WO2014110436A1

WO2014110436A1 - Fabric cover for a vehicle interior component

Info

Publication number: WO2014110436A1
Application number: PCT/US2014/011133
Authority: WO
Inventors: Glenn A. Cowelchuk; Craig D. Flowerday; Heather R. SPRINGER; David J. Mccarthy
Original assignee: Johnson Controls Technology Company
Priority date: 2013-01-11
Filing date: 2014-01-10
Publication date: 2014-07-17

Abstract

A vehicle interior component includes a substrate. The vehicle interior component also includes and a cover disposed at least partially about the substrate. The cover includes an opening and a string extending along a circumference of the opening. The string is configured to block expansion of the opening to secure the cover to the substrate.

Description

FABRIC COVER FOR A VEHICLE INTERIOR COMPONENT

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from and the benefit of U.S. Provisional Application Serial No. 61/751,696, entitled "FABRIC COVER FOR A VEHICLE INTERIOR COMPONENT", filed January 11, 2013, which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] The invention relates generally to vehicle interior components, and more specifically, to a fabric cover for a vehicle interior component.

[0003] Vehicle interior components are installed in many places throughout an interior of a vehicle to provide support to occupants and/or to create an aesthetic environment. For example, a center console or a door frame may include an armrest. Moreover, a dashboard, or a steering wheel may include a vehicle interior component with a foam substrate. Furthermore, an overhead portion of the vehicle may include sunvisors or handles.

[0004] Molded foam components covered in a finishing layer may be used to construct vehicle interior components. For example, vehicle interior components may include a foam substrate covered in a piece of fabric or leather that is held in place by staples, adhesive, or some other mechanism. In this manner, the vehicle interior component holds the shape of the foam substrate but maintains the look of the covering. Such a configuration may enable the vehicle interior component to match the contours of the curved sections of the vehicle into which it is installed. Unfortunately, because the coverings are generally constructed from substantially flat material, the vehicle interior component may use an excess amount of the covering material. In addition, attaching the cover to the foam substrate may increase the length of time taken to manufacture the vehicle interior component. BRIEF DESCRIPTION OF THE INVENTION

[0005] The present invention relates to a vehicle interior component, including a substrate and a cover disposed at least partially about the substrate. The cover includes an opening and a string extending along a circumference of the opening, and the string is configured to block expansion of the opening to secure the cover to the substrate.

[0006] The present invention also relates to a vehicle interior component, including a substrate comprising a base and at least two raised contact points and a three-dimensional cover. The cover includes an opening and a string disposed about a circumference of the opening, also, the cover at least partially surrounds the substrate and is suspended between the contact points and the string is configured to block expansion of the opening to secure the cover to the substrate.

[0007] The present invention further relates to a vehicle interior component for a vehicle including a substrate and a three-dimensional cover comprising flexible supports, an opening, and a string disposed about a circumference of the opening. The cover is configured to be secured to the substrate by disposing the cover at least partially about the substrate and tightening the string. Also, the flexible supports are configured to create a hollow area between the substrate and the cover.

DRAWINGS

[0008] FIG. 1 is a perspective view of an embodiment of a vehicle that may include one or more vehicle interior components.

[0009] FIG. 2 is a perspective view of an embodiment of a center console of the vehicle of FIG. 1.

[0010] FIG. 3 is a cross-sectional view of an embodiment of a vehicle interior component having a three-dimensional cover.

[0011] FIG. 4 is a perspective view of an embodiment of a vehicle interior component having a three-dimensional cover. [0012] FIG. 5 is a perspective view of an embodiment of a vehicle interior component having flexible supports.

[0013] FIG. 6 is a cross-sectional view of the vehicle interior component of FIG. 5 utilizing flexible supports.

[0014] FIG. 7 is a cross-sectional view of an embodiment of a knit-in bead of a cover installed on a vehicle interior component.

[0015] FIG. 8 is a cross-sectional view of an embodiment of a cover of a vehicle interior component that is aligned using a pull-cord.

DETAILED DESCRIPTION

[0016] FIG. 1 is a perspective view of an embodiment of a vehicle 10 that may include one or more vehicle interior components. The vehicle 10 includes an interior 12 having seats and a center console 16. As discussed in detail below, the center console 16 and/or other areas within the interior 12 may include an vehicle interior component 14 having a three-dimensional cover. Three-dimensional, as described herein, means that the cover is in the shape of a bag or sack. For example, certain vehicle interior component 14 may include an injection-molded substrate having the cover secured to the substrate with a drawstring disposed at least partially about an opening in the cover. The three-dimensional cover may match the curves and contours of the vehicle interior component 14 due to a knit-in shape. In certain embodiments, a knitting process may add material to areas where the substrate bulges outward, and may constrict or pull material to smaller or tucked-in areas of the substrate. The drawstring may be used to attach the cover to the substrate quickly and easily, thereby decreasing manufacturing time and/or cost.

[0017] FIG. 2 is a perspective view of an embodiment of the center console 16 of the vehicle 10 of FIG. 1. As discussed in detail below, the center console 16 may be at least partially enclosed by a cover having a drawstring around an opening in the cover. The drawstring may be used to secure the cover to a substrate, and hold fabric, leather, or other cover material in place on the substrate. In the present configuration, the console 16 may be configured to provide a storage area and/or an armrest cushion 18 for an occupant of the vehicle 10.

[0018] The armrest cushion 18 includes a cover 20. The cover 20 may be form fitted to the substrate of the cushion 18. As shown in FIG. 2, the cover 20 includes decorative features such as a French seam 22 and a straight seam 24. These features may be sewn into the cover 20 or may be formed with a faux technique whereby the cover 20 is knit with yarn or other thread to form the look of a seam or other feature.

[0019] The armrest cushion 18 may also include mechanisms hidden from view of the occupants of the vehicle 10. These mechanisms, such as rails, rollers, tracks, slides, etc., enable the armrest cushion 18 to move in a longitudinal direction 26. The cover 20 may be installed such that the mechanisms are entirely encased within the cover 20 and thus are concealed. Other vehicle interior components may include mechanisms that allow other movements, such as swiveling, swinging, folding, shifting, etc. While the present vehicle interior component 14 is described with reference to the center console 16, it may be appreciated that other embodiments may include other vehicle interior components having a cover 20 positioned throughout the interior 12 of the vehicle 10. For example, a vehicle interior component located within an overhead console, door panel, instrument panel, or other region of the interior 12 may include a three-dimensional cover form fitted to a substrate. Furthermore, other vehicle interior components 14 may include decorative features.

[0020] FIG. 3 is a cross-sectional view of an embodiment of the vehicle interior component 14 having the three-dimensional cover 20. The vehicle interior component 14 may be a center console armrest, a door panel armrest, or other component in the interior 12 of the vehicle 10. The vehicle interior component 14 includes a substrate 30 and a foam layer 32. The substrate 30 may be a solid-type foam formed by injection molding, or may be some other material suitable for use within the vehicle 10. The foam layer 32 may be formed from any suitable foam that provides cushion to an occupant of the vehicle 10. The substrate 30 and the foam layer 32 may be attached to one another with an adhesive, or may be held together by the cover 20. The cover 20 includes a drawstring 34 that is tightened to secure the cover 20. In additional embodiments, the drawstring 34 may also include an elastic band or stretchable string that tightens itself without an external tightening force. For example, the drawstring 34 may include a string the contracts when exposed to a heat source. This may enable an operator to easily install a loose cover 20 over the top of the substrate 30 and then heat the drawstring 34 which secures the cover 20 to the substrate 30. Other examples may include an elastic or stretchable drawstring 34 which enables the cover 20 to be easily secured to the substrate 30 and removed from the substrate 30. In the illustrated embodiment, the drawstring 34 is routed through a loop 36 that extends at least partially around an opening 38 in the cover 20 to the substrate 30. The opening 38 is used to place the cover 20 over the substrate 30 and the foam layer 32. After the cover 20 is placed over the substrate 30, the opening 38 may be constricted and closed by pulling on the drawstring 34. Pulling the drawstring 34 pulls on the loop 36, and decreases a size of the opening 38, thereby securing the cover 20 to the vehicle interior component 14. The vehicle interior component 14 includes rails 40 for attaching the interior component 14 to the vehicle 10. The rails 40 may be used to adjust a position of the vehicle interior component 14, and are concealed by the cover 20. This creates a more appealing view of the interior 12 of the vehicle 10 to the occupants. In other embodiments, the drawstring 34 may be replaced by other materials used to secure the cover 20 to the substrate 30. For example, a metal rod may be installed in the loop 36 and secured in place using a hook (not shown) in the substrate. The metal rod may be desirable due to its ability to hold the cover 20 in place without binding or pinching. Other examples include embodiments where a hole is knitted into the cover. The hole may slip over a corresponding feature in the substrate 30 without using a drawstring to secure the cover 20 to the substrate 30.

[0021] FIG. 4 is a perspective view of an embodiment of the vehicle interior component 14 having the three-dimensional cover 20. Similar to embodiments described above, the cover 20 is secured to the vehicle interior component 14 by tightening the drawstring 34 after the cover 20 has been placed over a portion of the vehicle interior component 14. The vehicle interior component 14 includes the substrate 30, but does not include a foam layer. In place of a foam layer, the vehicle interior component 14 includes a hollow portion 42 formed by the cover 20 being stretched over the substrate 30. In the illustrated embodiment, the hollow portion 42 is flanked on either side by walls 44. The walls 44 are resilient against force applied by tension formed by the cover 20 being attached to the substrate. Furthermore, the cover 20 may support an occupant resting or leaning on a stretched portion 46 of the cover 20. While supporting an occupant, the cover 20 may be depressed from a resting position 48 to a depressed or stretched position 50. The stretched position 50 may be adjusted by tightening or loosing the drawstring 34. Further comfort and softness may be incorporated in to the cover 20 by knitting a spacer fabric (not shown) into the stretched portion 46 of the cover 20. The spacer fabric may include extra yarn, other fabric, thread, or some additional material to provide a deep soft feel.

[0022] In certain embodiments, the vehicle interior component 14 may include various decorative features. In the illustrated embodiment, these decorative features include light sources 52 that emit light. The light sources 52 may emit light of one or multiple colors. Furthermore, the light sources 52 may emit patterns of light, such as a constant light emission or light emission that changes over time (e.g., based on a timing pattern, musical rhythm, etc.). The decorative features include designs 54 such as stitching or embroidery onto cover 20. The designs 54 may be on the top/visible side of the cover 20, or may be on the bottom of the cover 20. Furthermore, the light sources 52 may be used to illuminate the designs 54.

[0023] FIG. 5 is a perspective view of an embodiment of the vehicle interior component 14 having flexible supports. The illustrated embodiment includes the substrate 30 and the cover 20. The cover 20 is secured to the substrate 30 using the drawstring 34. The drawstring 34 is tightened around a portion of the vehicle interior component 14. The vehicle interior component 14 illustrated in FIG 5 includes flexible supports 56. The flexible supports 56 may be constructed using polypropylene, plastic, a polymer, wood, or other flexible resilient material suitable for use within the vehicle 10. The flexible supports 56 may be constructed during a knitting process used to form the cover 20. For example, the flexible supports 56 may be thickened or hardened yarn or thread, such as the yarn or thread used to construct the cover 20. The flexible supports 56 may be incorporated into the cover 20 before the cover 20 is placed over a portion of the vehicle interior component 14. After the cover 20 is placed over a portion of the vehicle interior component 14, the flexible supports 56 form a hollow portion 58 between the substrate 30 and the cover 20. This hollow area 58 provides cushion to an occupant of the vehicle 10. FIG. 6 is a cross- sectional view of the vehicle interior component of FIG. 5 utilizing flexible supports. As illustrated in FIG. 6, the cover 20 may transition between a relaxed position 60 (e.g., no force applied to cover 20) to a depressed position 62 (e.g., force applied to cover 20). In some embodiments, the flexible supports 56 are constructed such that, instead of laying flat, they have a tendency to curl toward the center. For installation over the substrate 30, the flexible supports 56 may be stretched in opposition to this tendency. Thus, after installation, this tendency provides extra stability due to the balance between the occupant pushing downward on the flexible supports 56 and the natural state of flexible supports 56 wanting to push the center spine upward.

[0024] FIGS. 7 and 8 illustrate embodiments of structures for alignment of the cover 20 with the substrate 30. FIG. 7 is a cross-sectional view of an embodiment of a knit-in bead of a cover installed on a vehicle interior component. The substrate 30 includes an alignment recess 62 capture an alignment feature of the cover 20. As illustrated, the alignment recess 62 is an indentation, but in other embodiments, the substrate 30 may include a raised area, or a series of raised and indented dashes to facilitate alignment. The cover 20 includes a knit-in bead 64 that may be formed while the cover 20 is knitted. In some embodiments, the knit-in bead 64 may be knitted into the cover 20 in line with a decorative feature, such as the French seam 22. The knit-in bead 64 aligns with the alignment recess 62, thereby holding the cover 20 in place to block movement of the cover 20 relative to the substrate 30. FIG. 8 is a cross-sectional view of an embodiment of a cover of a vehicle interior component that is aligned using a pull-cord. The pull cord 66 applies a force to direct the cover 20 into the alignment recess 62. Thus, the cover 20 is secured to the substrate 30, and movement of the cover 20 relative to the substrate 30 is blocked. Additional structures may be utilized to attach the cover 20 to the substrate 30. These include structures that may be sewn or knitted into the cover 20 itself. For example, the cover 20 may include button holes that hook or loop over a corresponding structure formed in the substrate 30. Other attachment structures not illustrated may also be used.

[0025] Technical advantages of the foregoing embodiments include reduction in the complexity of vehicle interior components. Complexity is reduced by eliminating structures used to form the vehicle interior components, and eliminating steps used to form the vehicle interior components. Specifically, foam layers may be eliminated from the vehicle interior component, utilizing instead a hollow portion created by a suspended cover. Also, attaching the cover to the vehicle interior component is less complex according to the embodiments described above. An additional advantage of the foregoing embodiments is the ability to customize the appearance of the vehicle interior component.

[0026] While only certain features and embodiments of the invention have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), 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. The order or sequence of any process or method steps may be varied or re- sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

Claims

CLAIMS:

1. A vehicle interior component, comprising:

a substrate; and

a cover disposed at least partially about the substrate, wherein the cover comprises an opening and a string extending along a circumference of the opening, and wherein the string is configured to block expansion of the opening to secure the cover to the substrate.

2. The vehicle interior component of claim 1, wherein the cover is configured to be secured to the substrate by disposing the cover at least partially about the substrate and tightening the string.

3. The vehicle interior component of claim 1, comprising a foam cushion secured between the substrate and the cover.

4. The vehicle interior component of claim 1, wherein the cover comprises a decorative feature, and wherein the substrate comprises a recess configured to align the decorative feature by tightening a pull cord.

5. The vehicle interior component of claim 1, wherein the cover comprises a decorative feature aligned with a knit-in bead, and wherein the substrate comprises a recess configured to align the decorative feature by securing the knit-in bead.

6. The vehicle interior component of claim 1, comprising at least one rail configured to facilitate longitudinal adjustment of the vehicle interior component, wherein the cover is configured to conceal the rail from view of a vehicle occupant.

7. A vehicle interior component, comprising:

a substrate comprising a base and at least two raised contact points; and a three-dimensional cover comprising an opening and a string disposed about a circumference of the opening, wherein the cover at least partially surrounds the substrate and is suspended between the contact points, and wherein the string is configured to block expansion of the opening to secure the cover to the substrate.

8. The vehicle interior component of claim 7, wherein a firmness of the cover is adjustable by varying a tension of the string.

9. The vehicle interior component of claim 7, comprising at least one rail configured to facilitate longitudinal adjustment of the vehicle interior component, wherein the cover is configured to conceal the rail from view of a vehicle occupant.

10. The vehicle interior component of claim 7, wherein the cover comprises embroidery.

11. The vehicle interior component of claim 7, wherein the substrate comprises a light emitting feature configured to emit light through the cover.

12. The vehicle interior component of claim 7, wherein the cover is secured against the substrate by the use of a knit-in bead, a pull cord, or a combination thereof.

13. A vehicle interior component, comprising:

a substrate; and

a three-dimensional cover comprising flexible supports, an opening, and a string disposed about a circumference of the opening, wherein the cover is configured to be secured to the substrate by disposing the cover at least partially about the substrate and tightening the string, and wherein the flexible supports are configured to create a hollow area between the substrate and the cover.

14. The vehicle interior component of claim 13, wherein the cover comprises knit-in loops, pockets, or a combination thereof configured to secure the cover against the flexible supports.

15. The vehicle interior component of claim 13, wherein the flexible supports comprise a center structural spine and flexible ribs extending outwardly from the spine.

16. The vehicle interior component of claim 13, comprising a light emitting feature configured to emit light through the cover.

17. The vehicle interior component of claim 13, wherein the cover comprises embroidery.

18. The vehicle interior component of claim 13, wherein the cover comprises a decorative feature configured to be aligned to a recess in the substrate by a pull cord, a knit-in bead, or a combination thereof.

19. The vehicle interior component of claim 13, wherein the flexible supports comprise polypropylene, thickened yarn, or a combination thereof.

20. The vehicle interior component of claim 13, wherein the substrate comprises hooks and the cover comprises holes configured to attach the cover to the substrate by stretching over the hooks.