Seat element and injection mold for corresponding seat element

Abstract

The present disclosure relates to a seat element for a vehicle seat and to an injection mold for a carrier element of a corresponding seat element for a method for producing the seat element. The seat element includes a carrier element having a first surface and a foam cushion disposed on the first surface of the carrier element. The carrier element has a plurality of protrusions protruding into the foam material cushion in at least one fixing region. The carrier element is a plastic injection molded part.

Description

Technical Field

[0001] The present disclosure relates to a seat element for a vehicle seat, an injection mold for a carrier element of a corresponding seat element, and a method for producing the seat element. Background Art

[0002] When producing a padded seat element, a foam pad is typically placed on a carrier element. The foam pad is then mounted with a cover fastened to the carrier element. When the cover is pulled up, this can cause shear forces between the foam pad and the carrier element, causing the pad to slip relative to the carrier. Because the foam pad must be securely positioned on the carrier element for safety and aesthetic reasons, the foam pad is typically glued to the carrier element or secured to the carrier element using a separate fastening device, such as a clamp.

[0003] Therefore, in the production of the seat element, additional process steps have to be included involving the application of adhesive or the attachment of fasteners. Utility Model Content

[0004] Therefore, the object of the present application is to propose a seat element which solves and avoids or at least minimizes these disadvantages.In addition, the object of the present application may be to propose an injection mold capable of producing a corresponding improved seat element and an improved production method for a corresponding seat element.

[0005] The proposed seat element for a motor vehicle seat comprises

[0006] - a carrier element having a first surface and

[0007] A foam pad is arranged on the first surface of the carrier element.

[0008] The carrier element has a plurality of protrusions protruding into the foam material pad in at least one fixing area. The carrier element is a plastic part. In particular, the plastic part can be a plastic injection molded part or a plastic part produced using 3D printing (additive manufacturing). The advantage of plastic parts is that they can be produced in almost any shape and wall thickness. This can be a particular advantage compared to sheet metal parts. In addition, plastic parts, in particular injection molded plastic parts, can have a high productivity and can be relatively well integrated into automated manufacturing processes. Plastic injection molded parts can be consistently produced using one plastic mold, and the production costs per part can be kept low, especially in mass production.

[0009] The foam padding can generally be compressible. When the foam padding is placed on the carrier element, the foam padding can surround a plurality of protrusions. When the covering is applied (e.g., laminated) with the foam padding, in addition to shear forces between the foam padding and the carrier element, forces are generally exerted to press the foam padding against the carrier element. The foam padding can be compressed more in areas with the protrusions than in areas without the protrusions. The protrusions can be formed to fit the foam padding. This prevents or at least minimizes the slippage of the foam padding relative to the carrier element.

[0010] In one embodiment, the carrier element can be a plastic injection molded part or a plastic part manufactured using 3D printing. The carrier element can be made of thermoplastic plastic, in particular polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polyamide (PA), polypropylene (PP), polyvinyl chloride (PVC) or polyethylene (PE), and / or made of thermosetting plastic, in particular glass fiber plastic (GRP), carbon-fiber-reinforced plastic (CFRP) or fiber-plastic composite materials containing natural fibers. The carrier element can include one or more of these substances.

[0011] In one embodiment, the protrusions can be conical and / or shaped as truncated cones and / or pyramids and / or truncated pyramids. The protrusions can also have a combined shape, such as a rectangular base block with a pointed tip arranged thereon, for example, in the form of a cone. Pointed protrusions have the advantage of better penetrating and securing the foam pad even under low pressure loads. On the other hand, a truncated shape can be advantageous if the foam pad is sensitive and / or has a sensitive surface. This can be used to prevent cracks or damage.

[0012] Specifically, the protrusions can point in the direction of the foam pad. Specifically, the respective longitudinal axis of the protrusions can extend substantially perpendicular to the surface of the carrier element from which the respective protrusion protrudes. Alternatively, the longitudinal axis of the protrusions can be oriented at an angle to the exposed surface, for example, so that the protrusions are shaped as tilted cones and / or tilted truncated cones and / or tilted pyramids and / or tilted truncated pyramids. For example, the longitudinal axis of the protrusions can point in a direction opposite to the shear forces acting during application (particularly lamination) of the covering.

[0013] For example, a carrier element may have more than one fixing area, each of which may have multiple protrusions. The protrusions in one fixing area may point in a different direction than the protrusions in another fixing area. The protrusions in each fixing area may be oriented individually to counteract shear forces.

[0014] Multiple fixing areas can be separated from one another by surfaces without such protrusions. A first fixing area can additionally or alternatively be located adjacent to another fixing area, wherein the two adjacent fixing areas can have protrusions oriented differently. Some or all of the multiple fixing areas can be separated from one another by areas without protrusions. One or more or all of the fixing areas can be arranged in an edge area of ​​the seat element. The seat element can have multiple fixing areas in which the protrusions are arranged in a clustered pattern.

[0015] Protrusions of different types and shapes can be arranged within a fixed area. Protrusions closer to the edge of the carrier element can be larger and / or more pointed than other protrusions, and vice versa. Larger and / or more pointed protrusions in the edge area have the advantage of better adhesion of the foam padding in the edge area. On the other hand, smaller and / or less pointed protrusions in the edge area can minimize cracks in the foam-filled edge area. It can be provided that the area density of the protrusions in the edge area of ​​the seat element is higher than the area density of the protrusions in areas further from the edge, excluding this edge area. The area density of the protrusions can increase towards the edge of the seat element.

[0016] The protrusions can be arranged in one or more ordered patterns. For example, rows of protrusions can be arranged one below the other. Additionally or alternatively, rows of protrusions can be arranged offset from one another. Protrusions can be evenly spaced from adjacent protrusions, or at least partially spaced differently. Protrusions can be arranged and / or oriented in a chaotic pattern.

[0017] The area density of the protrusions can vary within the fixed area. Several fixed areas with the same or different area densities can also be provided on the protrusions. The area density within the fixed area can gradually increase. Specifically, the area density can increase towards the edge area of ​​the carrier element. This improves the adhesion of the foam pad in the edge area and makes it easier to laminate the covering.

[0018] Specifically, the protrusions can be integrally formed with the carrier element. Thus, the protrusions can already be formed into the carrier element during injection molding of the carrier element, in particular by providing recesses in the cavity of the injection mold for the carrier element. The carrier element can thus be an integral component of the carrier element. This can simplify the production of the carrier element and reduce production steps and costs. If the plastic part is produced using 3D printing, the protrusions can be integrally molded during 3D printing, particularly during the layer-by-layer and / or drop-by-drop additive build-up of the carrier element.

[0019] In one embodiment, the foam pad may include polyurethane foam (PU) and / or fibers, such as fibers including polyester (PET).

[0020] The foam padding can have different thicknesses on the carrier element. The fixing regions can be located in areas with a smaller foam padding thickness. In particular, areas with a smaller foam padding thickness often present a risk of slippage. Therefore, protrusions can be arranged or increased in these areas. The fixing regions can be arranged in one or more edge regions of the seat element.

[0021] In one embodiment, the seat element may include a covering. The covering may be or may include, for example, a textile fabric and / or leather and / or artificial leather. The covering may at least partially cover the foam padding on a side of the foam padding facing away from the carrier element. The foam padding may be connected to the carrier element. Additionally or alternatively, the covering may be connected to the foam padding, for example, by lamination.

[0022] In one embodiment, the seat element may include a fastening device. The fastening device secures the cover to the carrier element. The fastening device may take the form of a gripping profile. The fastening device may be connected to the cover, for example, sewn thereto. The fastening device grips around the edge of the carrier element. The fastening device may reduce or prevent the cover from slipping relative to the carrier element. The fastening device may create an aesthetic transition between the cover and the carrier element and prevent the foam padding from being visible in the vehicle interior when the seat element is installed.

[0023] The seat element can be designed as a cushioning element of a vehicle seat, in particular a backrest of a vehicle seat, a seat pan of a vehicle seat, a headrest of a vehicle seat and / or an armrest of a vehicle seat, or another cushioning element of a vehicle seat.

[0024] The present disclosure also relates to an injection mold for producing a carrier element for a seat element as described above. The injection mold comprises two mold halves and a cavity formed between the mold halves. The cavity forms a female mold for a carrier element for a seat pan of a motor vehicle seat or a carrier element for a backrest of a motor vehicle seat. The female mold has an area with a plurality of grooves. The grooves can be conical and / or shaped as truncated cones and / or pyramids and / or truncated pyramids.

[0025] The grooves can also have a combined shape, such as a cuboid base with a pointed tip arranged thereon, for example, in the form of a cone. The advantage of a pointed groove is that the carrier element can be produced using an injection mold, and even under low pressure loads, the protrusions of the carrier element penetrate the foam pad better and hold it in place. On the other hand, if the foam pad is sensitive and / or has a sensitive surface, a truncated shape may be advantageous. The truncated shape of the groove can be designed to avoid cracks or damage.

[0026] The respective longitudinal axes of the grooves may be substantially orthogonal to the surface defining the cavity relative to which the grooves are recessed. Alternatively, the longitudinal axes of the grooves may be oriented at an angle to the exposed surface, for example, so that the grooves are in the shape of an inclined cone and / or an inclined truncated cone and / or an inclined pyramid and / or an inclined truncated pyramid.

[0027] For example, the cavity may have more than one region in which the plurality of grooves are arranged. The V grooves in one region may point in a different direction than the grooves in another region.

[0028] Several areas with grooves may be separated from each other by surfaces without such grooves.A first area with grooves may additionally or alternatively be located next to another area with grooves, wherein the two adjacent areas have grooves of different orientations.

[0029] Grooves of various types and shapes can be arranged within the grooved region. Grooves closer to the edge of the carrier element can be larger and / or more pointed than other grooves, and vice versa. Larger and / or more pointed grooves in the edge region have the advantage of providing a carrier element produced using the proposed injection mold with better adhesion to the foam pad arranged thereon in the edge region. On the other hand, smaller and / or less pointed grooves in the edge region can reduce or even prevent cracks in the edge region of the foam pad if the foam pad is arranged on a carrier element produced using a corresponding injection mold.

[0030] The grooves can be arranged in one or more ordered patterns. For example, several rows of grooves can be arranged one below the other. Additionally or alternatively, rows of grooves can be arranged offset from one another. Grooves can be evenly spaced from adjacent grooves, or at least partially spaced differently. Grooves can be arranged and / or oriented in a chaotic pattern.

[0031] The area density of the grooves can vary within the grooved region. It is also possible to provide several regions with grooves of the same or different area densities. The area density within the grooved region can be gradually increased. Specifically, the area density can increase toward the edge regions of the cavity. This improves the adhesion of the foam pad to the carrier element produced using the proposed injection mold in the edge regions and makes it easier to laminate the cover onto the foam pad.

[0032] The present disclosure also relates to a method for producing a seat element according to any one of the preceding embodiments. The method comprises the following steps:

[0033] - providing an injection molding tool having an injection mold, wherein the injection mold is formed in accordance with the injection mold described above,

[0034] - closing the injection mold,

[0035] - injecting liquid plastic material into the injection mold,

[0036] - solidifying the plastic material to form a carrier element for the seat element, the carrier element comprising at least one fixing region having a plurality of protrusions which protrude into the foam material padding,

[0037] - Opening the injection mold and ejecting the carrier element.

[0038] In a further step, a foam pad can be placed on the carrier element, wherein the foam pad at least partially covers the fixing area of ​​the carrier element. In a further step, a cover can be placed on the foam pad. The cover can be fastened to the carrier element and / or the foam pad. The cover layer can be laminated onto the foam pad. The foam pad is held in place by protrusions protruding into the foam pad. Slippage of the foam pad relative to the carrier element is minimized or even prevented. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Further advantages and / or features are explained in more detail with reference to the following non-limiting description of exemplary embodiments and with reference to the accompanying drawings.

[0040] In the attached figure:

[0041] Figure 1 shows a sectional view through a schematically shown detail of a seat element,

[0042] Figure 2a and 2b each showing a cross-sectional view of a schematically illustrated exemplary protrusion,

[0043] Figure 3 Four exemplary details of a plan view of each fixing region of a carrier element are shown,

[0044] Figure 4 shows a sectional view through a schematically shown detail of another seat element,

[0045] Figure 5 shows a sectional view through a schematically shown detail of another seat element,

[0046] Figure 6 shows a schematic perspective view of an exemplary carrier element in the form of a seat tray,

[0047] Figure 7 Shown according to Figure 6 A schematic side view of the seat pan,

[0048] Figure 8 Shown Figure 6 The enlarged details,

[0049] Figure 9 Shown Figure 8 The enlarged details,

[0050] Figure 10 shows a schematic perspective view of an exemplary carrier element in the form of a seat tray,

[0051] Figure 11 Shown with Figure 6 compared to, Figure 10 Magnified details in the rotated view,

[0052] Figure 12 Shown with Figure 10 and 11 compared to, Figure 10 Magnified details in the rotated view,

[0053] Figure 13 Shown is a section through a schematically illustrated injection mold for producing a carrier element according to one of the preceding figures.

[0054] Figure 14 Shown with Figure 13 A cross-sectional view of a schematic carrier element produced by an injection mold is shown.

[0055] Recurring features are denoted by the same reference numerals in the following description of the figures. DETAILED DESCRIPTION

[0056] Figure 1A schematic cross-sectional view of a seat element 1 according to the present application is shown. The seat element comprises a carrier element 2 formed as a plastic injection-molded part. In other examples, the carrier element can be manufactured using 3D printing. In this example, the carrier element 2 is made of polypropylene (PP). In a first fixing region 1, the carrier element 2 has protrusions 21, each longitudinal axis of which extends substantially perpendicular to the carrier element surface 22. Protrusions 21 are integral to the carrier element 2. A foam pad 3 is arranged on the carrier element 2. The protrusions 21 protrude into the foam pad 3. In this example, the foam pad is made of polyurethane foam. A covering 4, in this case in the form of a textile fabric, is arranged on the foam pad 3 and folded around one edge of the carrier element 2. For this purpose, a fastening device 5 is sewn onto the covering 4. The fastening device 5 grips around the edge of the carrier element 2. When the covering 4 is applied, the clamping force acts in the direction of arrow 6. The projections 21 penetrating the foam pad prevent the foam pad 3 from sliding relative to the carrier element 2 in the direction of the clamping force. The projections shown are conical. In other exemplary embodiments, the projections can have different shapes and different orientations.

[0057] Figure 2a and 2b An exemplary embodiment of a protrusion 21 is shown in a schematic sectional view. Figure 1 The carrier element or the carrier element of the following figures may have the following Figure 2a and / or the protrusion 21 shown in 2b.

[0058] Protrusion 211 is conical. Protrusion 212 is pyramidal, wherein the pyramid has a rectangular base. Protrusions 213 and 214 are truncated cones. Protrusion 215 is a truncated cone with a cone at the top. Protrusion 216 is a rectangular parallelepiped with a cone at the top. Protrusion 217 is a pyramid with a square base.

[0059] The longitudinal axes L of protrusions 211, 212, 214, 215, 216, 217 extend normal to surface 22. The longitudinal axes L of protrusions 213, 218, 220, 222, and 224 are angled relative to surface 22. The degree of inclination may facilitate the formation of barbs.

[0060] Figure 1 The fixing area 1 can have protrusions of different shapes. Some or all of the protrusions 21 can have different shapes and / or different heights and / or different orientations. Alternatively, the protrusions 21 can all have the same design.

[0061] The protrusions 21 may be arranged in the fixing region I in an ordered or disordered manner. Figure 3 An exemplary arrangement of the protrusions 21 is shown. The example shown (or other arrangements not shown) may be applied to Figure 1and / or the carrier elements of the following figures. Figure 3 A detail of a plan view of the fixing area 1 of the carrier element 2 is shown. In example a, only some of the protrusions 21 are denoted by reference numerals for clarity. The protrusions 21 are arranged in rows, one below the other. Successive rows of protrusions 21 are offset from one another. In example b, the rows are spaced farther apart than in example a. The protrusions are also aligned. In example c, the protrusions 21 are arranged more closely than in examples a and b. The area density of the protrusions is increased compared to examples a and b. In example b, eight protrusions 21 are arranged on the same surface, while in example c, eighteen protrusions are arranged. In example b, the protrusions 21 are arranged in ordered rows, with the protrusions in successive rows aligned with one another. Example d corresponds to example c, with successive rows of protrusions 21 arranged offset from one another. The seat element 1 can have multiple fixing areas. Each fixing area can have a single protrusion arrangement, such as that according to example c, or several different arrangements, such as one fixing area according to example a, another fixing area according to example d, and yet another fixing area according to example b.

[0062] Figure 4 Another example of a seat element 1 is shown. Figure 4 The seat element 1 is essentially the same as Figure 1 This corresponds to a seat element 1 of the embodiment of the present invention, in which the carrier element has an angled edge that partially grips around the fastening device 5. The projection 21 is arranged in the fixing region I. The fixing region I is located on the angled edge. The clamping force of the covering acts in the direction of the arrow 6. Therefore, the projection 21 is asymmetrical and, in cross-section, has an angled edge 21' and an orthogonal edge 21" relative to the surface 22. This prevents or at least reduces slippage of the foam padding 3 due to the clamping force.

[0063] Figure 5 Another example of a seat element 1 is shown. Figure 5 The seat element 1 is essentially the same as Figure 4 The seat element 1 corresponds to the seat element 1 of FIG. 1 , wherein the carrier element has another angled edge and a fastening device 5 that grips around the other angled edge portion. The protrusion 21 is arranged in the fixing area I. The fixing area I is located on the first angled edge, such as Figure 4 The clamping force of the cover acts in the direction of arrow 6. The protrusion 21 has a symmetrical conical shape.

[0064] Figure 6 An exemplary design of a carrier element 2 of a seat element 1 is shown in a perspective view. Figure 7 Shown Figure 6 A side view of the carrier element 2; Figure 8 and Figure 9 Each shows Figure 6 Zoomed in details. Figure 6 The carrier element 2 may be more schematically Figure 1 、 4 or 5. The carrier element 2 is an injection-molded plastic part in the shape of a seat pan for a motor vehicle seat. In the fixing region I, the carrier element 2 has a plurality of protrusions 21, of which only two protrusions 21 are provided with reference numerals. The protrusions 21 are arranged in rows one above the other. The first row 23 and the second row 24 are aligned one above the other, i.e. the center of area of ​​the bases of the protrusions of row 23 lies on the same virtual straight line extending parallel to the z-axis as the center of area of ​​the bases of the protrusions 21 of row 24. Furthermore, the fixing region has rows 25, 26 and 27 of protrusions 21 arranged offset from one another, i.e. the center of area of ​​the bases of the protrusions of row 25 do not lie on the same virtual straight line extending parallel to the z-axis as the center of area of ​​the bases of the protrusions 21 of row 26. In Figures 6 to 9 In the example shown, the protrusions 21 have the same design. The protrusions 21 in this example have a rectangular base and form an inclined pyramid. The side surfaces 21 of the pyramid III Oriented orthogonally to surface 22, side 21 IV Oriented at an angle to surface 22. Orthogonally oriented surface 21 III Points in the direction of the edge of the carrier element closest to the projection 21 .

[0065] Figure 10 An exemplary design of a carrier element 2 of a seat element 1 is shown in a perspective view. Figure 11 Shown Figure 10 Details of the carrier element 2, with respect to Figure 10 Rotated and enlarged, Figure 12 Shown Figure 10 Further details, relative to Figure 10 Zoomed in and rotated. Figure 10 The carrier element 2 may be more schematically Figure 1 、 4 An example of a carrier element 2 is shown in FIG. 5 . Carrier element 2 is a plastic injection-molded part shaped like a seat pan for a motor vehicle seat. In mounting area I, carrier element 2 has multiple protrusions 21, only two of which are designated with reference numerals. Protrusions 21 are arranged one above the other in three rows. The first row 23, the second row 24, and the third row 25 are aligned one above the other, i.e., the center of area of ​​the bases of the protrusions in row 23 lies on the same imaginary straight line extending parallel to the z-axis as the center of area of ​​the bases of the protrusions 21 in rows 24 and 25. Figure 10 The fixing area of ​​the carrier element is formed at the rear end area of ​​the seat plate. Figures 10 to 12In the example shown, the protrusions 21 have the same design. For example, the protrusions 21 in this example have a rectangular base and form a symmetrical pyramid, as shown in FIG. Figure 11 As shown in .

[0066] Figure 13 A schematic injection mould 10 is shown in a cross-sectional view. The injection mould comprises a first mould half 101 and a second mould half 102. The injection mould is made of metal, in this case of aluminium. Alternatively, the injection mould can be made of silicone or tool steel, for example. A cavity 103 is provided between the halves, into which the moulding material, in particular plastic, can be injected. The cavity has a first region I' in which a plurality of grooves 104 are arranged and a second region II' in which a plurality of grooves 105 are arranged. The grooves 104 are in the form of a cuboid with a cone at the top. In other exemplary embodiments, the injection mould can have different grooves. For example, the grooves can have the same shape as Figure 2a and 2b The concave shape of the protrusion 21 described in FIG. 2 corresponds to the shape of the protrusion 21. The carrier element 2 can be produced using the shown injection mold by injecting the injection molding material. Figure 14 An exemplary carrier element is schematically shown in . The injection mold can be configured to produce a carrier element according to the previous figures. Figure 14 The carrier element has a first fixing area I and a second fixing area II, each of which corresponds to areas I' and II' of the injection mold. The protrusions 21 in the first fixing area are rectangular parallelepiped with a cone at the top. The protrusions 21 in the second fixing area II are pyramidal.

Claims

1. A seat element (1) for a motor vehicle seat, characterized in that include - a carrier element (2) having a first surface, a foam pad (3) arranged on a first surface of the carrier element (2), wherein the carrier element (2) in at least one fixing region (I) has a plurality of projections (21) projecting into the foam material padding (3), Wherein, the carrier element (2) is a plastic part.

2. Seat element (1) according to claim 1, characterized in that The carrier element (2) is a plastic injection-molded part or a plastic part manufactured by 3D printing from a thermoplastic, in particular polypropylene (PP), acrylonitrile-butadiene-styrene (ABS), polyamide (PA), polypropylene (PP), polyvinyl chloride (PVC) or polyethylene (PE), and / or from a thermosetting plastic, in particular a fiber-plastic composite material, such as glass fiber plastic (GRP) or carbon fiber reinforced plastic (CFRP), and / or a fiber-plastic composite material with natural fibers, or the carrier element (2) comprises one or more of these materials.

3. Seat element (1) according to claim 1 or 2, characterized in that The protrusion (21) is conical and / or formed as a truncated cone and / or a pyramid and / or a truncated pyramid.

4. Seat element (1) according to claim 1 or 2, characterized in that The protrusion (21) is formed integrally with the carrier element (2).

5. Seat element (1) according to claim 1 or 2, characterized in that The fixing area is arranged in an edge area of ​​the seat element and / or is characterized in that the seat element has a plurality of fixing areas, in which the protrusions (21) are arranged in a clustered pattern, in particular wherein some or all of the plurality of fixing areas are separated from each other by areas without protrusions.

6. Seat element (1) according to claim 1 or 2, characterized in that The foam padding (3) has different thicknesses on the carrier element (2), and the fixing region (I) is arranged in a region of smaller thickness of the foam padding (3), and / or is characterized in that the fixing region (I) is arranged in one or more edge regions of the seat element (1).

7. Seat element (1) according to claim 1 or 2, characterized in that A covering (4) covers the foam padding (3) at least in a region on a side of the foam padding (3) facing away from the carrier element (2) and is connected to the carrier element (2).

8. Seat element (1) according to claim 7, characterized in that Fastening means (5), in particular in the form of a gripping profile, wherein the fastening means (5) is connected to the covering (4), in particular is sewn thereto, and fixes the covering (4) to the carrier element (2), in particular by gripping around the edge of the carrier element (2).

9. Seat element (1) according to claim 1 or 2, characterized in that The seat element (1) is formed as a cushioning element of a vehicle seat, in particular as a backrest of a vehicle seat, a seat pan of a vehicle seat, a headrest of a vehicle seat or an armrest of a vehicle seat.

10. An injection mold (10) for producing a carrier element (2) of a seat element (1) according to any one of the preceding claims, comprising two mold halves (101, 102) and a cavity (103) formed between the mold halves, wherein: The cavity (103) forms a die for a carrier element (2) for a seat pan or backrest of a motor vehicle seat, characterized in that the die has an area (I', II') with a plurality of grooves (104, 105), which are conically formed and / or formed as truncated cones and / or pyramids and / or truncated pyramids.

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