Foam part, in particular for vehicle seat, method for producing foam part, and vehicle seat

Abstract

The invention relates to a foam component (100, 200, 300, 400, 600), in particular for a vehicle seat, comprising a textile layer and a foam body (104, 204, 404, 604), in particular made of polyurethane foam, the textile layer being designed as a three-dimensionally shaped nonwoven layer (102, 202, 402, 502), the nonwoven layer (102, 202, 402, 502) having a grammage of 800 to 1200 grams per square meter. The invention further relates to a method for producing a foam part (100, 200, 300, 400, 600) and to a vehicle seat (1) having at least one foam part (300).

Description

[0001] This application is a divisional application of the invention patent application filed on September 29, 2021, with application number 202180053103.2 entitled "Foam component, particularly foam component for vehicle seat, method for producing foam component, and vehicle seat". Technical Field

[0002] This invention relates to a foam component, particularly a foam component for vehicle seats, having a textile layer and a foam body, particularly a foam body made of polyurethane foam, wherein the textile layer is implemented as a three-dimensional nonwoven layer. The invention also relates to a method for producing the foam component, and to a vehicle seat. Background Technology

[0003] The use of foam components in vehicle seats is known, as it cushions the seat structure and aims to provide the best possible riding comfort for vehicle seat users.

[0004] WO 2009 / 036841 A1 discloses a backrest for a vehicle seat in a motor vehicle, wherein the backrest is formed from a one-piece or multi-piece padded wire frame. The wire frame provides the necessary stiffness to the foam body of the foam component.

[0005] WO 2014 / 106592 A1 discloses a foam component, particularly a foam component for vehicle seats, having a first foam layer facing the user and a second foam layer facing away from the user, wherein the first foam layer has a different hardness and / or density than the second foam layer, and wherein the first foam layer has multiple comfort tubes facing the user. The first foam layer can be separated from the second foam layer by a mesh structure, particularly a mesh structure made of polyethylene, jute, gauze, or nonwoven fabric.

[0006] A known practice in the prior art is to provide decorative components made of polyurethane foam, with a reinforcement on the underside of the foam component. When the decorative component is used, the reinforcement is supported on a support frame or strut of the object to be decorated. Such a reinforcement must be particularly abrasion-resistant and tear-resistant to prevent damage or destruction of the foam component, which may be caused by the use of the decorative component and the associated repeated stresses and movements on the support frame or strut.

[0007] WO 2020 / 030725 A1 discloses a foam component for a vehicle seat, having a textile layer and a foam body, the foam body at least partially receiving the textile layer and being made of a foam material, particularly polyurethane foam, wherein the textile layer is partially penetrated by the foam material and the textile layer has liquid-repellent properties, particularly hydrophobic properties. The textile layer may be a nonwoven layer.

[0008] Existing PU foam components, particularly those used for backrests or seats, lack sufficient rigidity for independent implementation in a seating environment. Therefore, additional support via a load-bearing seat structure is always necessary. Such a seat structure can be made of metal or plastic. Thus, existing vehicle seats consist of a seat structure and foam components supported by that structure. These seat structures are typically very heavy, expensive, and space-consuming, but are generally rare. The foam components ensure comfort. The structural components of the seat ensure the necessary structural support for the foam components.

[0009] Overmolding frames or reinforcing materials with foam to increase stiffness is also known in practice. However, such foam-overmolded parts can lead to problems, difficulties, or high costs in the production process. Summary of the Invention

[0010] The fundamental objective of this invention is to improve upon foam components of the type described at the beginning, particularly simplifying or even completely eliminating the seat structure supporting the foam component. This aims to provide the possibility of constructing vehicle seats that are lighter and more comfortable than those in the prior art, and also require less installation space. Specifically, the objective is to replace the wire frame used for the foam component, which, while increasing the rigidity of the foam component, is heavy and costly.

[0011] Another fundamental objective of the present invention is to provide a method for producing foam components according to the invention, and a lightweight and low-cost vehicle seat having foam components according to the invention.

[0012] Solution

[0013] According to the invention, this objective is achieved by a foam component, particularly a foam component for vehicle seats, having a textile layer and a foam body, particularly a foam body made of polyurethane foam, wherein the textile layer is embodied as a three-dimensional nonwoven layer, wherein the nonwoven layer has a weight of 800 to 1200 grams per square meter.

[0014] The fact that the nonwoven layer has a basis weight of 800 to 1200 grams per square meter provides the possibility of making the foam component a load-bearing component and simplifying or even eliminating the seat structure supporting the foam component. The three-dimensional shape of the nonwoven layer increases its stiffness. The foam component with a three-dimensional nonwoven layer according to the invention can have very high stiffness and is also very comfortable. Because the nonwoven layer is very stiff due to the selected basis weight, good comfort can be achieved even when the foam thickness of the foam body is small. Compared with the prior art, this allows for foam components with small thicknesses, without the foam being too brittle or easily torn.

[0015] Nonwoven layers can be thermoformed. Nonwoven layers can be molded using foam overlay. Nonwoven layers can be partially penetrated by the foam material of the foam body. Nonwoven layers can be completely penetrated by the foam material of the foam body.

[0016] The nonwoven layer may include polyester fibers. The nonwoven layer may be composed of polyester fibers. The nonwoven layer may include polypropylene fibers. The nonwoven layer may be composed of polypropylene fibers. The nonwoven layer may include both polyester fibers and polypropylene fibers. The nonwoven layer may be composed of both polyester fibers and polypropylene fibers.

[0017] The nonwoven layer can have a layer thickness of 0.7 mm to 5 mm, that is, at least 0.7 mm but at most 5 mm. Preferably, the nonwoven layer has a layer thickness of 1.3 mm to 3.3 mm, particularly 1.5 mm to 2.5 mm. Most preferably, the nonwoven layer has a layer thickness of 2.3 mm to 2.5 mm.

[0018] The nonwoven layer preferably has a basis weight of 850 grams to 950 grams per square meter, that is, a basis weight of at least 850 grams per square meter and at most 950 grams per square meter. Most preferably, the nonwoven layer has a basis weight of 900 grams per square meter.

[0019] The nonwoven layer preferably has an elastic modulus of 300 MPa to 1000 MPa. Most preferably, the nonwoven layer has an elastic modulus of 381 MPa to 850 MPa.

[0020] According to Nissan standard M0086, the flexibility of the nonwoven layer is preferably between -1 mm and -0.1 mm.

[0021] The tensile strength of the nonwoven layer is preferably from 8 MPa to 20 MPa, most preferably from 10 MPa to 12 MPa, and particularly 11 MPa. The high tensile strength of the nonwoven layer allows for the attachment of external components made of plastic, composite materials, or metal. Other functions and components of the vehicle seat can be integrated into the nonwoven layer, such as spacers, cushioning pad anchors, massage pads, cable clip connectors, trim channels, and / or ventilation anchors. In the case of foam components known in the prior art, directly fastening external components is not possible due to the risk of tearing.

[0022] The pull-out force of the nonwoven layer is preferably greater than 200 Newtons. The nonwoven layer preferably has a Poisson's coefficient of 0.3 to 0.5, most preferably 0.4. The elongation at break of the nonwoven layer is preferably 30% to 40%, most preferably 35%. The Shore hardness is preferably greater than 50 Shore A. The Shore hardness is preferably 70 Shore A to 90 Shore A, most preferably 80 Shore A.

[0023] The nonwoven layer can be stiffened by ribs. Five ribs are preferably arranged along a length of 40 cm. Each rib is preferably 2 to 3 cm wide. The ribs can be acute-angled. The ribs can be vertically aligned. The depth of the ribs preferably corresponds approximately to the depth of the foam body. The number and shape of the ribs can vary depending on the desired stiffness, the seat structure of the vehicle seat, and the customer's preferences.

[0024] The three-dimensional nonwoven layer is preferably molded by overlaying a foam body, particularly a high-durability polyurethane foam. The foam body can have a material thickness of 5 mm to 60 mm. In the case of the foam component according to the invention, the nonwoven layer / foam ratio can be higher than that of foam components known in the prior art. Therefore, the recyclable portion can reach a higher value, especially up to 80%.

[0025] Furthermore, according to the present invention, this objective is achieved by a method for producing foam components according to the present invention, which comprises at least the following three method steps:

[0026] - Insert at least one three-dimensional nonwoven layer into the foaming tool, wherein the nonwoven layer has at least one previously described feature.

[0027] - Supplying foamable materials to the foaming tool, and

[0028] - Remove the foam parts from the foaming tool.

[0029] The nonwoven layer can be formed from a generally flat nonwoven layer into a three-dimensional shape before being inserted into the foaming tool. Formation can be accomplished through a deep drawing process.

[0030] According to the invention, this objective is also achieved by a vehicle seat having at least one foam component according to the invention, particularly a foam component produced by the method according to the invention. The vehicle seat may have a seating component. The vehicle seat may have a backrest. The backrest may be fixed to the seating component. The backrest may be pivotally fixed to the seating component, particularly by at least one fitting.

[0031] The fact that the vehicle seat has the foam component according to the invention allows the vehicle seat's airbag system to be secured to at least one nonwoven layer. The nonwoven layer has sufficiently high stiffness.

[0032] The seating component may have at least one load-bearing seat structure that carries at least one foam component according to the invention or supports one or more of its segments. The backrest may have at least one load-bearing seat structure that carries at least one foam component according to the invention or supports one or more of its segments.

[0033] In summary, and in other words, the present invention provides a high-stiffness, thin foam cushioning section by overmolding a high-stiffness thermoformed nonwoven fabric with foam. The nonwoven composition typically comprises polyester fibers. It may also contain polypropylene. A preferred nonwoven thickness is 2 mm, but it can vary between 0.7 mm and 5 mm. A preferred (relative) density is 900 g / m³. 2 However, it can be between 400 and 1800 g / m 2 The changes between them.

[0034] The use of high-stiffness thermoformed nonwovens is preferred. High-stiffness nonwovens can be molded using polyurethane foam overlay. The foam may or may not penetrate into the nonwoven fabric. The stiffness of the thermoformed nonwovens can be adjusted by changing the parameters of the drawing process, the geometry of the nonwoven fabric, or the nonwoven material. The nonwoven material can be nonwoven polyester or some other polymer. The nonwoven material can contain additives that can modify the mechanical properties of the thermoformed nonwovens. Attached Figure Description

[0035] The invention will be described in more detail below with reference to the preferred exemplary embodiments shown in the accompanying drawings. However, the invention is not limited to these exemplary embodiments. The drawings are schematic and

[0036] Figure 1 : Shows a cross-sectional view of a foam component according to a first exemplary embodiment of the present invention.

[0037] Figure 2 : Shows a cross-sectional view of a foam component according to a second exemplary embodiment of the present invention,

[0038] Figure 3 This illustration shows a vehicle seat according to the invention, which has at least one foam component according to a third exemplary embodiment of the invention.

[0039] Figure 4 : This illustrates a foam component according to a fourth exemplary embodiment of the invention.

[0040] Figure 5 : Show Figure 4 The nonwoven layer of the foam portion has multiple ribs.

[0041] Figure 6 The illustration shows the arrangement of two nonwoven layers of a foam component in an open foaming tool according to a fifth exemplary embodiment, and...

[0042] Figure 7 : This shows details of the foam component according to a sixth exemplary embodiment. Detailed Implementation

[0043] Figure 1The illustration shows a foam component 100 according to the invention for a vehicle seat, based on a first exemplary embodiment. The foam component 100 has a three-dimensional nonwoven layer 102 and a foam body 104. The foam body 104 is formed by foaming a foam material, particularly polyurethane foam. The foam component 100 is three-dimensional. The nonwoven layer 102 is three-dimensional. The foam body 104 is three-dimensional.

[0044] On the underside of the foam component 100 opposite to the occupant of the vehicle seat, the foam component has a preferably thermoformed nonwoven layer 102 for reinforcing the foam component 100, particularly for rigidifying it. When installed in the vehicle seat, the nonwoven layer 102 is supported, preferably partially supported, on the load-bearing seat structure, particularly on the support frame or bracing of the vehicle seat.

[0045] In this configuration, the nonwoven layer 102 is covered by the foam body 104 only on one side. The nonwoven layer 102 is attached to the foam body 104 to form the foam component 100. The nonwoven layer 102 can be partially or completely penetrated by the foam material of the foam body 104.

[0046] Figure 2 A cross-sectional view of a foam component 200 according to the invention for a vehicle seat, based on a second exemplary embodiment, is shown schematically and in a highly abstract form. The foam component 200 has a three-dimensional nonwoven layer 202 and a foam body 204. The foam component 200 is three-dimensional. The foam body 204 is made of foam material, particularly polyurethane foam. The nonwoven layer 202 is three-dimensional. The foam body 204 is three-dimensional. The nonwoven layer 202 can be partially or completely penetrated by the foam material of the foam body 204. In this case, the foam component 200 serves as a seat cushion for a seating component of a vehicle seat according to the invention.

[0047] On the underside of the occupant opposite the vehicle seat, when using foam component 200, foam component 200 is preferably partially supported on the support frame or bracing of the vehicle seat. Foam component 200 has a preferably thermoformed nonwoven layer 202 for reinforcement. In this case, nonwoven layer 202 is covered on both sides by foam body 204. Nonwoven layer 202 is attached to foam body 204 to form foam component 200. Nonwoven layer 202 can be partially or completely penetrated by foam material of foam body 204.

[0048] Figure 3A vehicle seat 1 according to the invention is shown, having a seating component 10 and a backrest 20, wherein the backrest tilt is adjustable relative to the seating component 10. The seating component 10 has a load-bearing seat structure 12 that carries a foam component 300 according to a third exemplary embodiment of the invention. The foam component 300 is covered by a cover 306, which is preferably made of fabric or animal hide (leather). Figure 3 In the figure, the foam component 300 is hidden by the covering 306 and is therefore not visible, which is why the reference numeral line of the foam component 300 is a dashed line.

[0049] In terms of structure and function, foam component 300 corresponds to foam components 100 and 200 as described above. Specifically, foam component 300 has a corresponding nonwoven layer and a corresponding foam body. Cover 306 can be suspended in a manner known per se, i.e., fastened to the load-bearing seat structure and / or to connecting elements foamed into the foam component. Alternatively or additionally, cover 306 can be attached to the nonwoven layer at least in certain locations.

[0050] Figure 4 A foam component 400 according to a fourth exemplary embodiment of the invention is shown. The foam component 400 has a three-dimensionally shaped nonwoven layer 402 in each of the two outer edge regions of the foam body 404, although... Figure 4 Only one of the two nonwoven layers 402 is shown. The foam body 404 is formed by three-dimensional foaming of foam material, particularly polyurethane foam. The nonwoven layer 402 is three-dimensional in shape. The foam body 404 is three-dimensional in shape. The nonwoven layer 402 can be partially or completely penetrated by the foam material of the foam body 404. In this case, the foam portion 400 serves as a seat cushion for the seating component of a vehicle seat according to the invention.

[0051] Figure 5 The nonwoven layer 402 of the foam component 400 is shown. The nonwoven layer 402 is rigidified by ribs 406. In this case, the nonwoven layer has six ribs 406, which are arranged adjacent to each other and integrated into the nonwoven layer 402. The nonwoven layer 402 is generally L-shaped, having a first leg 408 and a second leg 410. The two legs 408, 410 are rigidified relative to each other by the ribs 406.

[0052] Figure 6 The illustration shows the arrangement of two nonwoven layers 502 for a foam component in an open foaming tool 510 for producing the foam component, according to a fifth exemplary embodiment. Each of the two nonwoven layers has five ribs 506 for hardening. The ribs 506 are generally parallel to each other and spaced apart from each other.

[0053] Figure 7 Details of a foam component 600 according to a sixth exemplary embodiment of the present invention are shown. The foam component 600 has a nonwoven layer with ribs 606, which are completely surrounded by a foam body 604.

[0054] The method according to the invention for producing foam components 100, 200, 300, 400, 600 according to the invention envisions, in one method step, particularly in a first method step, inserting at least one nonwoven layer 502, particularly a nonwoven layer 502 of a previously three-dimensional shape, into a foaming tool 510. In a further method step, particularly in a subsequent method step, foamable material is supplied to the foaming tool 510. In a further method step, particularly in a subsequent method step, the foamable material in the foaming tool 510 is foamed to form foam bodies 104, 204, 404, 604, and in the process is attached to the nonwoven layers 102, 202, 402, 502 in a form-fitting and / or material-bonding manner. In a further method step, particularly in a final method step, the foam components 100, 200, 300, 400, 600 are removed from the foaming tool 510.

[0055] The features and method steps disclosed in the foregoing description, claims and drawings, whether individually or in combination, are important for carrying out the invention in its various embodiments.

[0056] List of reference numerals

[0057] 1. Vehicle Seats

[0058] 10 Seating components

[0059] 12 Load-bearing seat structure

[0060] 20 Backrest

[0061] 100 Foam Components

[0062] 102 Nonwoven Layer

[0063] 104 Foam Body

[0064] 200 Foam Components

[0065] 202 Nonwoven Layer

[0066] 204 foam body

[0067] 300 Foam Components

[0068] 306 Covering

[0069] 400 Foam Components

[0070] 402 Nonwoven Layer

[0071] 404 foam body

[0072] 406 Rib

[0073] 408 (First) Legs

[0074] 410 (Second) Legs

[0075] 502 Nonwoven Layer

[0076] 506 Rib

[0077] 510 Foaming Tools

[0078] 600 Foam Components

[0079] 604 foam body

[0080] 606 Rib

Claims

1. A foam component for a vehicle seat, comprising: Textile layer, and The foam body is made of polyurethane foam. The textile layer includes a three-dimensional nonwoven layer; The nonwoven layer has a weight of 800 to 1200 grams per square meter; The nonwoven layer is configured to harden the foam component; The nonwoven layer includes at least one rib configured to harden the nonwoven layer.

2. The foam component according to claim 1, wherein, The nonwoven layer includes a first leg and a second leg, wherein the at least one rib is configured to stiffen the first leg and the second leg.

3. The foam component according to claim 1, wherein, The nonwoven layer includes multiple ribs.

4. The foam component according to claim 3, wherein, The plurality of ribs are adjacent to each other and integrated into the nonwoven layer.

5. The foam component according to claim 4, wherein, The nonwoven layer includes a first leg and a second leg, wherein the plurality of ribs are connected to both the first leg and the second leg of the nonwoven layer.

6. The foam component according to claim 4, wherein, The multiple ribs are completely surrounded by foam.

7. The foam component according to any one of claims 1-6, wherein, The nonwoven layer includes a first nonwoven layer located on a first edge region of the foam body and a second nonwoven layer located on a second edge region of the foam body, wherein the first nonwoven layer includes a first leg, a second leg, and at least one rib, the at least one rib being configured to harden the first leg and the second leg.

8. The foam component according to any one of claims 1-6, wherein, The nonwoven layer has a tensile strength between 8 MPa and 20 MPa.

9. The foam component according to claim 8, wherein, The nonwoven layer is configured to attach (a) plastic parts, (b) composite parts, and / or (c) metal parts.

10. The foam component according to claim 8, wherein, The nonwoven layer is configured to integrate vehicle components, wherein the vehicle components include at least one of the following: (a) a spacer, (b) a spring pad fastener, (c) a massage pad, (d) a cable clip connector, (e) a trim channel, and / or (f) a ventilation fastener.

11. The foam component according to any one of claims 1-6, wherein, The nonwoven layer has a thickness of 1.3 mm to 3.3 mm.

12. The foam component according to any one of claims 1-6, wherein, The nonwoven layer has an elastic modulus of 381 MPa to 850 MPa.

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