Armrest for a comfort driver's seat for a vehicle and method for forming such an armrest

Abstract

Armrest (10, 26) for a comfort driver's seat for a vehicle, comprising: a mounting hole (16) for mounting the armrest (10, 26) on the comfort driver's seat; an outer layer (12); a foam interlayer, wherein the foam interlayer comprises a plastic and a foaming agent; and an inner layer (14, 28) that defines a hollow core (24), wherein the hollow core (24) is divided by the mounting hole (16).

Description

TECHNICAL AREA

[0001] The invention relates to an armrest for a comfort driver's seat for a vehicle, a vehicle equipped with such an armrest, and a method for forming such an armrest. BACKGROUND

[0002] Armrests are a common component of a comfort driver's seat in vehicles. Current comfort driver's seat armrests are manufactured using many methods. One-piece injection-molded armrests generally have an open bottom surface with several sharp edges that could cause injury during a collision. Two-piece injection-molded armrests can mitigate the sharp edge problem, but require the pieces to be assembled together (snapped or otherwise) and secured with fasteners such as screws. For this and other reasons, two-piece injection-molded armrests are also relatively expensive to manufacture. A steel-stamped armrest molded in foam is yet another method of manufacturing an armrest. However, steel-stamped armrests are generally heavy and therefore less desirable.

[0003] Further armrests for vehicles are known from US 5 290 087 A, US 5 395 161 A and US 5 445 430 A.

[0004] There is a need for an armrest for a comfort driver's seat that is lightweight, made from a single piece, and reduces sharp edges to a minimum, if not eliminates them entirely.

[0005] This problem of the invention is solved by the subject matter of the independent claims. Further developments of the invention are the subject matter of the dependent claims. SUMMARY

[0006] In accordance with the purposes and advantages described herein, an armrest is provided for a comfort driver's seat of a vehicle. The armrest can be roughly described as comprising an outer layer and an inner layer, defining a hollow core.

[0007] In one possible embodiment, at least one of the inner and outer layers comprises a reinforcing material. In another, at least one of the inner and outer layers has a varying thickness along its length. In yet another possible embodiment, the hollow core is divided.

[0008] In yet another possible embodiment, the inner layer comprises a plastic and a foaming agent.

[0009] According to the invention, an armrest for a comfort driver's seat for a vehicle has an outer layer, a foam intermediate layer and an inner layer that defines a hollow core.

[0010] In yet another possible embodiment, at least one of the inner layer, the foam intermediate layer, and the outer layer comprises a reinforcing material. In another, at least one of the inner layer, the intermediate layer, and the outer layer has a varying thickness along its length. In yet another, the hollow core is divided.

[0011] In yet another possible embodiment, the inner layer comprises a plastic and a foaming agent.

[0012] In other possible embodiments, the armrests described above are integrated into a vehicle.

[0013] According to another aspect, a method for forming an armrest for a comfort driver's seat of a vehicle is provided. The method can be broadly described as comprising the following steps: (a) forming a preform with a first layer and a second layer; (b) mixing a foaming agent into the second layer prior to forming the preform; (c) feeding the preform between a first and a second mold half shaped similarly to the armrest; (d) clamping the preform by moving the first and second mold halves together to form a mold; and (e) pressing the first and second layers of the preform outward using compressed air, so that the first layer is adjacent to the mold and the second layer forms a hollow core of the armrest, the hollow core being partially filled by expansion of the second layer during cooling.

[0014] In another possible embodiment, the method may further include the step of reinforcing at least one of the first layer and the second layer before forming the preform. The reinforcing step may further include mixing reinforcing fibers into at least one of the first layer and the second layer of the preform.

[0015] In another possible embodiment, the method may further include the step of varying the thickness of at least one of the first layer and the second layer. In yet another embodiment, the method may further include the step of dividing the hollow core of the armrest.

[0016] According to yet another aspect, a method for forming an armrest for a comfort driver's seat of a vehicle is provided.The process can be broadly described as comprising the following steps: (a) forming a preform with a first layer, a second layer, and a third layer; (b) mixing a foaming agent into the second layer prior to forming the preform; (c) feeding the preform between a first and a second mold half, which are shaped similarly to the armrest; (d) clamping the preform by moving the first and second mold halves together to form a mold; and (e) pressing the first, second, and third layers of the preform outward using compressed air, such that the first layer is adjacent to the mold, the second layer expands between the first and third layers, and the third layer forms a hollow core of the armrest, the hollow core being partially filled by expansion of the second layer during cooling.

[0017] In another possible embodiment, the method may further include the step of reinforcing at least one of the first layer, the second layer, and the third layer of the preform. The reinforcing step may further include mixing reinforcing fibers into at least one of the first layer, the second layer, and the third layer before forming the preform.

[0018] In another possible embodiment, the method may further include the step of varying the thickness of at least one of the first layer, the second layer, and the third layer. In yet another embodiment, the method may further include the step of dividing the hollow core of the armrest.

[0019] The following description shows and describes several preferred embodiments of the armrest and the associated methods. It should be clarified that the armrest and the methods are capable of other different embodiments, and their various details are capable of modifications in various obvious aspects, without deviating from the arrangements and methods as presented and described in the following claims. Accordingly, the drawings and the description are to be interpreted as illustrative and not as limiting. BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0020] The enclosed drawings, which form part of this specification, illustrate several aspects of the armrest and, together with the description, serve to explain certain principles thereof. The drawings show: Fig. 1. A top view of an armrest from the side; Fig. 2 a top view of an armrest from below; Fig. 3 a cross-sectional view showing the armrest and more precisely a hollow core defined by an inner foam layer of the armrest; Fig. 4 a cross-sectional view showing the armrest and more precisely a hollow core defined by an inner layer of the armrest; Fig. 5 a cross-sectional view of an armrest showing divisions in the hollow core formed by pressing the inner foam layer closer together along a length of the armrest; Fig. 6 a cross-sectional view of an armrest showing divisions in the hollow core formed by pressing the inner layer together along a length of the armrest; Fig. 7A a cross-sectional view of a two-layer preform extruded from an extrusion head and extending between mold halves; Fig. 7B a cross-sectional view of a two-layer preform being pressed outwards against a mold by a blowing fluid to form the armrest; Fig. 8A a cross-sectional view of a three-layer preform extruded from an extrusion head and extending between mold halves; and Fig. 8B a cross-sectional view of a three-layer preform being pressed outwards against a mold by a blowing fluid to form the armrest; Fig. 9 a top view of a bumper not belonging to the invention; Fig. 10 a cross-sectional view showing the bumper and more precisely a hollow core defined by an inner layer of the bumper; Fig. 11 a cross-sectional view of an alternative bumper designed to maximize energy absorption in the event of a collision; Fig. 12A a cross-sectional view of a three-layer preform extruded from an extrusion head and extending between mold halves; and Fig. 12B a cross-sectional view of a three-layer preform being pressed outwards against a mold by a blowing fluid to form the bumper.

[0021] Detailed reference will now be made to the present embodiment of the armrest, bumper and the associated methods, examples of which are shown in the accompanying drawings, using similar reference numerals to represent similar elements. DETAILED DESCRIPTION

[0022] The following will be discussed Fig. 1 and Fig. Reference is made to Figure 2, which describes an embodiment of an armrest 10 for a comfort driver's seat of a vehicle. The armrest 10 is extended to comfortably support the arm of an occupant and has an outer layer 12 and an inner foam layer 14. The outer layer 12 in the described embodiment is a plastic (e.g., polypropylene). The inner foam layer 14 in the described embodiment is a mixture of plastic (e.g., polypropylene) and a foaming agent. As described in more detail below, the foaming agent allows the inner foam layer to expand after extrusion and during cooling.

[0023] A mounting hole 16 for attaching the armrest 10 to the back of a comfort driver's seat extends through the armrest. The armrest 10 is attached to the back of the comfort driver's seat by means of a suitable fastening element (e.g., a bolt or screw). According to the prior art, the armrest 10 can be covered by a foamed fabric or leather 18. The fabric or leather 18 and the foam 20 are partially shown in the figure. As in Fig. As shown in Figure 2, the underside of the armrest 10 is a closed, smooth surface 22.

[0024] As in Fig. As shown in Figure 3, the inner foam layer 14 of the armrest 10 defines a hollow core 24. Limiting the material in the armrest 10 in this way reduces the overall weight while simultaneously providing suitable stiffness for the armrest 10. The extent of foaming, i.e., the expansion of the inner layer 14, depends on the ratio of plastic to the foaming agent used and / or the thickness of the extruded inner foam layer. In the described embodiment, the plastic and the foaming agent are in pellet form. The two are mixed at a desired ratio to control the thickness of the inner layer before heating and extruding the preform in a blow molding machine. Alternatively, the foaming agent could be an inert gas (e.g., nitrogen or carbon dioxide) injected into molten plastic before extrusion.One such method of injecting an inert gas is Mucell. ® -Foaming process by Trexel, Inc. During extrusion of the preform, the pressure on the plastic is relieved and foaming occurs.

[0025] In an alternative embodiment, which is described in Fig. As shown in Figure 4, an armrest 26 has an outer layer 12 and an inner foam layer 14, and further has a third, inner layer 28. In the described embodiment, the inner layer 28 is a plastic (e.g., polypropylene) and defines the hollow core 24.

[0026] In each of the described embodiments, at least one of the outer layer 12, the inner foam layer 14, and / or the inner layer 28 can comprise a reinforcing material. Among other fiber materials known in the prior art, the reinforcing material can be fibers, fiberglass, talc, wood, and / or carbon. As will be explained in more detail below, in the described embodiments, the reinforcing material is mixed with the plastic (or plastic and foaming agent in the case of the inner foam layer) before the plastic is heated for extrusion.

[0027] Similarly, in each of the described embodiments, at least one of the outer layer 12, the inner foam layer 14, and / or the inner layer 28 can have a varied thickness along its length. As will be explained in more detail below, varying the thickness of a layer is achieved by adjusting the spacing of the extrusion heads during manufacturing.

[0028] Furthermore, the hollow core 24 of the armrest 10 can have at least one partition 30, as shown in Fig. 5 shown. In the Fig. In the embodiment described in Figure 5, the partition 30 is formed by varying the thickness of the inner foam layer 14 at varying positions along the length of the armrest 10 during manufacturing. In this way, the inner foam layer 14 is thicker, so that expansion of the foaming agent during cooling bridges the hollow core 24, which forms the partition 30. Alternatively, the ratio of the layer thicknesses between the outer layer 12 and the inner foam layer 14 can be adjusted to achieve the same result, i.e., to create a partition 30.

[0029] The hollow core 24 of the armrest 26 can likewise have at least one partition 32, as in Fig. Figure 6 illustrates this. In the described embodiment, the partition 32 is formed by varying the thickness of the inner foam layer 14 at varying positions along the length of the armrest 10 during manufacturing. In this way, the inner foam layer 14 is thicker, so that expansion of the foaming agent during cooling bridges the hollow core 24, which forms the partition 32. Alternatively, the ratio of the layer thicknesses between the outer layer, the inner foam layer, and the inner layer can be adjusted to achieve the same result, i.e., to create a partition.

[0030] As described above, the armrest 10 is manufactured using a blow molding process in the described embodiment. The outer layer 12, which comprises plastic pellets, is melted in a melting chamber of an extruder (not shown) before being conveyed as a molten plastic 32 to an extrusion head 34. Similarly, the inner foam layer 14 comprises plastic pellets and foaming agent pellets, which are mixed together and melted in a separate melting chamber (not shown) before being conveyed as a molten combination 36 of plastic and foaming agent to the extrusion head. In the described embodiment, the extrusion head 34 is a double extrusion head, which allows simultaneous extrusion of the outer layer 12 and the inner foam layer 14.

[0031] As in Fig. As shown in Figure 7A, a preform 38, generally described as a tubular shape made of hot plastic, is formed by the extrusion head 34 and extends between the mold halves 40 and 42. The preform 38 has an outer layer 12 and an inner foam layer 14. As shown, the inner foam layer 14 begins to expand due to a reduction in pressure (as indicated by reference numeral 44) as it exits the extrusion head. Cooling of the preform 38 further contributes to the expansion of the inner foam layer 14. As the preform 38 extends from the extrusion head 34 along the length of the mold, the mold halves 40 and 42 come together, as indicated by action arrows A, to form the armrest shape and clamp the preform 38 securely.

[0032] As in Fig. As shown in Figure 7B, fluid is introduced through the tube 46, as indicated by the action arrows B. In the described embodiment, the fluid is ambient air, which pushes the preform 38, comprising the outer layer 12 and the inner foam layer 14, outward to conform to the shape of the mold. The tube 46 can be retractable, and its introduction through the mold can cause fluid to be blown into the open cavity 24 or into the inner foam layer 14. Since the inner foam layer 14 is an open-cell foam, the fluid can pass through the entire inner foam layer 14, having the same effect on the outer layer 12 and the inner foam layer 14. After the outer layer 12 and the inner foam layer 14 have cooled and hardened, the mold halves 40, 42 are opened, as indicated by the action arrows C, and the armrest 10 is ejected.Removal of overspray on the ejected armrest 10 may be necessary.

[0033] In an alternative embodiment described above, a third or inner layer 28 is included in the armrest 26. In this case, the inner layer 28 is a plastic formed by melting plastic pellets in a melting chamber as described above with respect to the outer layer 12. The molten plastic 48 is fed to the extrusion head 50, which in the described embodiment is a triple extrusion head.

[0034] As in Fig. As shown in Figure 8A, a preform 52, generally described as a tubular shape made of hot plastic, is formed by the extrusion head 50 and extends between the mold halves 40 and 42. The preform 52 has the outer layer 12 and the inner foam layer 14 and inner layer 28. As shown, the inner foam layer 14 begins to expand due to a reduction in pressure (as indicated by reference numeral 44) as the inner foam layer 14 exits the extrusion head 50. Cooling of the preform 52 further contributes to the expansion of the inner foam layer 14. As the preform 52 extends from the extrusion head 50 along the length of the mold, the mold halves 40 and 42 come together, as indicated by action arrows A, to form the armrest shape and clamp the preform 52 in place.

[0035] As in Fig. As shown in Figure 8B, fluid is introduced through the tube 46, as indicated by the action arrows B. In the described embodiment, the fluid is ambient air, which pushes the preform 52, comprising the outer layer 12, the inner foam layer 14, and the inner layer 28, outward to conform to the shape of the mold. Again, the tube 46 can be retractable, and its introduction through the mold can cause fluid to be blown into the open cavity 24 or into the inner foam layer 14. Since the inner foam layer 14 is an open-cell foam, the fluid can pass through the entire inner foam layer 14, having the same effect on the outer layer 12 and the inner foam layer.After the outer layer 12, the inner foam layer 14, and the inner layer 28 have cooled and cured, the mold halves 40 and 42 are opened as indicated by the action arrows C, and the armrest 26 is ejected. Removal of overspray on the ejected armrest 26 may be necessary.

[0036] As mentioned above, at least one of the outer layer 12, the inner foam layer 14, and / or the inner layer 28 in the described embodiments can comprise a reinforcing material. According to the method, reinforcing fibers (not shown) are mixed into at least one of the outer layer 12, the inner foam layer 14, and / or the inner layer 28 before forming the preform. Among other fiber materials known in the prior art, the reinforcing material can be fibers, fiberglass, talc, wood, and / or carbon.

[0037] Similarly, in each of the described embodiments, at least one of the outer layer 12, the inner foam layer 14, and / or the inner layer 28 can have a varied thickness along its length. As will be explained in more detail below, varying the thickness of a layer is achieved by adjusting the distance between one or more of the extrusion heads during manufacturing. Alternatively, varying the composition of the inner foam layer 14, such that it contains a higher percentage of foaming agent, can also be used to vary the layer thickness.

[0038] Finally, alternative embodiments may also include the step of dividing the hollow core 24 of the armrest 10, 26. In the two-layer embodiment of the armrest 10, which is described in Fig. As shown in Figure 5, the partitions 30, 32 are formed by varying the thickness of the inner foam layer 14 at different positions along the length of the armrest 10 during manufacturing. In this way, the inner foam layer 14 is thicker, so that expansion of the foaming agent during cooling bridges the hollow core 24, forming the partition 30. Alternatively, the ratio of the layer thickness between the outer layer and the inner foam layer can be adjusted to achieve the same result, i.e., to create a partition.

[0039] With reference to Fig. 9 and Fig. Figure 10, which represents an embodiment of a bumper 110 for a vehicle, states that the bumper 110 comprises an outer layer 112, an inner foam layer 114, and a third, inner layer 128. In the described embodiment, the outer layer 112 is a plastic (e.g., polypropylene). The inner foam layer 114 is a mixture of plastic (e.g., polypropylene) and a foaming agent. The inner layer 128 is a plastic (e.g., polypropylene) and defines the hollow core 124. As described in more detail below, the foaming agent allows the inner foam layer to expand after extrusion and during cooling.

[0040] As in Fig. As shown in Figure 10, the inner foam layer 114 of the bumper 110 defines a hollow core 124. Limiting the material in the bumper in this way reduces the overall weight while simultaneously providing suitable stiffness for the bumper. The extent of foaming, i.e., the expansion of the inner foam layer 114, depends on the ratio of plastic to the foaming agent used and / or the thickness of the extruded inner foam layer. In the described embodiment, the plastic and the foaming agent are in pellet form. The two are mixed at a desired ratio to control the thickness of the inner foam layer before heating and extruding the preform in a blow molding machine. Alternatively, the foaming agent could be an inert gas (e.g., nitrogen or carbon dioxide) injected into molten plastic before extrusion.One such method of injecting an inert gas is the Mucell® foaming process from Trexel, Inc. During extrusion of the preform, the pressure on the plastic is relieved, and foaming occurs.

[0041] As further indicated by reference numeral 129, the inner layers 128 can be fused together during the formation of one or more chambers 126 in the hollow core 124. The fusion of the inner layers 128 provides additional stiffness. In an alternative embodiment, which is described in Fig. As shown in Figure 11, a bumper 130 is formed in a nesting shape for energy absorption in the event of an accident. Of course, the bumper 130 of the present invention can be formed into any number of nesting shapes that provide energy absorption.

[0042] In each of the described bumper embodiments, at least one of the outer layer 112, the inner foam layer 114, and / or the inner layer 128 can comprise a reinforcing material. Among other fiber materials known in the prior art, the reinforcing material can be fibers, fiberglass, talc, wood, and / or carbon. As will be explained in more detail below, in the described embodiments, the reinforcing material is mixed with the plastic (or plastic and foaming agent in the case of the inner foam layer) before the plastic is heated for extrusion.

[0043] Similarly, in each of the described bumper configurations, at least one of the outer layer 112, the inner foam layer 114, and / or the inner layer 128 can have a varied thickness along its length. As will be explained in more detail below, varying the thickness of a layer is achieved by adjusting the spacing of the extrusion heads during manufacturing.

[0044] In alternative embodiments, a bumper may consist of only the outer layer and the inner foam layer, forming a hollow core. The outer layer would be a plastic (e.g., polypropylene), and the inner foam layer would be a mixture of a plastic and a foaming agent, as in the described embodiment of a bumper. The inner foam layers may be fused together to form chambers within the hollow core, as described above for the three-layer embodiment.

[0045] In the same manner as described above with regard to the armrest 10, the bumper 110 in the described embodiment is manufactured using a blow molding process, as shown in Fig. Figure 12A illustrates this. The outer layer 112, comprising plastic pellets, is melted in a melting chamber of an extruder (not shown) before being conveyed as a molten plastic 132 to an extrusion head 134. Similarly, the inner foam layer 114 comprises plastic pellets and foaming agent pellets, which are mixed together and melted in a separate melting chamber (not shown) before being conveyed as a molten combination 136 of plastic and foaming agent to the extrusion head. The inner layer 128 is also a plastic, formed by melting plastic pellets in the melting chamber as described above with respect to the outer layer 112. The molten plastic 148 is conveyed to the extrusion head 150, which in the described embodiment is a triple extrusion head.

[0046] The preform 152, generally described as a tubular shape made of hot plastic, is formed by the extrusion head 150 and extends between the mold halves 140 and 142. The preform 152 has the outer layer 112, the inner foam layer 114, and the inner layer 128. As shown, the inner foam layer 114 begins to expand due to a reduction in pressure (as indicated by reference numeral 144) as the inner foam layer 114 exits the extrusion head. Cooling of the preform 152 further contributes to the expansion of the inner foam layer 114. As the preform 152 extends from the extrusion head 150 along the length of the mold, the mold halves 140 and 142 come together, as indicated by the action arrows D, to form the bumper shape and clamp the preform 152 securely.

[0047] As in Fig.As shown in Figure 12B, fluid is introduced through the tube 146, as indicated by the action arrow E. In the described embodiment, the fluid is ambient air, which pushes the preform 138, comprising the outer layer 112, the inner foam layer 114, and the inner layer 128, outward to conform to the shape of the mold. The tube 146 can be retractable, and its introduction through the mold can cause fluid to be blown into the open cavity 124 or into the inner foam layer 114. Since the inner foam layer 114 is an open-cell foam, the fluid can pass through the entire inner foam layer, having the same effect on the outer layer 112 and the inner foam layer.After the outer layer 112, the inner foam layer 114, and the inner layer 128 have cooled and cured, the mold halves 140 and 142 are opened as indicated by the action arrows F, and the armrest 10 is ejected. Removal of overspray on the ejected bumper may be necessary.

[0048] In summary, numerous advantages result from providing an armrest comprising an outer layer and an inner layer defining a hollow core, with alternative embodiments featuring a third or inner layer defining the hollow core. Forming the armrest according to the described method provides a lightweight, one-piece armrest for a comfortable driver's seat, minimizing, if not eliminating, sharp edges. Similarly, forming the bumper according to the described method provides a lightweight, one-piece bumper that minimizes, if not eliminating, sharp edges. The bumper can also be formed with higher local stiffness, higher energy absorption, shorter peel distances, without visible peel marks, and in energy-absorbing configurations.

Claims

[1] Armrest (10, 26) for a comfort driver's seat for a vehicle, comprising: a mounting hole (16) for mounting the armrest (10, 26) on the comfort driver's seat; an outer layer (12); a foam interlayer, wherein the foam interlayer comprises a plastic and a foaming agent; and an inner layer (14, 28) that defines a hollow core (24), wherein the hollow core (24) is divided by the mounting hole (16). [2] Armrest (10, 26) for a comfort driver's seat for a vehicle according to claim 1, wherein at least one of the inner layer (14, 28), the foam intermediate layer and the outer layer (12) comprises a reinforcing material. [3] Armrest (10, 26) for a comfort driver's seat for a vehicle according to one of claims 1 or 2, wherein at least one of the inner layer (14, 28), the intermediate layer and the outer layer (12) has a varied thickness along its length. [4] Vehicle integrating the armrest (10, 26) for a comfort driver's seat according to one of claims 1 to 3. [5] Method for forming an armrest (10, 26) according to one of claims 1 to 3 for a comfort driver's seat of a vehicle, comprising the following steps: Forming a preform (38, 52) with a first layer and a second layer; Mixing a foaming agent into the second layer before forming the preform (38, 52); Feeding the preform (38, 52) between a first and a second mold half (40, 42) which are shaped similarly to the armrest (10, 26); Clamping of the preform (38, 52) by moving the first and second mold halves (40, 42) together to form a mold; and Pressing the first and second layers of the heated preform (38, 52) outwards using blown air, so that the first layer is adjacent to the mold and the second layer forms the hollow core (24) of the armrest (10, 26), the hollow core (24) being partially filled by expansion of the second layer during cooling. [6] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to claim 5, further comprising the step of reinforcing at least one of the first layer and the second layer of the preform (38, 52). [7] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to claim 6, wherein the reinforcement step comprises mixing reinforcing fibers into at least one of the first layer and the second layer prior to forming the preform (38, 52). [8] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to any one of claims 5 to 7, further comprising the step of varying the thickness of at least one of the first layer and the second layer. [9] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to any one of claims 5 to 8, further comprising the step of dividing the hollow core (24) of the armrest (10, 26). [10] Method for forming an armrest (10, 26) according to one of claims 1 to 3 for a comfort driver's seat of a vehicle, comprising the following steps: Forming a preform (38, 52) with a first layer, a second layer and a third layer; Mixing a foaming agent into the second layer before forming the preform (38, 52); Feeding the preform (38, 52) between a first and a second mold half (40, 42) which are shaped similarly to the armrest (10, 26); Clamping of the preform (38, 52) by moving the first and second mold halves (40, 42) together to form a mold; Pressing the first, second and third layers of the preform (38, 52) outwards using blown air, so that the first layer is adjacent to the mold, the second layer expands between the first layer and the third layer and the third layer forms the hollow core (24) of the armrest (10, 26), the hollow core (24) being partially filled by expansion of the second layer during cooling. [11] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to claim 10, further comprising the step of mixing reinforcing fibers into at least one of the first layer, the second layer and the third layer prior to forming the preform (38, 52). [12] Method for forming an armrest (10, 26) for a comfort driver's seat of a vehicle according to one of claims 10 or 11, further comprising the step of varying the thickness of at least one of the first layer, the second layer and the third layer.

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