Seat element, injection mold for the corresponding seat element, and method for manufacturing the seat element

Abstract

The present disclosure relates to a seat element for a vehicle seat, an injection mold for a support element of such a seat element, and a method for manufacturing the seat element. The seat element comprises a support element with a first surface and a foam pad arranged on the first surface of the support element. The support element has a plurality of projections extending into the foam pad in at least one fixing area. The support element is a plastic injection-molded part.

Description

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.In the manufacture of padded seat elements, a foam pad is typically arranged on a support element. The foam pad is then provided with a cover which is fastened to the support element. In this case, shear forces can occur between the foam cushion and the carrier element when the cover is pulled on, which leads to the cushion slipping relative to the carrier. Since it is possible to ensure compliance with a defined arrangement of the foam filter on the carrier element from a safety and also an aesthetic point of view, the foam cushion in the prior art is usually glued to the carrier element or is fastened to the carrier element by means of separate fastening means, for example clamps.Accordingly, additional process steps must be provided in the production of the seat element, which steps involve the application of adhesives or the attachment of fastening means.The object of the present invention is therefore to propose a seat element which addresses and avoids or at least reduces these disadvantages. Furthermore, the object of the present invention can be to propose an injection mold which enables the production of a correspondingly improved seat element and an improved production method of a corresponding seat element.The proposed seat element for a motor vehicle seat comprisesa support element having a first surface; anda foam pad disposed on the first surface of the support member.The carrier element has a plurality of projections projecting into the foam cushion in at least one fixing region. The carrier element is a plastic part. The plastic part can be, in particular, a plastic injection molded part or a plastic part produced by means of 3D printing (additive manufacturing). Plastic parts can have the advantage that almost any shapes and wall thicknesses can be produced. This can be an advantage in particular over sheet metal parts. Furthermore, plastic parts, in particular injection-molded plastic parts, can have a high productivity and can be integrated comparatively well in automated production processes. A plastic injection molded article can be manufactured consistent with an injection mold, and the manufacturing cost per one piece can be suppressed particularly in mass production.The foam pad may typically be compressible. When the foam pad rests on the support member, the plurality of protrusions may be surrounded by the foam pad. When applying, for example laminating on, a covering with the foam cushion, forces typically also act in addition to shear forces between the foam cushion and the carrier element, which forces press the foam cushion onto the carrier element. The foam cushion can be compressed more in the region of the projections than in regions in which no projections are provided. The projections can form a positive fit with the foam cushion. Thus, the foam cushion can be prevented from slipping with respect to the carrier element or slipping can be at least reduced.In one embodiment, the carrier element can be a plastic injection molded part or a plastic part manufactured by 3D printing. The carrier element can be made of a thermoplastic, in particular of polypropylene (PP), acrylonitrile butadiene styrene (ABS), polyamide (PA), polypropylene (PP), polyvinyl chloride (PVC) or polyethylene (PE), and / or of a thermosetting plastic, in particular glass fiber plastic (GRP), carbon fiber reinforced plastic (CFRP) or fiber-plastic composite material with natural fibers. The carrier element can comprise one or more of these substances.In one embodiment, the projections can be conical and / or designed as a truncated cone and / or as a pyramid and / or as a truncated pyramid. The projections can also have combined shapes, for example a cuboidal basic block and tips arranged thereon, for example in the form of cones. Sharp projections can have the advantage of better penetrating into the foam cushion and fixing this already under low compressive load. Truncated shapes, on the other hand, can be advantageous if the foam cushion is sensitive and / or has a sensitive surface. Truncated molds can be used to avoid cracks or damage.The projections can in particular point in the direction of the foam cushion. In particular, a respective longitudinal axis of the projections can run substantially orthogonally to a surface of the carrier element from which the respective projection protrudes. Alternatively, a longitudinal axis of the projections can be oriented at an angle with respect to the emerging surface, for example such that the projections have the shape of an oblique cone and / or oblique truncated cone and / or an oblique pyramid and / or an oblique truncated pyramid. For example, a longitudinal axis of the projections can point in a direction which counteracts a shear force which acts during the application, in particular laminating-on, of a reference.For this purpose, the carrier element can have, for example, more than one fixing region in which a plurality of projections is arranged in each case. The projections in one of the fixing regions can thereby point in a different direction than the projections in a further fixing region. In this case, the projections of the different fixing regions can each be aligned to oppose a shear force.A plurality of fixing portions may be separated from each other by surfaces having no such protrusions. A first fixing region can additionally or alternatively lie next to a further fixing region, wherein the two fixing regions lying next to one another can have projections aligned differently. Some or all of the plurality of fixing portions may be separated from each other by portions having no protrusions. One or more of the fixing regions or all of the fixing regions can / can be arranged in an edge region of the seat element. The seat member may include a plurality of fixing portions in which the protrusions are each arranged in a piled pattern.Within a fixing region, projections of different types and shapes can be arranged. Projections which are closer to an edge of the carrier element than other projections can be larger and / or more pointed or vice versa. Protrusions of larger and / or more pointed design in the edge region can have the advantage of enabling better adhesion of the foam cushion in the edge regions. On the other hand, smaller and / or less pointed projections in the edge region can reduce cracks in the edge region of the foam cushion. It can be provided that an area density of projections is higher in an edge region of the seat element than in regions which are spaced further from the edge than the edge region. An area density of protrusions may increase towards the edge of the seat element.The protrusions may be arranged in one or more ordered patterns. For example, several rows of protrusions can be arranged one below the other. Additionally or alternatively, rows of protrusions may be offset from each other. The projections can have uniform distances from the adjacent projections or at least partially different distances. The protrusions may be arranged and / or aligned in a chaotic pattern.An area density of protrusions may vary in a fixing region. It is also possible to provide a plurality of fixing regions with identical or different surface densities on projections. The areal density in a fixing region can have a gradual transition. In particular, a surface density may increase in the direction of an edge region of the carrier element. This can improve adhesion of the foam pad in the edge region and facilitate laminating of a cover.The projections can be formed in particular integrally with the carrier element. The projections can thus already be formed into the carrier element during the injection molding of the carrier element, in particular by providing recesses in a cavity of the injection mold for the carrier element. The carrier elements can thus be integral components of the carrier element. This can simplify production of the support member and reduce production steps and production costs. If the plastic part is produced by means of 3D printing, the projections can be integrally formed during 3D printing, in particular can be formed during the layer-wise and / or droplet-wise additive construction of the carrier part.In one embodiment, the foam pad may comprise polyurethane foam (PU) and / or fibers, for example fibers comprising polyester (PET).The foam cushion can have a thickness that varies over the support element. The fixing region can be arranged in a region of smaller thickness of the foam cushion. In particular, regions of the foam cushion with a small thickness can typically be exposed to the risk of slipping. Projections or more projections can therefore be arranged in these regions. The fixing region can be arranged in one or more edge regions of the seat element.In one embodiment, the seat member may include a trim cover. The cover can be or comprise, for example, a textile fabric and / or leather and / or artificial leather. The cover can cover the foam cushion at least in regions on a side of the foam cushion facing away from the carrier element. The foam cushion can be connected to the carrier element. Additionally or alternatively, the cover can be connected to the foam cushion, for example by means of laminating.In one embodiment, the seat element may have a fastening profile. The fastening means can fix the cover to the carrier element. The fastening means can have the form of a grip profile. The fastening profile can be connected to the cover, for example sewn to it. The fastening means can encompass an edge of the carrier element. The fastening means can reduce or prevent the cover from slipping with respect to the carrier element. The fastening means can form an aesthetic transition between the cover and the carrier element and prevent the foam cushion from being visible in a vehicle interior when the seat element is installed in the vehicle interior.The seat element can be designed as a cushion element of a vehicle seat, in particular as a backrest of a vehicle seat, as a seat pan of a vehicle seat, as a headrest of a vehicle seat and / or as an armrest of a vehicle seat or as another cushion element of a vehicle seat.The present disclosure further relates to an injection mold for producing a carrier element of a seat element according to the preceding description. The injection mold has two mold halves and a cavity formed between the mold halves. The cavity forms a negative shape of a carrier element for a seat pan of a motor vehicle seat or a negative shape of a carrier element for a backrest of a motor vehicle seat. The negative mold has a region with a plurality of recesses. The recesses can be conical and / or as truncated cone and / or as pyramid and / or as truncated pyramid.The recesses can also have combined shapes, for example a cuboidal basic block and tips arranged thereon, for example in the form of cones. Sharp recesses can have the advantage that a carrier element can be produced by means of the injection mold, the projections of which better penetrate into the foam cushion and fix the foam cushion even under low pressure loading. Truncated shapes, on the other hand, can be advantageous if the foam cushion is sensitive and / or has a sensitive surface. In order to avoid cracks or damage, truncated shapes of the recesses can be provided.A respective longitudinal axis of the recesses can be substantially orthogonal to a surface delimiting the cavity, to which the recess is recessed with respect to. Alternatively, a longitudinal axis of the recesses can be oriented at an angle with respect to the emerging surface, for example such that the recesses have the shape of an oblique cone and / or oblique truncated cone and / or an oblique pyramid and / or an oblique truncated pyramid.For this purpose, the cavity can have, for example, more than one region in which a plurality of recesses is arranged in each case. The V recesses in one of the regions can thereby point in a different direction than the recesses in a further region.A plurality of regions with recesses may be separated from each other by surfaces which do not have such recesses. A first region with recesses can additionally or alternatively be located next to a further region with recesses, wherein the two adjacent regions have differently oriented recesses.Within a region with recesses, recesses of different types and shapes can be arranged. In this case, recesses which are closer to an edge of the carrier element than other recesses can be formed larger and / or more pointed or vice versa. Larger and / or more pointed recesses in the edge region can have the advantage of enabling better adhesion of a carrier element produced by means of the proposed injection mold to a foam cushion arranged thereon in edge regions. On the other hand, smaller and / or less pointed recesses in the edge region can reduce or even avoid cracks in the edge region of a foam cushion if the foam cushion is arranged on a carrier element produced by means of the correspondingly configured injection mold.The recesses may be arranged in one or more ordered patterns. For example, a plurality of rows of recesses can be arranged one below the other. Additionally or alternatively, rows of recesses can be arranged offset with respect to one another. The recesses can have uniform distances from the adjacent recesses or at least partially different distances. The recesses may be arranged and / or aligned in a chaotic pattern.An area density of recesses may vary in a region with recesses. It is also possible to provide a plurality of regions with recesses having identical or different surface densities of recesses. The surface density in a region with recesses can have a gradual transition. In particular, an area density may increase in the direction of an edge region of the cavity. This can improve adhesion of a foam cushion to a carrier element produced by means of the proposed injection mold in the edge region and facilitate laminating of a trim on the foam cushion.The present disclosure further relates to a method for producing a seat element according to one of the preceding claims. The method comprises the following stepsproviding an injection mold with an injection mold, wherein the injection mold is formed in particular according to the above-described injection mold,closing the injection mold,injecting a liquid plastic material into the injection mold,curing the plastic material to form a carrier element for a seat element, the carrier element comprising at least one fixing region having a plurality of projections projecting into the foam cushion,opening the injection mold and ejecting the carrier element.In a further step, a foam cushion can be arranged on the carrier element, wherein the foam cushion at least partially covers the fixing region of the carrier element. In a further step, a cover can be arranged on the foam cushion. The trim cover can be fastened to the carrier element and / or to the foam cushion. The covering can be laminated onto the foam cushion. The foam pad is held in place by the projections projecting into the foam pad. Slipping of the foam cushion relative to the carrier element is reduced or even avoided.Further advantages and / or features will be explained in more detail on the basis of the following, non-limiting description of exemplary embodiments and with reference to the attached drawings.They show FIG. 1 is a sectional view through a schematically illustrated detail of a seat element, FIGS. 2 aand 2 b show in each case a sectional view of schematically illustrated, exemplary projections, FIG. 3 shows four exemplary sections of a plan view of a fixing region of a carrier part, FIG. 4 shows a sectional view through a schematically illustrated detail of a further seat element, FIG. 5 shows a sectional view through a schematically illustrated detail of a further seat element, FIG. 6 shows a schematic, perspective view of an exemplary carrier element in the form of a seat pan, FIG. 7 shows a schematic side view of the seat pan according to FIG. 6, FIG. 8 is an enlarged detail of FIG. 6, FIG. 9 shows an enlarged detail of FIG. 8, FIG. 10 shows a schematic, perspective view of an exemplary carrier element in the form of a seat pan, FIG. 11 shows an enlarged detail of FIG. 10 in a view rotated with respect to FIG. 6, FIG. 12 shows an enlarged detail of FIG. 10 in a view rotated with respect to FIGS. 10 and 11, FIG. 13 shows a sectional view through a schematically illustrated injection mold for producing a carrier part according to one of the preceding figures, FIG. 14 shows a sectional view of a schematic carrier part, produced with the injection mold of FIG. 13.Recurring features are provided with the same reference numerals in the following description of the figures.FIG. 1 shows a sectional view of a seat element 1 according to the invention in schematic illustration. The seat element comprises a carrier element 2, which is designed as a plastic injection molded part. In other examples, the support part may be manufactured by 3D printing. In the present example, the carrier element 2 is made of PP. In a first fixing region I, the carrier element 2 has projections 21, the longitudinal axes of which each extend substantially orthogonally to a carrier element surface 22. The projections 21 are an integral component of the carrier element 2. The projections 21 project into the foam cushion 3. In the present example, the foam pad is made of a PU foam. A cover 4, in the present case in the form of a textile fabric, is arranged on the foam cushion 3 and folded over around an edge of the carrier part 2. For this purpose, a fastening means 5 is sewn to the cover 4. The fastening means 5 engages around an edge of the carrier element 2, and when the covering 4 is applied, a clamping force acts in the direction of the arrow 6, and the foam cushion 3 is prevented from slipping relative to the carrier element 2 in the direction of the clamping force by the projections 21 penetrating into the foam cushion. The projections shown here are designed conically. In other embodiments, the protrusions may have a different shape and orientation. FIGS. 2 aand 2 b show exemplary embodiments of the projections 21 in a schematic sectional view. The carrier element of FIG. 1 or the carrier element of the subsequent figures can each have projections according to FIGS. 2 aand / or 2 b.The protrusion 211 has a conical shape. The protrusion 212 has a pyramidal shape, and the pyramid has a rectangle as a base. The projection 213 and the projection 214 have a shape of a truncated cone. The projection 215 has the shape of a truncated cone with a cone placed on it. The projection 216 has the shape of a cuboid with a cone placed on it. The projection 217 is in the form of a pyramid having a square base.The longitudinal axes L of the projections 211, 212, 214, 215, 216, 217 run orthogonally to the surface 22. The oblique extension may be advantageous in order to form barbs.The fixing region I of FIG. 1 can have projections of different degrees. Some or all of the protrusions 21 may have different shapes and / or different heights and / or different orientations. Alternatively, the projections 21 can all be of the same design.The protrusions 21 can be arranged in an ordered or disordered manner in the fixing region I. FIG. 3 shows exemplary arrangements of protrusions 21, The examples shown (or other arrangements which are not shown) can each be used in the carrier part of FIG. 1 and / or in the carrier part of the subsequent figures. FIG. 3 ashows a detail of a top view of a fixing region I of a carrier part 2. projections 21, of which only some are provided with reference numerals for the sake of clarity, are arranged in rows one below the other in example a. In this case, the successive rows of projections 21 are arranged offset with respect to one another. In example B, the rows are spaced further apart than in example a. In addition, the projections are aligned with one another. In Example c, the protrusions 21 are arranged closer to each other than Examples a and b. An area density of protrusions is increased compared to Examples a and b. In Example b, eight projections 21 are arranged on the same surface, while in Example c, 18 projections are arranged. The projections 21 of Example b are arranged in ordered rows, the projections of successive rows being aligned with each other. Example d corresponds to example c, wherein successive rows of protrusions 21 are arranged offset from one another. The seat element 1 can have a plurality of fixing regions. The fixing regions can all have an arrangement of projections, for example according to example c, or a plurality of different arrangements, for example a fixing region according to example a, another fixing region according to example d and a further fixing region according to example b.FIG. 4 shows a further example of a seat element 1. the seat element 1 of FIG. 4 corresponds substantially to that of FIG. 1, wherein the carrier element has an angled edge which partially surrounds the fastening means 5. The protrusions 21 are arranged in the fixing region I. The fixing region I lies on the angled edge. The tension force of the reference acts in the direction of the arrow 6, and therefore the projections 21 are formed asymmetrically and have, in the sectional view, an edge 21' angled with respect to the surface 22 and an orthogonal edge 21". Thus, a slipping of the foam cushion 3 can be prevented or at least reduced by the clamping force.FIG. 5 shows a further example of a seat element 1. the seat element 1 of FIG. 5 corresponds substantially to that of FIG. 4, wherein the carrier element has a further angled edge and the fastening means 5 partially surrounds this further angled edge. The protrusions 21 are arranged in the fixing region I. The fixing region I lies on the first angled edge, as in the example of FIG. 4. the clamping force of the reference acts in the direction of the arrow 6.FIG. 6 shows an exemplary embodiment of a carrier element 2 for a seat element 1 in a perspective view. FIG. 7 shows a side view of the carrier element 2 of FIG. 6, and FIGS. 8 and 9 each show portions of FIG. 6 in an enlarged illustration. The carrier element 2 of FIG. 6 can be an example of the carrier element 2 of the schematic FIGS. 1, 4 or 5. The carrier element 2 is a plastic injection molded part in the form of a seat pan for a motor vehicle seat. In a fixing region I, the carrier element 2 has a multiplicity of projections 21, of which only two are provided with reference numerals. The projections 21 are arranged in rows one above the other. A first row 23 and a second row 24 are arranged aligned one above the other, i.e. a surface center of a base surface of the projection of the row 23 lies on the same virtual straight line running parallel to the z-axis as a surface center of a base surface of the projection 21 of the row 24. Furthermore, the fixing region has rows 25, 26 and 27 on projections 21 which are arranged offset from one another, i.e. a surface center of a base surface of the projection of the row 25 does not lie on the same virtual straight line running parallel to the z-axis as a surface center of a base surface of the projection 21 of the row 26. The protrusions 21 of this example have a rectangular base and form an oblique pyramid. A side surface 21"' of the pyramid is oriented orthogonally to the surface 22 and a side surface 21 IV is oriented at an angle with respect to the surface 22. The orthogonally oriented surface 21''' points in the direction of the edge of the carrier element closest to the projection 21.FIG. 10 shows an exemplary embodiment of a carrier element 2 for a seat element 1 in a perspective view. FIG. 11 shows a detail of the carrier element 2 of FIG. 10 rotated and enlarged with respect to FIG. 10, and FIG. 12 shows a further detail of FIG. 10 in an enlarged illustration rotated with respect to FIG. 10. The support element 2 of FIG. 10 may be an example of the support element 2 of the schematic FIGS. 1, 4 or 5. The carrier element 2 is a plastic injection molded part in the form of a seat pan for a motor vehicle seat. In a fixing region I, the carrier element 2 has a multiplicity of projections 21, of which only two are provided with reference numerals. The projections 21 are arranged in order in three rows one above the other. A first row 23, a second row 24 and a third row 25 are arranged aligned one above the other, i.e. a surface center of a base surface of the projection of the row 23 lies on the same virtual straight line running parallel to the z-axis as a surface center of a base surface of the projection 21 of the rows 24 and 25. In the example shown in FIGS. 10 to 12, the projections 21 are of similar design. The protrusions 21 of this example have a rectangular base and form a symmetrical pyramid as shown in FIG. 11, for example.FIG. 13 shows a schematic injection mold 10 in a sectional view. The injection mold comprises a first half 101 and a second half 102. The injection mold is made of metal, presently aluminum. The injection mold can alternatively be made of silicone or tool steel, for example. Between the halves a cavity 103 is provided into which injection-molded material, in particular plastic, can be injected. The cavity has a first region I' in which a plurality of recesses 104 are arranged and a second region II' in which a plurality of recesses 105 are arranged. The recesses 104 have the shape of a cuboid with a cone placed on. In other exemplary embodiments, the injection mold can have different recesses. For example, the recesses may have shapes corresponding to the negative shape of the protrusions 21 described in FIGS. 2 aand 2 b. By injecting an injection molding material, a carrier part 2 can be produced by means of the injection mold shown. An exemplary support member is shown schematically in FIG. 14. The injection mold can be designed to produce carrier parts according to the preceding figures. The carrier part of FIG. 14 has a first fixing region I and a second fixing region II, which correspond in each case to the regions I' and II' of the injection mold. The projections 21 in the first fixing region have the shape of a cuboid with a cone placed on. The protrusions 21 of the second fixing portion II have a shape of a cone.

Claims

Seat element (1) for a motor vehicle seat, comprising - a carrier element (2) having a first surface, - a foam cushion (3) arranged on the first surface of the carrier element (2), wherein the carrier element (2) has a plurality of projections (21) protruding into the foam cushion (3) in at least one fixing region (I), wherein the carrier element (2) is a plastic part.Seat element (1) according to the preceding claim, characterized in that the carrier element (2) is a plastic injection-molded part or a plastic part manufactured by 3D printing made of a thermoplastic, in particular polypropylene (PP), acrylonitrile butadiene styrene (ABS), polyamide (PA), polypropylene (PP), polyvinyl chloride (PVC) or polyethylene (PE), and / or made of a thermosetting plastic, in particular a fiber-plastic composite material, e.g. glass fiber plastic (GFK) or carbon fiber-reinforced plastic (CFRP) and / or a fiber-plastic composite material with natural fibers, or comprises one or more of these substances.Seat element (1) according to one of the preceding claims, characterized in that the projections (21) are designed conically and / or as a truncated cone and / or as a pyramid and / or as a truncated pyramid.Seat element (1) according to one of the preceding claims, characterized in that the projections (21) are formed integrally with the carrier element (2).Seat element according to one of the preceding claims, characterized in that the fixing region is arranged in an edge region of the seat element and / or in that the seat element has a plurality of fixing regions in which the projections (21) are each arranged in a clustered pattern, in particular wherein some or all of the plurality of fixing regions are separated from one another by regions without projections.Seat element according to one of the preceding claims, characterized in that the foam cushion (3) has a varying thickness via the carrier element (2), and the fixing region (I) is arranged in a region of smaller thickness of the foam cushion (3), and / or in that the fixing region (I) is arranged in one or more edge regions of the seat element (1).Seat element (1) according to one of the preceding claims, characterized bya covering (4) which covers the foam cushion (3) at least in regions on a side of the foam cushion (3) facing away from the carrier element (2) and is connected to the carrier element (2).Seat element (1) according to the preceding claim, characterized bya fastening profile (5), in particular in the form of a embracing profile, wherein the fastening profile (5) is connected to the cover (4), in particular is sewn thereto, and fixes the cover (4) to the carrier element (2), in particular by embracing an edge of the carrier element (2).Seat element (1) according to one of the preceding claims, wherein the seat element (1) is designed as a cushion element of a vehicle seat, in particular as a backrest of a vehicle seat, as a seat trough of a vehicle seat, as a headrest of a vehicle seat or as an armrest of a vehicle seat.Injection mould (100) for producing a carrier element (2) of a seat element (1) according to one of the preceding claims, having two mould halves (101, 102) and a cavity (103) formed between the mould halves, wherein the cavity (103) forms a negative mould of a carrier element (2) for a seat pan or for a backrest of a motor vehicle seat, characterized in that the negative mould has a region (I', II') with a multiplicity of recesses (104, 105) formed conically and / or as a truncated cone and / or as a pyramid and / or as a truncated pyramid.Method for producing a seat element (1) according to Claims 1 - 9, comprising the following steps - providing an injection mould with an injection mould (100) according to Claim 10 - closing the injection mould (100) - injecting a liquid plastics material into the injection mould (100) - curing the plastics material to form a carrier element (2) for a seat element, the carrier element (2) comprising at least one fixing region (I) having a plurality of projections (21) projecting into the foam cushion (3) - opening the injection mould (100) and ejecting the carrier element (2).Method for producing a seat element (1) according to one of Claims 1 to 9, wherein the carrier element (2) is produced in a 3D printing process and the projections (21) are integrally formed on the carrier element in the 3D printing process.

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