Method for producing cushion element having cushion heating element from at least one fibrous nonwoven element, vehicle seat having such cushion element, and vehicle having such vehicle seat

Abstract

The invention relates to a method for producing a cushion element for a vehicle seat, comprising the following steps: providing at least one plate-shaped fibrous nonwoven element; placing at least one fibrous nonwoven element in a forming tool; arranging an electrical pad heating element having at least one electrical plug in the forming mold, the electrical plug and at least one section of the cable connected to the electrical plug being received in a separate chamber formed in the forming mold; closing the forming mold, the mat heating element being arranged on the at least one fibrous nonwoven element; expanding and shaping the at least one fibrous nonwoven element under the action of high temperature and high pressure, the mat heating element being integrally bonded to the at least one fibrous nonwoven element; the forming tool is opened and the formed pad element and the pad heating element connected to the pad element are removed, on which the electrical plug and the section of the cable are freely displaceably located. A vehicle seat having such a cushion element and a motor vehicle having such a vehicle seat are also provided.

Description

TECHNICAL FIELD

[0001] The invention relates to a method for producing a cushion element of a vehicle seat, a vehicle seat having at least one such cushion element and a motor vehicle having at least one such vehicle seat. BACKGROUND

[0002] Currently, efforts are being made to produce cushion elements from fiber materials for sustainability reasons, in order to avoid the use of foam plastics. In cushion elements made of foam plastic material, a cushion heating element, which can also be referred to as a seat heating device, is installed as a separate element on a fully formed foam cushion element in a separate processing step and bonded thereto.

[0003] With regard to the prior art, reference can be made, for example, to DE 10 2010 005 994 A1 and DE 698 13 691 T2. SUMMARY

[0004] It is an object of the invention to provide a method for producing a cushion element having a cushion heating element from at least one fiber nonwoven element / fiber nonwoven material element, in which subsequent installation of the cushion heating element can be avoided.

[0005] This object is achieved by the method, the vehicle seat and the motor vehicle having the features of the respective independent claims. Advantageous design schemes with suitable refinements are given in the dependent claims.

[0006] A method for producing a cushion element of a vehicle seat is therefore proposed, which comprises the following steps:

[0007] at least one fiber nonwoven element is provided; the at least one fiber nonwoven element is placed into a forming mold; an electrical cushion heating element having at least one electrical plug is arranged in the forming mold, wherein the electrical plug and at least one section of an electrical cable connected to the electrical plug are received in a separate cavity formed in the forming mold; the forming mold is closed, wherein the cushion heating element is located or arranged on the at least one fiber nonwoven element; the at least one fiber nonwoven element is expanded and formed under the action of high temperature and high pressure, in particular by injecting a steam-like fluid, in particular water vapor, wherein the cushion heating element is materially bonded to the at least one fiber nonwoven element; the forming mold is opened and the formed cushion element and the cushion heating element connected thereto are removed, wherein the electrical plug and the section of the electrical cable are removed from the separate cavity and are freely moveably located on the cushion element.

[0008] Since no liquid, in particular no plastic material to be foamed, is used in this method, the electrical connection of the mat heating element can be kept in the forming mold during the mat element forming by means of a separate chamber, so that the entire mat heating element can also be connected to the mat element at the same time when the mat element is formed. Thus, there is no need to separately install or adhere the mat heating element after the mat element is formed.

[0009] In this method, the mat heating element can have heating wires connected to the electrical plug and to the cable section, wherein the heating wires are arranged on a heating wire carrier element, which is put together with the at least one fiber nonwoven element into the forming mold.

[0010] The heating wire carrier element can for example be a flat fiber nonwoven, the heating wires being arranged on or in the heating wire carrier element in a loop-like or meandering manner. Alternatively, the loop-like or meandering heating wires can also be arranged on an adhesive strip as the heating wire carrier element.

[0011] In this method, the at least one fiber nonwoven element or / and the heating wire carrier element can have a coating made of a temperature-activatable, surface-adhesive material, so that the heating wire carrier element and the at least one fiber nonwoven element are materially bonded to each other, in particular are bonded to each other, in the closed forming mold.

[0012] Here, in order to activate the adhesive material coating, heat can be input in the forming mold, for example by means of the temperature increase in the forming mold required by the forming process of the mat element itself.

[0013] In this method, as an alternative or in addition to the activated adhesive material coating, the electrical plug of the mat heating element can be electrically connected to an electrical socket arranged in the separate chamber, wherein the heating wires are flowed through by an electrical current and are heated during the forming. Thereby, a specific temperature level can be achieved locally, targeted in the area of the mat heating element or the heating wires, which allows or facilitates a materially bonded connection between the heating wire carrier element and the mat element.

[0014] According to an alternative, in this method, the mat heating element can have heating wires connected to the electrical plug and to the cable section, wherein, when the forming mold is opened, the heating wires are fixed to one mold half of the forming mold, in particular by means of a plurality of fixing pins. For example, the at least one fiber nonwoven element can be arranged in the lower mold half, and the heating wires can be arranged in the upper mold half, so that, when the mold halves are closed, the heating wires are arranged on the at least one fiber nonwoven element.

[0015] Here, the heating wire can be arranged directly on the at least one fibrous nonwoven element and materially bonded thereto when the forming mold is closed. In this case, the method can be carried out without a heating wire carrier element.

[0016] In the method, the electrical plug of the mat heating element can be electrically connected with an electrical socket arranged in the chamber, wherein the heating wire is flowed through by an electrical current and heated during the forming, in particular such that the temperature of the heating wire is above the melting temperature of the at least one fibrous nonwoven element. In other words, the heating wire, which locally melts the fibrous nonwoven element, is directly materially bonded with the fibrous nonwoven element or built into the fibrous nonwoven.

[0017] It is also proposed a vehicle seat with at least one mat element manufactured according to the above method, wherein the mat element with the mat heating element is a seat mat or / and a backrest mat or / and a side wing mat. A side wing mat can for example be understood as a lateral leg support device in the area of the seat mat or a lateral body support device in the area of the backrest.

[0018] Furthermore, a motor vehicle with at least one such vehicle seat is also proposed. BRIEF DESCRIPTION OF DRAWINGS

[0019] Further advantages and details of the invention result from the following description of embodiments in conjunction with the drawings. Therein:

[0020] Figure 1 A method for manufacturing a mat element of a vehicle seat is shown in a simplified sectional view;

[0021] Figure 2 A mat heating element with and without a heating wire carrier element is shown in a simplified schematic top view;

[0022] Figure 3 A slightly modified method for manufacturing a mat element of a vehicle seat is shown in a simplified sectional view;

[0023] Figure 4 A mat element with a mat heating element as well as a schematic vehicle seat and motor vehicle are shown in a simplified top view. DETAILED DESCRIPTION

[0024] In Figure 1 A method 500 for manufacturing a mat element 10 is shown in a simplified and schematic illustration.

[0025] According to step S501, at least one fibrous nonwoven element 12 in the form of a plate is provided, wherein according to step S502, the fibrous nonwoven element is placed into a forming mold 50.

[0026] It is to be noted in this respect that a plurality of plate-like fibrous nonwoven elements 12 can also be arranged on top of one another in the forming mold and then a formed mat element 10 is produced from these plate-like fibrous nonwoven.

[0027] According to step S503, an electrical mat heating element 14 is arranged in the forming mold 50, which has at least one electrical plug 16, wherein the electrical plug 16 and at least one section 18 of the electrical cable 18k connected with the electrical plug 16 are received in a separate cavity 52 formed in the forming mold 50.

[0028] According to step S504, the forming mold 50 is closed, wherein the mat heating element 14 is located or arranged on at least one fibrous nonwoven element 12.

[0029] According to step S505, at least one fibrous nonwoven element 12 is expanded and formed under the influence of high temperature and high pressure, in particular by injecting a steam-like fluid, in particular water vapor, wherein the mat heating element 14 is materially bonded to the at least one fibrous nonwoven element 12.

[0030] According to step S506, the forming mold 50 is opened and the formed mat element 10 and the mat heating element 14 connected therewith are removed, wherein the electrical plug 16 and the section 18 of the electrical cable 18k are removed from the separate cavity 52 and are freely moveably located on the mat element 10.

[0031] In Figure 2 , possible design variants of the mat heating element 14 are shown in simplified form. Each of these mat heating elements 14 has a heating wire 20 connected with the electrical plug 16 and the section 18 of the electrical cable 18k. The heating wire is shown here in simplified form in zigzag form. However, the heating wire 20 can also be designed in the form of a coil, a loop or other course, for example meandering.

[0032] As can be seen from Figure 2 A and Figure 2 B, the heating wire 20 is arranged on a heating wire carrier element 22. In Figure 2 A, the heating wire carrier element 22 is designed as a flat fibrous nonwoven. In Figure 2 B, the heating wire carrier element 22 is formed by two strips, in particular adhesive strips, on which longer sections of the heating wire 20 are arranged.

[0033] In the method 500 shown in Figure 1 , it is possible to arrange the heating wire carrier element 22 ( Figure 2 A, Figure 2In step S503, the pad heating element 14 is placed in the molding die 50 such that the heating wire carrier element 22 is placed on at least one nonwoven fiber element 12. In other words, the pad heating element 14 with the heating wire carrier element 22 can be arranged on the uppermost layer of the nonwoven fiber element 12.

[0034] At least one nonwoven fiber element 12 and / or heating wire carrier element 22 used in method 500 Figure 2 A, Figure 2 B) It may have a coating formed of a temperature-activated, surface-adhesive material, such that the heating wire carrier element 22 and at least one nonwoven fiber element 12 are materially locked together in a closed molding die 50, particularly in step S505. Simultaneously in step S505, heat is introduced into the molding die 50 to activate the coating of the adhesive material.

[0035] exist Figure 3 In the middle, at least partially, it was shown again. Figure 1 Method 500, used here according to Figure 2 The pad heating element 14 of C has a heating wire 20 connected to an electrical plug 16 and a section 18 of a cable 18k, but no heating wire carrier element 22. In step S503, the pad heating element is placed into a molding die. In this example, with the molding die 50 open, the heating wire 20 is fixed to the upper half 50a of the molding die 50, specifically by means of a plurality of fixing pins 54. With the molding die 50 closed (S504), the heating wire 20 of the pad heating element 14 is directly located on at least one nonwoven fiber element 12 and is lockedly connected to the nonwoven fiber element material. In other words, Figure 3 A method 500 is shown in which a pad heating element 14 without a heating wire carrier element 22 is used.

[0036] Furthermore, steps S501, S502, S504 to S507 are essentially the same as those described above. Figure 1 The description is the same.

[0037] exist Figure 3 In the mold 50, an optional electrical socket 56 is also shown in a separate chamber 52. The plug 16 of the pad heating element 14 can be connected to this socket 56, particularly during step S503. This not only allows for... Figure 3 The method shown in 500 can be performed, or it can be performed in Figure 1 The method shown is performed, although in Figure 1 Socket 56 is not shown.

[0038] Refer to the description above Figure 1In method 500, in order to activate the adhesive material coating, the electrical plug 16 of the pad heating element 14 can be electrically connected to the electrical socket 56 arranged in a separate chamber 52, wherein the heating wire 20 is heated by current flowing through it during molding (S504, S505).

[0039] Similarly, in targeting Figure 3 In the described method 500, the electrical plug 16 of the pad heating element 14 can also be electrically connected to the electrical socket 56 arranged in a separate chamber 52, wherein the heating wire 20 of the pad heating element 14 is heated by current flowing through it during molding (S504, S505), in particular making the temperature of the heating wire (20) higher than the melting temperature of at least one nonwoven fiber element 12.

[0040] For the sake of completeness, it should be noted that, in Figure 3 The final step S506 is also performed in the described method 500, so that the pad element 10 with the properties described above can also be removed from the molding die 50.

[0041] exist Figure 4 The image shows a simplified and schematic top view of the pad element 10, in which the pad heating element 14 is materially and lockingly received within the pad element.

[0042] from Figure 4 It can also be seen that the pad element 10 manufactured according to the above method 500 can be part of the vehicle seat 30 shown here as a rectangle drawn with a dashed line. Furthermore, Figure 4 It is also shown that the motor vehicle 200 may have at least one such vehicle seat 30.

Claims

1. A method (500) for manufacturing a cushion element (10) for a vehicle seat (30), the method comprising the following steps: Provide (S501) at least one plate-shaped fiber nonwoven element (12); At least one nonwoven fiber element (12) is placed into the molding die (50) (S502); An electric pad heating element (14) having at least one electric plug (16) is arranged (S503) in the molding die (50), wherein at least one section (18) of the electric plug (16) and the cable (18k) connected to the electric plug (16) is received in a separate chamber (52) formed in the molding die (50); A closed (S504) forming mold (50) wherein a pad heating element (14) is located or arranged on at least one fiber nonwoven element (12); Under high temperature and high pressure, especially by injecting a steam-like fluid, particularly water vapor, at least one nonwoven fiber element (12) is expanded and shaped (S505), wherein the pad heating element (14) is materially locked to at least one nonwoven fiber element (12). Open (S506) the molding mold (50) and remove the molded pad element (10) and the pad heating element (14) connected to the pad element, wherein the section (18) of the electrical plug (16) and the cable (18k) is removed from the separate chamber (52) and is located on the pad element (10) with free movement.

2. The method (500) according to claim 1, characterized in that, The pad heating element (14) has a heating wire (20) connected to an electrical plug (16) and a section (18) of a cable, wherein the heating wire (20) is arranged on a heating wire carrier element (22), and the heating wire carrier element (22) is placed together on at least one nonwoven fiber element (12) into a molding die (50) (S503).

3. The method (500) according to claim 2, characterized in that, At least one nonwoven fiber element (12) and / or heating wire carrier element (22) has a coating made of a temperature-activated, surface-adhesive material, such that the heating wire carrier element (22) and at least one nonwoven fiber element (12) are materially locked together in a closed molding die (50).

4. The method (500) according to claim 3, characterized in that, In order to activate the viscous material coating, heat is introduced into the molding die (50).

5. The method (500) according to claim 3 or 4, characterized in that, In order to activate the coating of the adhesive material, the electrical plug (16) of the pad heating element (14) is electrically connected to the electrical socket (56) arranged in a separate chamber (52), wherein the heating wire (20) is heated by current flowing through it during molding (S504, S505).

6. The method (500) according to claim 1, characterized in that, The pad heating element (14) has a heating wire (20) connected to an electrical plug (16) and a section (18) of a cable, wherein when the molding die (50) is opened, the heating wire (20) is fixed to a mold half (50a) of the molding die (50), in particular by means of a plurality of fixing pins (54) on a mold half of the molding die.

7. The method (500) according to claim 6, characterized in that, When the molding die (50) is closed (S504), the heating wire (20) is directly arranged on at least one nonwoven fiber element (12) and is locked to the material of the at least one nonwoven fiber element.

8. The method (500) according to claim 6 or 7, characterized in that, The electrical plug (16) of the pad heating element (14) is electrically connected to the electrical socket (56) arranged in a separate chamber (52), wherein the heating wire (20) is heated by current flowing through it during molding (S504, S505), in particular making the temperature of the heating wire (20) higher than the melting temperature of at least one nonwoven fiber element (12).

9. A vehicle seat (30) having at least one cushion element (10) manufactured according to the method (500) of any one of the preceding claims, wherein, The pad element (10) with the pad heating element (14) is a seat pad or / and back pad or / and side wing pad.

10. A motor vehicle (200) having at least one vehicle seat (30) according to claim 9.

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