# US 10,500,810 B2 · Decorative covering material with alignment features

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- Number: US 10,500,810 B2
- Document ID: US10500810B2
- Status: Granted
- Kind: B2
- Application number: 15/940,061
- Filed: 2018-03-29
- Published: 2019-10-03
- Granted: 2019-12-10
- Earliest claimed: 2018-03-29
- Assignees: Faurecia Interior Systems, Inc.
- Applicants: Faurecia Interior Systems, Inc.
- Inventors: Nicholas Natale; Brad Kusky
- Web page: https://patentgrep.com/patent/US10500810B2

## CPC

- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 7/08: by mechanical means
- B32B 7/09: by stitching, needling or sewing (by {mechanically connecting} fibrous layers {to another layer} B32B5/06)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/025: {comprising leather}
- B32B 9/04: comprising such {particular} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/045: {of synthetic resin}
- B32B 9/046: {of foam}
- B32B 9/047: {made of fibres or filaments}
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/18: characterised by the use of special additives
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- D05B 93/00: Stitches; Stitch seams
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2307/51: Elastic
- B32B 2307/732: Dimensional properties
- B32B 2451/00: Decorative or ornamental articles
- B32B 2605/003: Interior finishings
- B60R 13/02: {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18})
- B60R 13/0243: {Doors}
- B60R 21/04: Padded linings for the vehicle interior {; Energy absorbing structures associated with padded or non-padded linings}
- B60R 2013/0293: {Connection or positioning of adjacent panels}
- D05D 2305/08: Cutting the workpiece
- D10B 2505/12: Vehicles (D10B2505/08 takes precedence)
- Y10T 428/192: Sheets or webs coplanar
- Y10T 428/24033: including stitching and discrete fastener[s], coating or bond
- Y10T 428/24777: Edge feature
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D05B: SEWING (appliances for the tailoring trade A41H; sewing tables A47B29/00; sewing in bookbinding B42B2/00; sewing machines modified for knitting D04B39/08)
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- D05D: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A decorative covering for a vehicle interior panel is made from two sheets of material joined together at a seam. The sheets of material have matching alignment features along respective edges to aid in visual alignment during the joining operation. The alignment features are spaced along the edge of a decorative layer, and cutouts are formed along a corresponding edge of an attached backing layer such that each alignment feature is visible through one of the cutouts when viewed from the back side. The cutouts are larger than the alignment features and formed before the two layers are laminated together, effectively increasing allowable tolerances during lamination. This construction is particularly useful with leather, which is often subjected to cut-and-sew operations and used with a backing layer.

## Claims

### Claim 1

A sheet of material for use in making a decorative covering for a vehicle interior panel, the sheet of material comprising:
a decorative layer having a decorative side, an opposite back side, and an edge extending along a perimeter of the sheet of material;
a backing layer attached to the back side of the decorative layer and having a corresponding edge extending along the edge of the decorative layer;
a plurality of alignment features spaced along the edge of the decorative layer in an edgewise pattern; and
a plurality of cutouts formed along the corresponding edge of the backing layer, each cutout being located such that each alignment feature is visible through one of the cutouts when the sheet of material is viewed from the back side,
wherein the sheet of material forms a portion of the decorative covering when joined at a seam with another different sheet of material having alignment features spaced in a matching edgewise pattern along an edge of the different sheet of material, and
wherein the decorative layer is leather or imitation leather.

### Claim 2 (depends on 1)

A sheet of material as defined in claim 1, wherein each alignment feature along the edge of the decorative layer is a notch.

### Claim 3 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a shape different from a shape of each alignment feature that is visible therethrough.

### Claim 4 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a width greater than a width of each alignment feature that is visible therethrough.

### Claim 5 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a width that is at least twice a width of each alignment feature that is visible therethrough.

### Claim 6 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a width that is at least three times and no more than five times a width of each alignment feature that is visible therethrough.

### Claim 7 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a depth equal to a depth of each alignment feature that is visible therethrough.

### Claim 8 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a projected area that is at least twice a projected area of each alignment feature that is visible therethrough.

### Claim 9 (depends on 1)

A sheet of material as defined in claim 1, wherein each cutout has a projected area that is at least five times and not more than ten times a projected area of each alignment feature that is visible therethrough.

### Claim 10 (depends on 1)

A sheet of material as defined in claim 1, wherein the backing layer is adhered to the back side of the decorative layer.

### Claim 11 (depends on 1)

A sheet of material as defined in claim 1, wherein the alignment features and the cutouts are arranged along a curvilinear portion of the perimeter of the sheet of material.

### Claim 12

A vehicle interior panel comprising a decorative covering formed from a first sheet of material joined with a different sheet of material at a seam with each of the sheets of material being on opposite sides of the seam, the first sheet of material comprising:
a decorative layer having a decorative side, an opposite back side, and an edge extending along a perimeter of the first sheet of material;
a backing layer attached to the back side of the decorative layer and having a corresponding edge extending along the edge of the decorative layer;
a plurality of alignment features spaced along the edge of the decorative layer in an edgewise pattern; and
a plurality of cutouts formed along the corresponding edge of the backing layer, each cutout being located such that each alignment feature is visible through one of the cutouts when the first sheet of material is viewed from the back side,
wherein the different sheet of material has alignment features spaced in a matching edgewise pattern along an edge of the different sheet of material.

### Claim 13 (depends on 12)

A sheet of material as defined in claim 12, wherein the decorative layer is leather or imitation leather.

### Claim 14

A method of making a decorative covering for a vehicle interior panel, the method comprising the steps of:
joining a first sheet of material to a different sheet of material at a seam; and
aligning alignment features of the first sheet of material with alignment features of said different sheet of material during the step of joining, wherein the first sheet of material comprises:
a decorative layer having a decorative side, an opposite back side, and an edge extending along a perimeter of the first sheet of material, wherein the alignment features of the first sheet of material are spaced along the edge of the decorative layer in an edgewise pattern;
a backing layer attached to the back side of the decorative layer and having a corresponding edge extending along the edge of the decorative layer; and
a plurality of cutouts formed along the corresponding edge of the backing layer, each cutout being located such that each alignment feature is visible through one of the cutouts when the first sheet of material is viewed from the back side,
wherein the alignment features of the different sheet of material are spaced in a matching edgewise pattern along an edge of the different sheet of material.

### Claim 15 (depends on 14)

The method of claim 14, wherein the backing layer is attached to the back side of the decorative layer before the step of joining, and
wherein the alignment features of the first sheet of material are formed along the edge of the decorative layer and the cutouts are formed along the corresponding edge of the backing layer before the backing layer is attached to the back side of the decorative layer.

### Claim 16 (depends on 14)

The method of claim 14, wherein the step of joining includes sewing.

### Claim 17 (depends on 14)

The method of claim 14, further comprising the step of trimming away at least a portion of a margin of the joined sheets of material along a trim line spaced from said edges.

### Claim 18 (depends on 17)

The method of claim 17, wherein the step of trimming includes removal of the alignment features of the joined sheets of material.

### Claim 19 (depends on 14)

The method of claim 14, wherein the decorative layer is leather or imitation leather.

### Claim 20 (depends on 14)

The method of claim 14, wherein each alignment feature along the edge of the decorative layer is a notch.