Backrest system, backrest set, method for manufacturing a backrest and vehicle seat

Abstract

The invention relates to a backrest system (100) for the modular production of a backrest for a vehicle seat, comprising at least: - a backrest frame (2), preferably made of metal, and - a lower functional component (3a), preferably made of plastic, and a number of at least two separate or independent upper module components (3b1, 3b2, 3b3), preferably made of plastic, wherein the upper module components (3b1, 3b2, 3b3) are geometrically non-identical to each other, wherein the lower functional component (3a) and each of the at least two geometrically non-identical upper module components (3b1, 3b2, 3b3), individually, can together form a backrest support (3), such that the number of geometrically non-identical backrest supports (3) can be formed from a combination of the lower functional component (3a) with the geometrically non-identical upper module components (3b1, 3b2, 3b3) of the backrest system (100), and wherein each of the respective trainable backrest supports (3) can be mounted on the backrest frame (2).

Description

[0001] The invention relates to a backrest system, a backrest set, a method for producing a backrest from the backrest system and a vehicle seat.

[0002] Vehicle seats typically comprise a seat section and a backrest that can be pivoted relative to each other. The backrest consists of a backrest frame, a backrest support mounted thereon, usually made of plastic, as well as a backrest cushion, a backrest cover, and other accessories with which the backrest support is fitted. There is normally little variation in the manufacture of the backrest frame, although modular structures are also used, for example, according to DE 10 2008 038 851 A1. The backrest support is normally individually adapted to meet a customer requirement or depending on the vehicle class, in particular a requirement regarding design and / or comfort.

[0003] As an example, a backrest with a one-piece backrest support, a backrest cushion, a backrest cover, and accessories is described in US 10,166,894 B2 and US 10,166,895 B2. The disadvantage of such vehicle seats or backrests is that, depending on the specifications, a separate tool must be manufactured for the entire backrest support to be adapted, which is very complex. However, even during the development phase, the entire backrest support must be tested and validated to determine whether the respective adaptation meets the requirements.

[0004] The invention is therefore based on the object of providing a possibility with which a backrest can be provided in a modular manner with low manufacturing and development costs.

[0005] This object is achieved by a backrest system, a backrest set, a method, and a vehicle seat according to the independent claims. The subclaims describe preferred developments.

[0006] According to the invention, a backrest system for the modular production of a backrest of a vehicle seat is provided, which has at least: - a backrest frame, preferably made of metal, and - a lower functional component, preferably made of plastic, and a number of at least two separate or independent upper module components, preferably made of plastic, wherein the upper module components are geometrically non-identical to one another, wherein the lower functional component and each of the at least two geometrically non-identical upper module components can, individually, together form a backrest support, so that the number of geometrically non-identical backrest supports can be formed from a combination of the lower functional component with the geometrically non-identical upper module components of the backrest system, and Each of the backrest supports can be mounted on the backrest frame. Taking manufacturing tolerances into account, the upper module components are considered "geometrically non-identical" if their dimensions differ by more than 1%.

[0007] It was recognized that certain specifications from a customer or due to the vehicle model, which primarily relate to design and / or comfort, have a significant impact on the upper section of the backrest support. Accordingly, simplification in production and development can be achieved if only the upper section of a backrest is adapted depending on the respective specification, as then only this change needs to be tested and validated. It is preferably provided that the lower functional component makes up at least two-thirds and the respective upper modular component a maximum of one-third (but not less than one-fifth) of the total clear height of the designed backrest support, as the specifications relating to design and / or comfort primarily influence the upper third of the backrest support.

[0008] Simplification is achieved by providing different, non-identical upper module components, which can then be selected according to the specifications and combined with the lower functional component to form the respective backrest support. Accordingly, the manufacturer can offer a backrest set consisting of different backrests, of which a first backrest, according to a first specification, can be installed for a specific customer or in a first vehicle class, and a second backrest, according to a second specification, can be installed for a different customer or in a different vehicle class.

[0009] Preferably, the backrest system further comprises at least one backrest cushion and / or at least one backrest cover with which the respectively formed backrest support can be equipped. Depending on the specifications and design of the backrest support, the backrest cushion and / or the backrest cover can also vary, so that these can also be selected according to this embodiment depending on the specifications. In an embodiment in which all of the formable backrest supports differ significantly from one another geometrically, it can preferably be provided that the backrest system also comprises the number N of geometrically non-identical backrest cushions and / or geometrically non-identical backrest covers. Within the backrest system, there is therefore the same number of geometrically non-identical backrest cushions and / or geometrically non-identical backrest covers as there are geometrically non-identical upper module components.In the event that a particular backrest cushion fits several geometrically non-identical backrest supports, the number of geometrically non-identical backrest cushions and / or geometrically non-identical backrest covers may also be lower.

[0010] Preferably, the backrest system further comprises at least one accessory part with which the respective backrest support can be fitted. Thus, additional accessories that can be attached according to the specifications are also part of the backrest system.

[0011] Preferably, it is further provided that - the lower functional component of the backrest system has at least one upper connection part in an upper area, and - Each of the at least two geometrically non-identical upper module components has at least one lower connecting part in a lower region, wherein the at least one upper connecting part on the lower functional component and the at least one lower connecting part on the respective upper module component are connectable to one another to form a connection between the lower functional component and the respective upper module component, wherein the at least one lower connecting part on each of the upper module components is identical. This enables simple and modular assembly, in particular by means of a clip connection or snap-in connection or the like.

[0012] According to the invention, a backrest set is also provided which comprises at least: - a first backrest, which is preferably made from the backrest system according to the invention, preferably according to a first specification with at least --- a backrest support formed from a lower functional component and a first upper modular component, and --- a backrest frame to which the formed backrest support is mounted; and - a second backrest, which is preferably also made from a backrest system according to the invention, preferably according to a second specification deviating from the first specification, and which differs from the first backrest, with at least --- a backrest support formed from a lower functional component that is identical to the lower functional component of the first backrest and a second upper module component that differs from the first upper module component of the first backrest, and --- a backrest frame to which the formed backrest support is mounted.

[0013] In a method according to the invention for producing a backrest, preferably from a backrest system according to the invention, at least the following steps are provided: - Reading or querying a specification in a query step; - picking or providing a lower functional component and an upper modular component from a number of geometrically non-identical upper modular components in one picking step, wherein the upper modular component is picked or provided depending on the read-in or queried specification, and wherein the lower functional component and the upper modular component together form a backrest support, wherein the lower functional component makes up at least two-thirds and the respective upper modular component a maximum of one-third (but not less than one-fifth) of the total clear height of the formed backrest support; - Mounting the lower functional component and the upper modular component and / or the formed backrest support to a backrest frame in one assembly step; - Equipping the formed backrest support in one assembly step; and - Finishing the backrest in further steps.

[0014] It can be provided that the assembled backrest support is assembled in an assembly step prior to the assembly step, which simplifies the manufacturing process, for example, in a JIT factory, since the already assembled backrest support does not need to be assembled. Preferably, the lower functional component and the selected upper modular component are connected to each other via a connection in a joining step prior to the assembly step. The backrest support is thus formed before assembly on the backrest frame.

[0015] The invention is explained in more detail below with reference to an embodiment of the invention and the accompanying drawings. They show: Fig. 1 a vehicle seat in a schematic side view; Fig. 2 a backrest of the vehicle seat in accordance with Fig. 1 in an exploded view; Fig. 3 a backrest system; Fig. 4 a flowchart of embodiments of the method according to the invention; and Fig. 5 a backrest set.

[0016] Fig. 1 schematically shows a vehicle seat 1 with a seat part 1a and a backrest 1b that can be pivoted relative to it. The backrest 1b has a metal backrest frame 2, to which a plastic backrest support 3 is attached. In the simplest version, the backrest support 3 is equipped with a backrest cushion 4, e.g., made of foam, and a backrest cover 5 surrounding the backrest cushion 4. As shown in the exploded view according to Fig. As shown in Figure 2, depending on the application, additional accessories Z can be arranged on the backrest support 3, e.g., a suspension system Z1 or a lumbar support, side bolsters, speakers in speaker mounts Z2, a massage system, etc. On the back of the backrest frame 2 is a rear cover 6, which covers or encloses the backrest 1b to the rear. The rear cover 6 can also be secured to the backrest support 3, for example, by clipping or snapping it in place or the like.

[0017] In Fig. 3 shows a backrest system 100 from which such a backrest 1b can be manufactured. The backrest system 100 comprises the backrest frame 2 and a lower functional component 3a and, separated therefrom, a number N of at least two (in Fig. 3: N=3) upper module components 3bi, with i = 1, ... N (N>1), wherein the lower functional component 3a and a single one of the at least two upper module components 3bi together form the backrest support 3. It is provided that the lower functional component 3a makes up at least two-thirds and the respective upper module component 3bi a maximum of one-third of the total clear height of the formed backrest support 3. The backrest system 100 is characterized in that the upper module components 3bi are each structurally different from one another, so that the same number N of differently constructed backrest supports 3 can be formed from a combination of the lower functional component 3a with a single one of the different or geometrically non-identical upper module components 3bi.

[0018] The backrest system 100 further comprises one or more backrest cushions 4 and / or backrest covers 5, with which the respectively formed backrest supports 3 can be fitted in order to complete the respective backrest 1b. Fig. 3 shows, by way of example, only one such backrest cushion 4 with a backrest cover 5. Depending on the shape and construction of the geometrically non-identical upper module components 3bi, it may happen that a specific backrest cushion 4 and / or a specific backrest cover 5 fits different upper module components 3bi if, for example, they only differ in terms of loudspeaker mounts Z2. If the shapes and constructions of the upper module components 3bi differ to a greater extent, for example in the upper back area, shoulder area, or head area, the backrest system 100 can also have different backrest cushions 4 and / or backrest covers 5 that are adapted to the shape of the upper module components 3bi.

[0019] With such a backrest system 100, according to the flow chart in Fig. 4 it is possible to manufacture a backrest 1b in a modular design as follows: In an initial query step STA, a specification V is first read or queried, which characterizes a backrest property that the backrest 1b to be manufactured is to have. The specification V or the backrest property refers to a comfort property or a design property of the backrest 1b, which can depend, for example, on the vehicle model and / or the customer's request and / or the like.

[0020] Subsequently, in a picking step STK, components are picked or prepared for the further production of the backrest 1b, whereby this preferably takes place in a JIT plant (just-in-time plant). During picking, a lower functional component 3a is taken from a large number of essentially identically constructed lower functional components 3a and prepared. Furthermore, an upper modular component 3bi is selected from a large number of differently or geometrically non-identically constructed upper modular components 3bi, with i=1,...N (N>1), and prepared. Which of the differently constructed upper modular components 3bi is selected, i.e. which "i", depends on the specification V. Furthermore, depending on the specification V, a backrest cushion 4, a backrest cover 5 and possibly accessories Z are prepared that match the respectively prepared components 3a, 3bi.

[0021] According to one embodiment, a connecting step STV is subsequently provided, in which the backrest support 3 is formed from the two provided components 3a, 3bi. With this modularly constructed backrest support 3, the previously read-in specifications V can be met. The backrest support 3 can be formed, for example, by connecting the two components 3a, 3bi to one another via several connections 7, for example via clip connections, snap-in connections, screw connections, or via another force-fitting and / or material-fitting and / or form-fitting connection type.

[0022] The plurality of connections 7 are each formed by a lower connecting part 7a, which is arranged in an upper region 10 of the respective lower functional component 3a, and an upper connecting part 7b, which is arranged in a lower region 11 of the respectively selected upper module component 3bi. The connecting parts 7a, 7b are not necessarily arranged on the lower end face or upper end face of the respective component 3a, 3bi, but can also be arranged in the upper or lower region 10, 11 of the respective component 3a, 3bi on the rear or front side such that both overlap or interact with each other in the assembled state, e.g., can engage with each other. Fig. In Figure 3, these connecting parts 7a, 7b are shown only in a highly schematic manner. The connecting parts 7a, 7b of the respective connection 7 interact with each other according to the respective connection type. Each of the N different upper module components 3bi has identical upper connecting parts 7b, so that they can each be connected in an identical manner to the lower functional component 3a in order to form the backrest support 3 according to the respective specification V.

[0023] In an assembly step STB, the components 3a, 3bi or the assembled backrest support 3 are equipped with the possibly provided accessories Z, the provided backrest cushion 4 and the provided backrest cover 5.

[0024] In an assembly step STM, the provided and assembled components 3a, 3bi or the assembled backrest support 3 are mounted on the backrest frame 2 to complete the backrest 1b, whereby the rear cover 6 is also mounted depending on the application.

[0025] The steps described can also be carried out in a different order in different embodiments. For example, the connecting step STV of the provided components 3a, 3bi after the picking step STK can be omitted and at least partial assembly of the provided components 3a, 3bi can take place individually. The at least partially assembled components 3a, 3bi can then be individually mounted on the backrest frame 2 in the assembly step STM. The backrest support 3 is therefore only formed during or after assembly on the backrest frame 2. In this embodiment, the components 3a, 3bi can also be held together via the connections 7, or the connection 7 can be omitted. The backrest support 3 made up of the two components 3a, 3bi that are not directly connected to one another is therefore held together via the backrest frame 2.After assembly, the assembly can then be continued, for example if an accessory Z is to be attached to both components 3a, 3bi, for example the suspension system.

[0026] With several of these backrest systems 100, different backrests 1b can be produced depending on the specification V, so that the respective manufacturer is able to easily produce a modular backrest set 200, which in Fig. 5 consists of two backrests 1 b1, 1b2. If a number N of two different upper module components 3b1, 3b2 are offered, two different backrests 1b1, 1b2 can be produced from them based on different specifications V, e.g. from different customers or for different vehicle classes, each according to the flow chart in Fig.4. For a larger number N, a correspondingly larger backrest set 200 comprising more than two backrests 1b can be provided. List of reference symbols 1 vehicle seat 1a seat part 1b Backrest 1b1 first backrest 1b2 second backrest 2 backrest frames 3a lower functional component 3bi i. upper module component 3b1 first upper module component 3b2 second upper module component 3b3 third upper module component 5 Backrest cover 6 Back cover 7 Connection 7a lower connection part 7b upper connection part 10 upper area 11 lower area 100 backrest system 200 backrest set i Index N number STA query step STB assembly step STK picking step STM assembly step STV connection step Z Accessory Z1 suspension system Z2 speaker recordings QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2008 038 851 A1

[0002] US 10,166,894 B2

[0003] US 10,166,895 B2

[0003]

Claims

[1] Backrest system (100) for the modular production of a backrest (1b) of a vehicle seat (1), at least comprising: - a backrest frame (2), preferably made of metal, and - a lower functional component (3a), preferably made of plastic, and a number (N) of at least two separate or independent upper module components (3bi, i=1,...,N), preferably made of plastic, wherein the upper module components (3bi) are geometrically non-identical to one another, wherein the lower functional component (3a) and each of the at least two geometrically non-identical upper module components (3bi), each individually, together can form a backrest support (3), so that the number (N) of geometrically non-identical backrest supports (3) can be formed from a combination of the lower functional component (3a) with the geometrically non-identical upper module components (3bi) of the backrest system (100), and wherein each of the respectively formable backrest supports (3) can be mounted on the backrest frame (2). [2] Backrest system (100) according to claim 1, characterized by that the backrest system (100) further comprises at least one backrest cushion (4) and / or at least one backrest cover (5) with which the respectively formed backrest support (3) can be equipped. [3] Backrest system (100) according to claim 2, characterized by that the backrest system (100) has the number (N) of geometrically non-identical backrest cushions (4) and / or geometrically non-identical backrest covers (5). [4] Backrest system (100) according to one of the preceding claims, characterized by that the backrest system (100) further comprises at least one accessory part (Z) with which the respectively formed backrest support (3) can be equipped. [5] Backrest system (100) according to one of the preceding claims, characterized by , that - the lower functional component (3a) of the backrest system (100) has at least one lower connection part (7a) in an upper region (10), and - each of the at least two geometrically non-identical upper module components (3bi) has at least one upper connecting part (7b) in a lower region (11), wherein the at least one lower connecting part (7a) on the lower functional component (3a) and the at least one upper connecting part (7b) on the respective upper module component (3bi) can be connected to one another to form a connection (7) between the lower functional component (3a) and the respective upper module component (3bi). [6] Backrest system (100) according to claim 5, characterized by that the at least one upper connection part (7b) on each of the upper module components (3bi) is identical. [7] Backrest system (100) according to one of the preceding claims, characterized bythat the lower functional component (3a) makes up at least two thirds and the respective upper module component (3bi) a maximum of one third and preferably not less than one fifth of the total clear height of the formed backrest support (3). [8] Backrest set (200), comprising at least: - a first backrest (1b1), which is preferably made from a backrest system (100) according to the preceding claims, preferably according to a first specification (V1) with at least --- a backrest support (3) which is formed from a lower functional component (3a) and a first upper module component (3b1), and --- a backrest frame (2) to which the formed backrest support (3) is mounted; and - a second backrest (1b2), which is preferably made from a backrest system (100) according to the preceding claims, preferably according to a second specification (V2), and which differs from the first backrest (1b1), with at least --- a backrest support (3) which is formed from a lower functional component (3a) and a second upper module component (3b2) which differs from the first upper module component (3b2), and --- a backrest frame (2) on which the formed backrest support (3) is mounted. [9] Method for producing a backrest (1b), preferably from a backrest system (100) according to claims 1 to 7, comprising at least the following steps: - Reading in or querying a specification (V) in a query step (STA); - picking or providing a lower functional component (3a) and an upper module component (3bi) from a number (N) of geometrically non-identical upper module components (3bi) in one picking step (STK), wherein the upper module component (3bi) is commissioned or provided depending on the read-in or queried specification (V), and wherein the lower functional component (3a) and the upper module component (3bi) together form a backrest support (3); - Mounting the lower functional component (3a) and the upper module component (3bi) and / or the formed backrest support (3) on a backrest frame (2) in one assembly step (STM); - equipping the formed backrest support (3) in one assembly step (STB); and - Finish the backrest (1b) in further steps. [10] Method according to claim 9, characterized bythat the assembly of the formed backrest support (3) takes place in an assembly step (STB) before the assembly step (STM). [11] Method according to claim 9 or 10, characterized by that the lower functional component (3a) and the selected upper module component (3bi) are connected to one another via a connection (7) in a connecting step (STV) before the assembly step (STM). [12] Vehicle seat (1) with a seat part (1a) and a backrest (1b), wherein the backrest (1b) is produced from a backrest system (100) according to claims 1 to 7, preferably according to a method according to one of claims 9 to 11.

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