A (en) * | 1988-01-28 | 1989-03-21 | Vockler Larry D | Silicone-coated opaque glass |
US5789037A (en) * | 1997-01-31 | 1998-08-04 | Premier Colors, Inc. | Cross-linking agent and process for cross-linking binder and textile colorant on a textile fabric |
US5861451A (en) * | 1996-10-31 | 1999-01-19 | Dow Corning Corporation | Sprayable silicone emulsions which form elastomers having smoke and fire resistant properties |
US6025077A (en) * | 1996-12-13 | 2000-02-15 | Matsushita Electric Works, Ltd. | Silicone emulsion coating composition and processes for the preparation thereof |
US6221498B1 (en) * | 1997-03-14 | 2001-04-24 | Matsushita Electric Works, Ltd. | Antifouling silicone emulsion coating-composition, process for producing the same and antifouling article coated therewith |
US20060141228A1 (en) * | 2004-12-23 | 2006-06-29 | Rearick Brian K | Color harmonization coatings for articles of manufacture comprising different substrate materials |
US20070134502A1 (en) * | 2005-12-14 | 2007-06-14 | Fonda James B | Aqueous dispersion coating composition having noise and/or friction abatement properties |
-
2007
- 2007-03-30 US US11/730,346 patent/US7883770B2/en not_active Expired - Fee Related
-
2011
- 2011-01-05 US US12/985,249 patent/US20110101557A1/en not_active Abandoned
- 2011-01-05 US US12/985,270 patent/US20110105679A1/en not_active Abandoned
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4113677A (en) * | 1976-01-14 | 1978-09-12 | Turtle Wax, Inc. | Polished composition containing microcrystalline wax |
US4784844A (en) * | 1979-12-03 | 1988-11-15 | General Electric Company | Volatile silicone-water emulsions and methods of preparation and use |
US4814230A (en) * | 1988-01-28 | 1989-03-21 | Vockler Larry D | Silicone-coated opaque glass |
US5861451A (en) * | 1996-10-31 | 1999-01-19 | Dow Corning Corporation | Sprayable silicone emulsions which form elastomers having smoke and fire resistant properties |
US6025077A (en) * | 1996-12-13 | 2000-02-15 | Matsushita Electric Works, Ltd. | Silicone emulsion coating composition and processes for the preparation thereof |
US5789037A (en) * | 1997-01-31 | 1998-08-04 | Premier Colors, Inc. | Cross-linking agent and process for cross-linking binder and textile colorant on a textile fabric |
US6221498B1 (en) * | 1997-03-14 | 2001-04-24 | Matsushita Electric Works, Ltd. | Antifouling silicone emulsion coating-composition, process for producing the same and antifouling article coated therewith |
US20060141228A1 (en) * | 2004-12-23 | 2006-06-29 | Rearick Brian K | Color harmonization coatings for articles of manufacture comprising different substrate materials |
US20070134502A1 (en) * | 2005-12-14 | 2007-06-14 | Fonda James B | Aqueous dispersion coating composition having noise and/or friction abatement properties |
Also Published As
Publication number | Publication date |
---|---|
US20110105679A1 (en) | 2011-05-05 |
US7883770B2 (en) | 2011-02-08 |
US20070269607A1 (en) | 2007-11-22 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
KR101864637B1 (en) | Planar heater and method thereof | |
CN1120080C (en) | Decorative automobile interior trim articles with integral in-mold coated polyurethane aromatic elastomer covering and process for making the same | |
EP1577166B1 (en) | Process for manufacturing a skin type lining, in particular for automotive trim parts. | |
US7883770B2 (en) | Vehicle seat with improved craftsmanship | |
SK104299A3 (en) | Process for making decorative automotive interior trim articles with integral light stable polyurethane elastomer covering | |
EP1066985B1 (en) | Simulated wood tone member and method of manufacturing the same | |
CN103921707B (en) | There is vehicle seat assemblies and the manufacture method thereof of colored film | |
US20130017356A1 (en) | Soft component with decorative surface finish | |
CN105691475B (en) | The production method of lower cover lid, the kit for producing lower cover lid and lower cover lid | |
US20110109112A1 (en) | Steering assembly for a vehicle | |
CN102958659B (en) | For generating the method for the molding epidermis with decoration, method, molding epidermis and the automotive trim hub sections for the manufacture of automotive trim hub sections | |
US8002330B2 (en) | Interior trim component and method of forming the same | |
KR20170002009U (en) | Door trim for vehicle | |
CN215971366U (en) | Air conditioner air outlet decorative structure and vehicle | |
CN207587605U (en) | Function key assembly, door handle assembly and car door | |
US20030151270A1 (en) | Liner apparatus and method of making a liner | |
KR20190112240A (en) | On skin print method and system of automotive interior plastic part | |
CN115891374A (en) | Intelligent light-transmitting surface, automotive interior containing intelligent light-transmitting surface and preparation method | |
JP5633324B2 (en) | Parting structure of resin parts | |
CN205646148U (en) | Vehicle | |
CN104485241A (en) | Auto electric window switch assembly | |
KR200185153Y1 (en) | Interior material for an automobile | |
CN109131584A (en) | A kind of automobile engine cabin cover | |
ITTO960759A1 (en) | DASHBOARD FOR A VEHICLE. | |
JP2001187549A (en) | Steering wheel for automobile, interior trim part and decoration method thereof |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |