MXPA97001844A - A cover tej - Google Patents

Abstract

A woven cloth cover, especially for a vehicle seat having a vehicle air bag housed there, in which the cover is adapted to provide a minimum obstacle to inflation of the air bag by having at least one line of weakness woven on the cover, particularly in one direction of the spool

Description

A WOVEN COVER Field of the Invention This invention relates to woven fabric covers and in particular to woven covers used in automobiles.

Background of the Invention The invention is useful in machine weaving on weft knitting machines having independently operable needles arranged in two needle beds, for example, a flat "V" bed machine producing mainly a fabric of double fine yarn structure.

It has recently been found that it is possible to weave one-piece upholstery covers to cover three-dimensional objects that removes the need to sew together parts of the covers. In U.S. Patent Nos. 5,308,141 and 5,326,150, a method for weaving one-piece covers for the base and / or back cushions of a motor vehicle seat is described.

Motor vehicles, in particular motor cars, are now commonly provided with a restriction air bag to prevent passengers or vehicle drivers from being injured during a crash. Some vehicles are now being provided with airbags for side collisions, which in their waiting condition can be housed inside the base or inside the backrest of the vehicle seat.

In conventional seats when the airbag is activated and inflated, it escapes through the seat covers by exploding through the sewn seams where the parts of the cover are sewn together.

With the three-dimensional woven seat covers, the covers are completely homogeneous and there may be a slight delay of time before the air bag explodes through the cover. Also, since the material is homogeneous, the location of the burst is not completely predictable.

An object of this invention is to provide a woven cover which can be divided or broken in a predicted manner.

Synthesis of the Invention According to the present invention there is provided a one-piece fabric cover for an object, the cover having a weakened line weaved within the woven fabric, in a direction in the direction of the stroke.

Preferably the cover fabric is a woven fine woven fabric of weft having a back layer with a technical backing face and a front layer with a technical front face.

Preferably, the line of weakness comprises at least a portion of at least one weaving stroke which is of a single fine yarn construction.

For a seat cover, it is preferred to form the line of weakness so that it is not visible on the front face of the cover, and therefore the single fine yarn race or races are or are formed in the front layer of the cloth.

Alternatively, the cover has a woven run which is at least partly formed of a yarn which is weaker than the base yarn from which that layer of the cover fabric is formed.

Preferably the line of weakness comprises at least a portion of at least one stroke in the back layer which is formed at least in part from a thread which is weaker than the base wire or threads from which they are formed both the back layer and the front layer.

Alternatively, the front layer of the double fine worsted fabric is woven from a weakened yarn, and the front and back layers of the fabric are interconnected by a structure of between a weakened thread fixation formed on alternating stitches in the front and back layer .

Such a cover can be made by a three-dimensional fabric and is suitable for use in a motor vehicle and in particular for use as the covers for motor vehicle seat.

The invention also provides a method for forming a woven, one-piece fabric covering wherein the woven fabric is woven such that at least a portion of at least one stroke of the fabric is made of a weaker construction than the construction. general of the surrounding woven fabric.

Preferably, the fabric is a fine woven double woven fabric of weft woven on a weft knitting machine having the needles arranged in two independently operable needle beds. The fabric has a woven front layer on a needle bed and a woven back layer on a second needle bed. The fabric is woven on both needle beds in a mainly double jersey construction, and at a predetermined stroke said part is made weaker by several different methods.

Said part is made weaker by removing the stitches from at least some of the needles of the second needle bed while said needle bed continues weaving for two to five additional runs and then starting the fabric over both beds again. needles to continue the construction of double thin yarn.

The stitches can be transferred to the needles in said needle bed. Alternatively, the stitches on some or all of the needles on the second needle bed can be depressed and preferably the edge is sealed by a fusible thread.

Alternatively, said part is made weaker by retaining the needles on said needle bed while some or all of the needles of the second needle bed continue weaving using a thread weaker than the base yarn for between one to four runs. , and then the fabric of a double thin yarn construction continues on both needle beds.

In another alternative, the base yarn is woven over only selected needles in both needle beds and a weaker yarn than the base yarn is woven over the other needles by at least one additional stroke, and preferably no more than four runs additional, and then the base yarn is woven on all needles in both needle beds.

In yet another method wherein the front layer of the double thin worsted fabric is made of at least one base yarn and the back layer of the fabric is made of a lower resistance base yarn which is weaker than the yarn. first base yarn, said part is made weaker by weaving the lower resistance base yarn over selected needles on said needle bed and on the second needle bed by at least one stroke, and preferably on alternate needles over two races In a further method, a low resistance yarn is woven on the needles of the second needle bed at least one stroke while said needle bed continues to knit the front layer. The weaker yarn is depressurized, and preferably sealed with a meltable yarn, and then the double thin yarn construction fabric continues on both needle beds.

Preferably the double woven fine worsted fabric has its front layer formed of a chenille yarn and its back layer is formed of a polyester yarn. The chenille yarn may be of the type described in the published patent application of applicant EP-A-0, 627, 516. The chenille yarn may have a decitex in the range of 1500 to 3000. Conveniently, the cloth has 8 at 16 relieves per inch (2.54 cm) in one direction in the direction of the stroke, and in the range of 8 to 30 strokes per inch in the direction of relief. The chenille thread is woven into the fabric as woven linked stitches.

The polyester yarn is preferably an air textured polyester yarn having a decitex in the region of 550 to 900, or 600 to 800, or 600 to 750, or 650 to 700 decitex. The chenille yarn can be formed from a pair of twisted nylon and / or polyester yarns, for example, by using a low melting point nylon yarn, or the stack can move relative to the yarns.

The chenille thread can have an account in the range of 1500 to 3000 decitex. The chenille thread is preferably one having a movable stack and an extendable core.

Preferably, the textured polyester yarns are continuous filament yarns having a count in the non-relaxed state of 680 to 750 decitex.

Preferably, the weaving method is such that in the relaxed state the fabric has from 4 to 6 embossments per centimeter.

The fabric can be woven on a flat bedding machine having a pair of beds of opposite needles.

The machine can have a meter in the range of 10 to 16, preferably 10 to 14, additionally and preferably 12.

The machine can be a double system machine or a triple system or a quad system.

The present invention preferably provides a method for having a cover, preferably an upholstery fabric, in which the fabric is carried out on a machine having a pair of needle beds independently operable and opposite, and in which the needles in each The bed can move independently of each other in that bed within the path of an operating cam box reciprocating along the needle beds.

An upholstery fabric for a vehicle seat preferably has a weight in the relaxed state ready to be used in excess of 500 grams / m2, preferably 500 to 900 grams / m2. This compares to traditional woven products which have a weight of 300 to 350 grams / m2.

Preferably, the upholstery fabric is a weft woven upholstery fabric formed of yarn having a decitex in the range of 625 to 850 and having been woven on a machine having a machine measurement in the range of 10 to 18, the fabric being generally of a double thin yarn construction having interlocking curls between the two layers of the double fine yarn structure.

The woven fabric can be a three-dimensional cover for use on a three-dimensional structure to form an upholstery structure. The fabric can be formed of two or more different colored base yarns.

Also according to the present invention there is provided a method that allows with a minimum obstacle the inflation of an air bag housed within a vehicle upholstery component having a cover, typically a vehicle seat cushion, wherein the component is covered with a cover of woven cloth having a line in the direction of the weakness race woven into the woven cover allowing inflation of the air pocket with a minimum obstacle of the cover. Preferably, the weakness becomes virtually invisible external to the cover.

Brief Description of the Drawings The invention will be described by way of example and with reference to the accompanying drawings in which: Figure 1 is a tissue diagram of a first embodiment of the invention, Figure 2 is a second woven diagram of a second embodiment of the invention, Figure 3 is a third diagram of a third embodiment of the invention, Figure 4 is a fourth woven diagram of a fourth embodiment of the invention, Figure 5 is a fifth pattern of a fifth embodiment of the invention; Figure 6 is a sixth tissue diagram of a sixth embodiment of the invention; Y Figure 7 is an isometric view of a vehicle seat cushion.

Description of the Preferred Modalities In order that the invention can be fully understood, reference will now be made to a flat V-bed weaving machine. More details on such weaving machines can be found in the publication "Manual of Dubied Fabric" published by Eduardo Dubied y Cía, S.A. from Neu Chatel, Switzerland in 1967. The flat V bedding machine is well known and many machines are now controlled by computer. It has been proposed recently to manufacture an upholstery fabric on such V-bed weaving machines and the proposals have been made (for example, see United States patents for North American Nos. 5,308,141 and 5,326,150) with respect to a woven upholstery fabric suitable for use in vehicles.

The fabric of a cloth cover by the method according to the invention uses a Stohl CMS machine with 12 needles.

This machine is a flat V-bed machine of the type provided with a pressing pedal to help take the woven fabric. The machine can operate with a plurality of supplied wires, each which is associated with a respective cam box.

The cam box traverses through the needle beds by supplying threads to the needles as desired in each direction of travel.

Referring to Figure 7, there is shown an upholstered seat cushion generally indicated by the number 1. The seat cushion is formed by the cover of a core 2 normally in the form of semi-rigid foam supported on a frame, with the cloth cover generally indicated by the number 3. The core is formed so as to provide the wings 4 or any other desired shape in the seat.

Such seats have particular application in vehicles but can be used in numerous other applications. When used in motor cars, the seat frame can support an air bag inflation mechanism which is operated by side collisions.

Stretched onto the core 2 is a cloth cover 5 which is provided with a main body part covering the seat with the integral wing portions 6 and 7 and the side parts such as the part 8. There is also a front part 9 The cloth cover is folded over the base of the seat cushion and can be secured in a known manner. The seat may have the indentations 10 formed there in order to create aesthetic effects.

Such seat structures are described in U.S. Patent Nos. 5,308,141 and 5,326,150. In those patents, a three-dimensional woven cloth upholstery cover is described which is woven in a single operation. In the present invention, the fabric cover 5 is stretched over the core 2. In order to assist or control the bursting of the air pocket through the otherwise homogeneous woven cover 5, the cover is provided with a line of weakness 11 that extends in a direction in the direction of the stroke in relation to the direction of the fabric. A direction in the direction of the race is the direction in the fabric extending at right angles to the edge.

Referring to Figure 1, a stitch diagram is shown in which each row indicated as 101-117 represents a row of fabric, each using a different thread on one pass of the yarn carrier for a three-system machine. A machine with three systems has a cam box which can carry up to three thread carriers on one pass through the needle beds. In each row, such as row 101, the upper row of small dots represents individual needles on the back layer of the knitting machine, and the lower row of dots represents the front bed of the knitting machine. In the terminology used here, the front face of the fabric is woven on the front needle bed and the back face is woven on the back needle bed. The thread is represented by the curls and interconnecting transverse links.

The zones X and Z outside the lines A and B represent a double fine yarn structure woven of a chenille yarn according to the European patent application EP-A-0,627,516. Zone Y between lines A and B where the line in the direction of weakness course 11 is formed.

On the first pass of the yarn carriers on the weaving machine from right to left, a chenille yarn 21 is woven on all the needles on the front bed. There is no difference between the zones. A first contrast thread 22 is woven on the alternating needles on the front bed and all the needles of the rear bed (row 102) with interconnecting curls between the yarn fabric on the front and rear beds. A second contrast thread 23 is woven over the other alternate needles in the front bed and all the needles over the rear bed with interconnecting curls between the woven thread over the two beds (see row 103). The three rows 101-103 constitute a repeating unit (R. The relationship between the contrast yarns 22 and 23 in the front needle bed was determined by the required pattern on the front face of the fabric.) On the next pass of carriers of thread from left to right, the needles in the zone Z are put out of action and the wires 21-23 weave as before, forming the second repeat unit R2.

On the next pass of the cam box, the yarn carrier for the first contrast yarn 22 weaves only from right to left, the zones X and Z are put out of action, with the first contrast yarn 22 being woven only in zone Y on the rear needle bed (row 107). This is repeated in the next pass of that yarn carrier, from the left to the right (row 108). These two races can be called "preparation races". The curls are then transferred to the front needle bed (row 109).

The chenille yarn 21 is then woven on alternating needles in the Y area as the yarn carrier passes from the right to the left (row 110) and then from the left to the right (row 111), weaving on alternate needles in each pass.

On the next pass, all three yarn carriers move from right to left to repeat the repeating unit R2 with the rows 112-114. Finally on the next pass, all the yarn carriers pass from left to right, forming the repeating unit Rx with the rows 115-117, which are part of the main jacquard material.

Therefore, a zone of weakness is created in the Y zone adjacent to the transfer of the stitches from the back layer to the front bed when the two subsequent rows 110 and 111 form a race of a single fine yarn fabric.

In Figure 2, a second embodiment of the invention is illustrated, and the same reference numbers will be used in this figure and in subsequent figures as used with respect to Figure 1.

The first four passes of the cam box from right to left and from left to right are identical to those described with reference to figure 1, forming the repetition units Rx and R2 and the two preparation runs 107 and 108.

The curls are then transferred from the needle bed to the front needle bed in row 109. Alternatively, these stitches may be pressed, especially if the first contrast yarn 22 was replaced by a fusible yarn.

A weaker yarn 24 is then carried through the X zone by flotation stitches and stitching and is woven on alternate needles on the front needle bed in the Y area in two passes of its respective row carrier (row 110). and 111) from left to right and then from right to left.

The two repeating units R2 and R? they are then woven as previously described with reference to Figure 1.

The weaker yarn 24 on the front bed provides a weakened line that extends in the direction of the direction of travel in a single stroke of fabric.

The chenille yarn 21 will have a yarn count of about 2000 decitex. The contrast yarns 22 and 23 are preferably polyester yarns with a count of about 900 decitex while weakened thread 24 will have an account of around 200 decitex.

The weakened yarn can be a two-component meltable yarn called Grillon Yarn or a three-component yarn comprising nylon 11, acrylic and polyester fibers.

Referring to Figure 3, another method to form a weakened race is shown. The first two passes of the thread carrier from right to left and from left to right form the repeat units R1 and R2.

A weaker yarn 24 is then carried through zone X by the flotation stitches and the stitches of tuck until it is woven in the area Y on the back needle bed on all the needles in the area Y, on both passes of the thread carrier from left to right and from right to left (row 107 and 108). The repeating units R2 and R? they are then produced as previously described.

Thus in this embodiment, the weaker yarn 24 forms two weakened runs in the back layer of the double thin yarn material.

Referring to Figure 4, the embodiment shown there is very similar to that shown in Figure 3 except that in rows 107 and 108, the weaker yarn 24 is woven on the alternating needles on the rear needle bed over the two passes of its respective yarn carrier, thereby forming only a single weaving run of weakened yarn on the rear bed.

Referring to Figure 5, again the repeating units Ri and R2 are woven as before. In the row 107 the weakened thread 24, in this case a fusible yarn, is floated and reinforced through the zone X to be woven on the rear needle bed in the Y area. Several runs of fusible yarn are woven in the area Y. This is represented by row 108 only. At least two and preferably four or six rows of fusible yarn are woven. Then the yarn carrier takes the meltable yarn back through the zone X by the flotation stitches and the stitches of stitching as shown in row 109.

The meltable yarn 24 in the zone Y is then pressed out of the rear bed needles (row 110). The repeating units R2 and Rx are then woven as before.

The two courses of weakened fused yarn on the rear needle bed again form a weakened single fine yarn construction area in the fabric formed in the back needle bed.

Referring to Figure 6, a weakened line • in the zone Y is created by carrying a weakened thread 24 after the repeating unit Rx and then weaving a run of a standard interlock construction using the weakened yarn in two runs of the yarn carrier to form the rows 104 and 105 The weakened thread interleaving stroke provides a line of stitches extending in the weakened direction of travel.

Claims (27)

R E I V I N D I C A C I O N S

1. A one-piece woven cloth cover for an object, characterized in that the cover has a line of weakness woven into the woven fabric in a direction in the direction of travel.

2. A cover as claimed in clause 1, characterized in that said cover fabric is a fine woven double woven fabric of weft having a back layer with a technical back face and a front layer with a technical front layer, and the line of weakness comprises at least a portion of at least one woven race which is of a single fine yarn construction.

3. A cover as claimed in clause 2, characterized in that the single fine yarn race or races are formed in the front layer.

4. A cover as claimed in any of clauses 1 to 3, characterized in that a run of the woven fabric, at least in part, is formed of a yarn which is weaker than the base yarn of which it is formed that layer of the cover.

5. A cover as claimed in clause 3 or clause 4 when dependent on clause 3, characterized in that at least said part of said a stroke is formed in the front layer of a wire which is weaker than the thread or base yarns from which the front layer and the back layer are formed.

6. A cover as claimed in clause 3 or clause 4 when dependent on clause 2, characterized in that the line of weakness comprises at least a part of at least one stroke in the back layer which is formed by at least in part of a yarn which is weaker than the yarn or base yarns from which both the back layer and the front layer are formed.

7. A cover as claimed in any of clauses 4 to 6, characterized in that the stitches in the weakened part of said stroke are formed from the weakest yarn.

8. A cover as claimed in clause 1, characterized in that the cover layer is a fine woven double woven fabric of weft having a back layer with a technical back face and a front layer with a technical front face and therefore less a run of double fine worsted fabric is woven from a weakened yarn, and the front and back layers of the fabric are interconnected by a weakened yarn interlock structure formed on alternating stitches in the front and back layers.

9. A vehicle fitting component that includes a tire as claimed in any of clauses 1 to 8.

10. A seat for a motor vehicle that includes a cover as claimed in any of clauses 1 to 8.

11. A method for forming a woven piece fabric cover characterized in that the woven fabric is woven so that at least a portion of at least one stroke of the fabric is made of a weaker construction than the general construction of the fabric woven surrounding.

12. A method as claimed in clause 11, characterized in that the fabric is a fine woven double woven fabric of woven weft of at least one base yarn on a weft knitting machine having needles arranged on two needle beds independently operable, the fabric has a front layer woven on a needle bed and a back layer woven on a second needle bed characterized in that the fabric is woven on both needle beds in a double thin yarn construction mainly and in a predetermined course said weaker part is formed in at least one of the two layers by weaving said stroke with a weaker construction than the double thin yarn construction.

13. A method as claimed in clause 12, characterized in that at least said predetermined stroke of said part is made weaker by removing the stitches from at least some of the needles of the second needle bed, while said Needle bed continues weaving for one to four additional runs, and then the fabric starts over both needle beds to continue the construction of the double fine yarn.

14. A method as claimed in clause 13, characterized in that in said predetermined stroke, the stitches on at least some needles of the second needle bed are transferred to the needles in said needle bed.

15. A method as claimed in clause 13, characterized in that in said predetermined stroke, the stitches on said at least some needles of the second needle bed are depressurized and the edge sealed with a fusible thread.

16. A method as claimed in any of clauses 12 to 15, characterized in that the one to four additional runs are woven from a yarn weaker than a base yarn used for the double thin yarn construction fabric.

17. A method as claimed in clause 12, characterized in that in said predetermined stroke, said part is made weaker by retaining the needles on that one bed of needles while some or all of the needles on the second bed of needles they continue weaving using a weaker yarn for between two to six runs, and then the fabric of the double thin yarn construction continues on both needle beds.

18. A method as claimed in clause 17, characterized in that to form said weakened part, the weakest yarn is woven in selected needles on the second needle layer, and outside the weakened part the weaker yarn is hooked as stitches of flotation and tuck over selected needles spaced apart on the second needle bed.

19. A method as claimed in clause 18, characterized in that to form said weakened part, the weakest yarn is woven on all the needles on the second needle bed which extend for the length in the direction of the stroke of the needle. weakened part, and outside the weakened parts the weakest thread is hooked as floating and stitching stitches over selected needles spaced apart on the second needle bed.

20. A method as claimed in clause 19, characterized in that the weaker yarn is woven for a single stroke and is woven on alternating needles for one pass of the yarn in one direction, and on the intervening needles on the return pass of the yarn. weaker thread.

21. A method as claimed in clause 12, characterized in that in the predetermined stroke said part is made weaker by weaving the base yarn only on selected needles in both needle beds, and a thread weaker than the yarn of base is woven on the other needles for at least one fourth stroke, and then the base yarn is woven on all the needles on both needle beds.

22. A method as claimed in clause 21, characterized in that to form the weakened part, the weakest yarn is woven on all the needles on the second needle bed.

23. A method as claimed in clause 12, characterized in that the cover is woven from at least two base yarns, the front layer being woven from a first base yarn and the subsequent layer being woven from one more base yarn. weak, characterized in that in the predetermined stroke it becomes weaker by weaving the weaker base yarn over the selected needles on that needle bed and the second needle bed by at least one stroke, and then that needle bed continue weaving with the weaker base yarn fed to the second needle bed only.

24. A method as claimed in clause 12, characterized in that in said predetermined stroke said part is weakened by weaving a low resistance yarn over the needles of the second needle bed for at least one stroke while that bed of The needle continues to knit with its respective base yarn, the weaker yarn is then depressurized and the double fine yarn fabric continues on both needle beds.

25. A method for forming a weakened zone in a woven fabric cover, said zone contains a plurality of spaced and spaced weakened lines formed by a method as claimed in any of clauses 11 to 24.

26. A method for allowing a minimum obstacle to inflation of a motor vehicle airbag housed within an internal upholstery component of the vehicle, wherein the component is covered by a woven fabric cover having lines of weakened tissue within the fabric woven by a method as claimed in any of clauses 11 to 24.

27. A method for allowing a minimum obstacle to inflation of a vehicle airbag housed in a vehicle seat that is covered by a three-dimensional woven fabric cover, by a method as claimed in any one of clauses 11 to 24 SUMMARY A woven fabric cover, especially for a vehicle seat having a vehicle air bag housed there, in which the cover is adapted to provide a minimum obstacle to inflation of the air bag by having at least one line of air weakness woven on the deck, particularly in a direction of the race.