Seat element for a vehicle seat and method for producing a corresponding seat element
By designing a cushion made of elastic material and utilizing a combination of elastic folding and fastening elements, the problem of existing vehicle seat cushioning elements is easily damaged under load, achieving greater durability and comfort.
Patent Information
- Application Number
- CN202411726942.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-11-30
- Filing Date
- 2024-11-28
- Publication Date
- 2025-05-30
AI Technical Summary
The buffering elements of existing vehicle seats are prone to cracks or damage under load and may tear under bending loads, unable to fold around the edge to cover the undercut.
A seat element is designed, including a carrier portion and a cushion made of elastic material. The cushion may be integrally formed with a planar structure and fixed to the edge of the carrier portion by elastic folding, and is maintained in a folded state with a fastening element.
The design effectively prevents damage to the cushion under load, maintains its elastic properties, and can elastically fold around the edge of the carrier part, covering the undercut, and improves seat comfort and durability.
Smart Images
Figure CN120056831A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to a seat element for a vehicle seat and a method for producing a corresponding seat element. Background Art
[0002] Generally, vehicle seats, especially for motor vehicles and / or aircraft and / or trains, have a frame, a plurality of cushioning elements, and a covering material. Here, the function of the cushioning elements is especially to provide support and comfort for the occupant. The cushion is usually composed of a foam material, for example, formed of polyurethane foam or polyethylene formed by injection molding. However, the injection molding method has the disadvantage that complex shapes with undercuts cannot be formed in one go.
[0003] In addition, the foam material may, for example, have a sensitive surface that may form cracks or progressive damage under load. Additionally or alternatively, the foam material may have the disadvantage that they tear under bending loads around the edges of the carrier part and cannot be folded around the edges. Summary of the Invention
[0004] Therefore, an object of the present invention is to provide a seat element that solves and avoids or at least minimizes these disadvantages. In addition, an object of the present invention is to provide a method for producing a corresponding seat element.
[0005] This object is achieved by a seat element having the features of claim 1 and / or a method according to the dependent claims.
[0006] The proposed seat element for a vehicle seat includes at least one carrier part. The carrier part has a first side and a second side opposite the first side. The seat element further includes a cushion. The cushion can be integrally formed in particular and can be planar. The cushion has a first side and a second side opposite the first side. The cushion can include especially an elastic material or can be made of an elastic material. The material can include non-directionally arranged fibers.
[0007] The first side of the cushion is at least arranged in certain areas of the first side of the carrier part and is elastically folded around a first edge of the carrier part, such that the first side of the cushion is at least also arranged in the areas of the second side of the carrier part. The cushion is fixed in the form of an elastic fold in particular, for example, by fastening elements.
[0008] In this case, the expression "elastic fold" can be understood as the cushion being bent, where the combined bending load of the cushion is lower than the elastic limit of the material of the cushion.
[0009] Due to being fixed in the elastic folding position, the load on the cushion can be maintained by mechanical stress. When the fixing and mechanical stress are removed, the cushion can substantially resume its original shape, i.e., the shape of the cushion before it was subjected to the bending load.
[0010] The proposed seat element can have the advantage that the cushion can be folded around the edge of the carrier part, where the cushion can also cover undercuts.
[0011] In one embodiment, the cushion can include one or more fastening elements arranged in the area on the second side. The fastening element or the plurality of fastening elements can fix the cushion in its elastically folded state. For example, an adhesive can be applied between the carrier part and the cushion. Additionally or alternatively, clips and / or hooks and / or eyelets can be connected to the cushion and / or to the carrier part. Additional fastening of the cushion to the carrier part can be provided on the first side of the carrier part.
[0012] In one embodiment, the fastening elements engage with each other in a form - fitting manner to keep the cushion in its elastically folded state. For example, the cushion can include a first flap to be folded and a second flap to be folded. The flaps to be folded can be arranged and formed in such a way that when the cushion is arranged on the carrier part, they rest completely or at least partially on the second side of the carrier part. The first and second flaps can have edges that, in the state of being folded around the carrier part, are directly adjacent to each other or are at a certain distance from each other. As fastening elements, the first edge of the first flap can, for example, have a shape complementary to the second edge of the second flap. For example, the first edge can have one or more protrusions that can be arranged in one or more corresponding depressions, thereby creating a form - fit. The shape of the protrusions and depressions can correspond to, for example, a jigsaw shape. Additionally or alternatively, the first and / or second edges can have interlocking hooks and / or hooks and associated eyelets and / or interlocking guide rails as fastening elements.
[0013] In one embodiment, one fastening element or several or all fastening elements can be integrally formed with the cushion. The fastening elements can be formed from the same material as the cushion. This can simplify the production and / or logistics of the seat element. For example, in the production step, there is no need to connect any additional parts as fastening elements to the cushion. Instead, the fastening elements may already be formed in the cushion, for example, by thermoforming. This can save time, additional production steps, logistics work (especially due to fewer individual parts), and / or costs.
[0014] In one embodiment, the buffer pad may have a uniform thickness, particularly in the production state. The buffer pad can be processed to have a specific shape. For example, the buffer pad can be heated and / or pressurized in a hot tool in a mold. For example, the buffer pad can be formed in a molding tool at a temperature of at least 140 °C and / or at least 150 °C and / or at least 160 °C. For example, the buffer pad can be formed in a molding tool at a temperature of at most 240 °C and / or at most 220 °C and / or at most 200 °C. The buffer pad can undergo plastic deformation at least in certain regions within the mold, particularly permanently assuming the shape after being removed from the molding tool. In particular, after forming, the buffer pad can have local regions with different thicknesses.
[0015] The buffer pad can have at least two local regions with different densities. The region with a lower density can undergo plastic deformation.
[0016] The region with a lower density can be formed as a folding edge. In particular, such a region of the buffer pad can be arranged on the edge or in the region of an undercut or on the edge of the carrier part. The buffer pad can have regions with different densities of different sizes. For example, compared with the region with a lower density, the region with a higher density can form a support part, for example.
[0017] The density difference between at least two local regions can be at least 5 kg / m 3 and / or at least 10 kg / m 3 and / or at least 15 kg / m 3 . The density difference between at least two local regions can be at most 70 kg / m 3 and / or at most 50 kg / m 3 and / or at most 30 kg / m 3 . The region with a higher density may be more compressible than the region with a lower density. In particular, the material of the buffer pad may not be a foam material.
[0018] The carrier part can be, in particular, a plastic injection molding. The carrier part can include a polyester-based plastic elastomer and / or polyamide and / or polyolefin and / or copolymer. The carrier part can be, for example, the carrier part of the seat area and / or the backrest and / or the armrest and / or the leg rest and / or the foot rest of a motor vehicle seat.
[0019] In particular, the non-directionally arranged fibers of the buffer pad can be formed of polyester and / or of a polyester-based elastomer and / or of a polyolefin, or can include one or more of these materials. The fibers can be composed of a material containing a thermoplastic polymer. The fibers can, for example, include a material or be composed of a material containing at least one thermoplastic polymer.
[0020] The fibers can be referred to as "endless" as their length can be significantly greater than their diameter. For example, the ratio of the length of the fibers to their diameter is at least 100, preferably 500, and even more preferably 1000. Additionally, the diameter of the fibers can be between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm. The fibers can be presented in the form of a fiber entanglement. The fiber entanglement can be referred to as "three-dimensional", especially since the thickness of the obtained fiber entanglement is non-negligible as it is much greater than the diameter of the fibers. In particular, the thickness of the obtained fiber entanglement is at least 10 times, preferably at least 30 times, and more preferably at least 50 times the fiber diameter of the fiber entanglement.
[0021] The fiber entanglement can consist of or include molten fibers, where the fibers form coils that are welded to each other.
[0022] The bulk density of the fiber entanglement can be less than 30 kg / m 3 . Alternatively, the bulk density of the fiber entanglement can be greater than or equal to 30 kg / m 3 , preferably greater than or equal to 35 kg / m 3 , more preferably greater than or equal to 45 kg / m 3 , and / or less than or equal to 70 kg / m 3 , preferably less than or equal to 55 kg / m 3 .
[0023] The space between the fibers of the fiber entanglement forming the cushion is preferably kept free and filled only with air or another ambient gas. In other words: It may be advantageous not to fill the space between the fibers of the fiber entanglement with a liquid material in the form of a gel or a liquefiable solid, for example, the liquid material is poured between the fibers. By keeping the space between the fibers free, a particularly breathable cushion can be obtained as the space between the fibers promotes air circulation in the cushion. In particular, such a cushion may have better breathability than a cushion part (especially made of polyurethane foam). Such a cushion can also have the advantage that it absorbs significantly less moisture compared to a cushion part formed of polyurethane foam.
[0024] The cushion can have a generally cubic shape. In particular, the thickness of the fiber entanglement can be greater than or equal to 60 mm and / or less than or equal to 200 mm.
[0025] The cushion can be elastically folded around multiple edges of the carrier part. For this purpose, the cushion can have multiple regions that have one or more flaps folded around the corresponding edges.
[0026] The cushion has a cutout, in particular in order to be able to fold along the shape of the carrier part.
[0027] Furthermore, the seat element may have a covering which is arranged on the side of the cushion facing the carrier part. The covering may include fabric and / or wool and / or woven fabric and / or felt and / or leather and / or artificial leather.
[0028] Other layers may be arranged between the covering and the cushion and / or between the carrier part and the cushion, for example in the form of spacer fabric.
[0029] In particular, the seat element may be a seat back, a seat cushion, a headrest, an armrest or a leg rest.
[0030] This application also relates to a method of manufacturing a seat element according to the above description. The method generally includes the following steps
[0031] - Providing a cushion according to the above description, wherein the cushion is made of an elastic material comprising non-directionally arranged fibers,
[0032] - Providing a carrier part according to the above description,
[0033] - By placing the cushion on the carrier part such that the first side of the cushion is at least arranged in certain areas of the first side of the carrier part and in particular folded elastically around the first edge of the carrier part such that the first side of the cushion is at least also arranged in the areas of the second side of the carrier part and fixed in the form of an elastic fold.
[0034] According to one embodiment, the method of forming the cushion may include one or more of the following steps:
[0035] - Extruding a material through an extrusion die including a plurality of die holes to form a sheath of molten fibers, the material particularly including at least one thermoplastic polymer;
[0036] - Forming a molten fiber entanglement, wherein the fibers form coils that are welded to each other;
[0037] - Cooling the fiber entanglement.
[0038] The sheath of molten fibers may be guided between two counter-rotating guide members. A fiber blockage may be formed upstream of the two guide members, thereby producing a fiber entanglement forming coils that are welded to each other.
[0039] Before attaching the cushion disposed on the carrier part thereto, the cushion can be shaped and / or cut to a suitable size. In particular, the cushion can be trimmed and / or formed in a molding tool, in particular by thermoforming and / or pressure forming, in particular at the above-mentioned temperature and / or pressure.
[0040] Further advantages and / or features can be explained in more detail with reference to the following non-limiting description of exemplary embodiments and with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS
[0041] In the drawings:
[0042] Figures 1a to 1e Exemplary embodiments of a vehicle seat cushion are shown in different perspectives,
[0043] Figures 2a to 2f Exemplary embodiments of a vehicle seat backrest are shown in different perspectives,
[0044] Figure 3 A schematic view of a vehicle seat backrest and an associated cushion is shown,
[0045] Figure 4 A schematic view of an upper part of an exemplary vehicle seat backrest having a cushion including a fastener is shown,
[0046] Figure 5 A schematic view of an upper part of an exemplary vehicle seat backrest having a cushion including a flap and a folding area is shown,
[0047] Figure 6 A further schematic view of an upper part of a vehicle seat backrest having a cushion including a flap is shown,
[0048] Figure 7 A schematic flow chart of an exemplary production method for visualizing a seat element is shown.
[0049] Features described in connection with an exemplary embodiment of one figure can be applied to an exemplary embodiment of another figure, unless otherwise explicitly stated. In the following description, features that occur repeatedly have the same or similar reference signs. DETAILED DESCRIPTION
[0050] FIG. 1 schematically shows a seat cushion 100 for a motor vehicle. Figure 1a A perspective view of the seat cushion 100 is shown. Figure 1b A plan view of the seat cushion 100 is shown. Figure 1c A bottom view of the seat cushion 100 is shown. Figure 1d A side view of the seat cushion 100 is shown. Figure 1eShows a cross-sectional view of the xz plane passing through the seat cushion 100. The seat cushion 100 includes a carrier part 1 and a buffer pad 2. The carrier part 1 has a first side 11 and a second side 12. When the seat cushion 100 is installed in a vehicle, the first side 11 corresponds to the side where the vehicle occupant sits, and the second side 12 corresponds to the bottom surface facing the vehicle floor. The first side 11 is Figure 1a back to the observer in Figure 1c and 1e shows the area 3 where the buffer pad 2 is folded around the edge of the carrier part 1. Figure 1e The cross-sectional view of Figure 1e shows the undercut of the buffer pad 3 around the carrier part 1. In Figure 1d the upper tip of the triangle 31 marks the folding edge 23 of the buffer pad 2, and the buffer pad 2 is folded along the folding edge 23.
[0051] Figure 2 schematically shows the backrest 200 of a vehicle seat for a motor vehicle. Figure 2a Shows a rear view of the backrest 200. Figure 2b Shows a perspective view obliquely below the backrest 200. Figure 2c Shows a cross-sectional view of the backrest 200 in a section parallel to the xy plane from below. Figure 2d Shows a side view of the backrest 200. Figure 2e Shows a cross-sectional view of the backrest 200 passing through and parallel to the yz plane. The backrest 200 includes a carrier part 1 and a buffer pad 2. The carrier part 1 has a first side 11 and a second side 12. When the backrest 200 is installed in a vehicle, the first side 11 corresponds to the side facing the vehicle occupant, and the second side 12 corresponds to the rear side facing away from the occupant sitting on the vehicle seat. The first side 11 is Figure 2aThe back faces away from the observer. The cushion 2 has a first side 21 and an opposite second side 22. The first side 21 lies flat on the first side 11 of the carrier part 1. In addition, regions of the cushion 2 project beyond the first side 11 of the carrier part and fold around the edge of the carrier part 1. In certain regions, the first side 21 of the cushion 2 thus also lies on the second side 12 of the carrier part 1. The second side 22 of the cushion 2 faces away from the carrier part 1. The cushion 2 can be elastically folded around the edge of the carrier part and fixed in that position. For example, fixation can be achieved by means of a fastener 4, which will be described separately later. Figure 2a and 2e shows a region 3 in which the cushion 2 is folded around the edge of the carrier part 1. Figure 2e The sectional view shows the undercut of the cushion 3 around the carrier part 1. The triangles 31 respectively mark the folding edges 23 of the cushion 2, and the cushion 2 is folded around the carrier part 1 along the folding edges 23. In the region of the folding edges 23, the cushion 2 can have a higher density than the regions around the folding edges 23.
[0052] The cushion 2 of the seat cushion shown in FIG. 1 and the cushion 2 of the backrest shown in FIG. 2 each have regions of different thicknesses. For example, the respective cushion 2 can be preformed in a molding tool to adapt to the shape of the carrier part 1 and / or have support parts. The cushion 2 can be glued to the carrier part 1 at least in some regions.
[0053] Figure 3 shows a perspective schematic view of a vehicle seat backrest. The backrest 300 includes a carrier part 1 and a cushion 2. The cushion 2 is arranged on the carrier part 1, wherein the first side 21 of the cushion 2 is arranged on the first side 11 of the carrier part 1 and the second side 12 opposite the first side 11. For this purpose, the cushion 2 has flaps 24, each flap 24 folding around the edge of the carrier part 1. In particular, the cushion 2 can have four flaps, wherein a first flap 24 in the upper region of the backrest folds around the carrier part, two opposite side flaps 24 fold around the side edges of the carrier part 1, and a lower flap 24 folds around the lower edge of the carrier part 1. Figure 3 b shows the cushion 2 in the unfolded state. The cushion 2 can be transported in the unfolded state, for example, this can make logistics easier.
[0054] Figure 4shows the upper part of the backrest 400 of a motor vehicle seat, wherein the backrest 400 has a carrier part 1 and a cushion 2 arranged thereon. The arrangement of the cushion 2 on the carrier part 1 generally corresponds to Figure 3 and the arrangement in FIG. 2. Figure 4 shows an exemplary fastening. Each flap 24 has at least one outer edge, the shape of which corresponds to the shape of the respective adjacent outer edges of the adjacent flaps 24. In particular, the outer edge has a projection 241, which has an undercut that mates with a corresponding receiving groove 242. In this way, a form-fit can be formed between two adjacent flaps. The flap 24 can be elastically folded around the edge of the carrier part 1 under tension and held in the folded shape by the form-fit between the projection 41 and the receiving groove 42. The projection 41 and the receiving groove 42 can be part of a fastener 4. The fastener 4, for example in the form of the projection 41 and the receiving groove 42, can be a separate part fastened to the flap 24, or preferably, can be formed as one part with the flap 24 and be formed of the same material as the flap 24. Alternative fasteners 4 are, for example, eyelets and / or hooks and / or tracks and / or clamps.
[0055] Figure 5 and Figure 6 show the upper parts of the backrests 500 or 600 of a motor vehicle seat, respectively, wherein the backrests 500 or 600 respectively have a carrier part 1 and a cushion 2 arranged thereon. The arrangement of the cushion 2 on the carrier part 1 generally corresponds to the arrangements in FIGS. 2, 3, and 4. Figure 5 shows the folding regions, the thickness of which is less than the surrounding region of the flap 24. The flap 24 is folded around the carrier part 1 along these folding regions 3. Figure 6 The folding direction is again shown using an arrow in.
[0056] The cushion 2 is formed by fiber entanglement. The cushion 2 includes a three-dimensional ("3D") entanglement of endless fibers. The ratio of the length to the diameter of the fibers is at least 100, preferably 500, and even more preferably 1000. The diameter of the fibers is between 0.3 mm and 1.5 mm. The fiber entanglement is called "three-dimensional" because the thickness of the obtained fiber entanglement is non-negligible, as it is much larger than the diameter of the fibers. In particular, the thickness of the obtained fiber entanglement is at least 50 times larger than the fiber diameter of the fiber entanglement. The fibers here are, for example, composed of a material containing at least one thermoplastic polymer. For example, the fibers are composed of a material containing at least 95% by weight of polyethylene terephthalate (or PET). For example, the fibers are composed of a material containing the following components:
[0057] - 95% to 99% by weight of a first polymer of the polyester family, such as PET; and
[0058] - 1% to 5% by weight of a second polymer of the polyester family, such as polytrimethylene terephthalate (or PTT) or polybutylene terephthalate (or PBT). This material is particularly well - known under the brand name "Auraloop".
[0059] In addition to the cushion 2, the seat element may further include a covering for covering the cushion 2. The covering may be made of a single piece or of a plurality of pieces stitched together. The latter solution is preferred in order to best adapt the shape of the covering to the geometry of the cushion 2. This means that wrinkles in the covering covering the cushion 2 can be avoided as much as possible.
[0060] The covering can be fastened to the cushion 2 and / or the carrier part 1 in any way available to those skilled in the art.
[0061] Figure 7 An exemplary production method for producing a seat element according to the foregoing figures is shown.
[0062] In a first step, as Figure 7 shown in a, the fiber mat 2 is initially made into strips and shortened to form a fiber mat part. In this method step, a preform of the fiber mat may already have been formed, for example by rolling. In a subsequent method step 2, as Figure 7 shown in b, the fiber mat 2 is placed in a molding tool and heated and / or pressed, for example in a mold. The fiber mat 2 can be further shaped in this step, in particular plastically deformed, and can permanently assume the shape specified by the tool mold. For example, support parts and parts with increased density can be formed. The fiber mat can additionally or alternatively be cut to a suitable size. After removing the fiber mat 2 from the molding tool, the fiber mat is in a formed and unfolded state and can be packaged and transported. The fiber mat 2 can be applied to the carrier part 1 in a further step (as Figure 7 shown in c). In particular, the fiber mat 2 can be folded around the edge of the carrier part 1 (especially around an undercut), as already referred to above with reference to the foregoing figures. The fiber mat 2 can be fixed in the folded state by a fastener 4 of the above - mentioned type. Then the covering can be applied to the cushion.
Claims
1. A seat element for a vehicle seat, comprising: at least one carrier portion (1) having a first side (11) and a second side (12) opposite to the first side (11), and An integral planar cushion (2) having a first side (21) and a second side (22) opposite to the first side (21), Wherein, the cushion (2) is made of an elastic material including non-directionally arranged fibers. Features The first side (21) of the cushion pad (2) is arranged at least in certain areas of the first side (11) of the carrier part (1) and is elastically folded around the first edge of the carrier part (1), so that the first side (21) of the cushion pad (2) is also arranged at least in the area of the second side (12) of the carrier part (1) and is fixed in an elastically folded form.
2. Seat element according to claim 1, wherein The cushioning pad (2), in particular arranged in the region of the second side (12) of the carrier part, comprises a fastening element (4) which secures the cushioning pad (2) in its elastically folded state.
3. The seat element according to claim 2, wherein The fastening elements (4) engage with each other in a form-fitting manner to keep the cushion (2) in its elastically folded state.
4. Seat element according to claim 2 or 3, wherein The fastening element (4) and the buffer pad (2) are formed integrally.
5. Seat element according to any one of claims 1 to 4, wherein The cushioning pad (2) has at least two local areas with different densities.
6. Seat element according to any one of claims 1 to 5, wherein The non-oriented fibers are formed from polyester and / or from polyester-based elastomer and / or from polyolefin, or contain one or more of these materials.
7. Seat element according to any one of claims 1 to 6, wherein The ratio of the length of the fiber to its diameter is at least 100, preferably 500, even more preferably 1000, and / or The diameter of the fibers is between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm.
8. Seat element according to any one of claims 1 to 7, wherein The cushioning pad (2) is elastically folded around a plurality of edges of the carrier portion (1).
9. Seat element according to any one of claims 1 to 8, wherein The buffer pad (2) has a cutout.
10. A method for producing a seat element according to any one of claims 1 to 9, comprising the following steps - providing a cushioning pad (2) made of an elastic material comprising non-oriented fibers, - providing a carrier part (1), By placing the cushion pad (2) on the carrier part (1), the first side of the cushion pad (2) is arranged at least in a certain area of the first side (11) of the carrier part (1) and is elastically folded around the first edge of the carrier part (1), so that the first side of the cushion pad (2) is also arranged at least in the area of the second side (12) of the carrier part (1) and is fixed in an elastically folded form.