Seat element for a vehicle seat and method for producing a corresponding seat element

Abstract

The present disclosure relates to a seat element for a vehicle seat and a corresponding method. The seat element comprises at least one support part (1) with a first side (11) and a second side (12) opposite the first side (11), and a one-piece, flat cushioning mat (2) with a first side (21) and a second side (22) opposite the first side (21), wherein the cushioning mat (2) is made of an elastic material comprising non-directionally arranged fibers. The first side (21) of the cushioning mat (2) is arranged at least in regions on the first side (11) of the support part (1) and is elastically folded around a first edge of the support part (1), such that the first side (21) of the cushioning mat (2) is also arranged at least in regions on the second side (12) of the support part (1) and is fixed in the elastically folded form.

Description

The present disclosure relates to a seat element for a vehicle seat and to a method for producing a corresponding seat element.Vehicle seats, in particular for motor vehicles and / or aircraft and / or trains, typically have a frame, a plurality of upholstery elements and a covering material. The cushioning elements serve in particular to provide a passenger with support and comfort. The pads are typically made of a foam, e.g., polyurethane foam or, e.g., injection molded polyethylene. Injection molding methods, however, have the disadvantage that complex molds with undercuts cannot be produced in one piece.Furthermore, foams can have, for example, a sensitive surface which can form cracks or damage when exposed to stress. Additionally or alternatively, foams may have the disadvantage that they tear around edges of the carrier part under bending stress, such that undercuts and edges cannot be folded over.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 a method for producing a corresponding seat element.This object is achieved by a seat element having the features of claim 1 and / or by a method according to an independent claim.The proposed seat element for a vehicle seat comprises at least one carrier part. The support part has a first side and a second side opposite the first side. The seat member further comprises a cushion mat. The upholstery mat can in particular be formed in one piece and can be configured flat. The upholstery mat has a first side and a second side opposite the first side. The upholstery mat can in particular comprise an elastic material or be made of an elastic material. The material may comprise non-directionally arranged fibers.The first side of the upholstery mat is arranged at least in regions on the first side of the carrier part and folded around a first edge of the carrier part in particular elastically, so that the first side of the upholstery mat is also arranged at least in regions on the second side of the carrier part. The upholstery mat is fixed in particular in the elastically folded form, for example by means of fastening elements.In the present case, "elastically folded" can be understood to mean that the upholstery mat is bent, wherein a bending stress of the upholstery mat resulting therefrom lies below the elastic limit of the material of the upholstery mat.By fixing in the elastically folded position, a load of the upholstery mat with a mechanical tension can be maintained. Upon removal of the fixation and thus of the mechanical tension, the cushioning mat can substantially resume its original shape, i.e. a shape that the cushioning mat had prior to the bending stress.The proposed seat element can have the advantage that the upholstery mat can be folded around edges of the carrier part, wherein undercuts can also be embraced by the upholstery mat.In one embodiment, the upholstery mat can comprise one or more fastening elements in regions arranged on the second side. The fastening element or the fastening elements can / can fix the upholstery mat in its elastically folded state. For example, an adhesive can be applied between the carrier part and the upholstery mat. Additionally or alternatively, clamps and / or hooks and / or eyes can be connected to the upholstery mat and / or to the carrier part. An additional fastening of the cushioning mat to the support part can be provided on the first side of the support part.In one embodiment, the fastening elements can engage in a form-fitting manner in order to hold the upholstery mat in its elastically folded state. For example, the cushion mat may include a first flap to be folded and a second flap to be folded. The flaps to be folded can be arranged and designed in such a way that, when the upholstery mat is arranged on the carrier part, they rest completely or at least partially on the second side of the carrier part. The first and the second flap can have edges which, in the state folded around the carrier part, are situated directly next to one another or at a certain distance. As a fastening element, a first edge of the first flap can have, for example, a shape which is formed complementarily to a shape of a second edge of the second flap. For example, the first edge can have one or more projections which can be arranged in one or more corresponding recesses, so that they form a positive fit. The shape of the projections and recesses can correspond, for example, to a puzzle piece shape. Additionally or alternatively, the first and / or the second edge can have, as a fastening element, mutually engaging hooks and / or hooks and associated eyes and / or mutually engaging rails.In one embodiment, one fastening element or several or all fastening elements can be formed integrally with the upholstery mat. The fastening elements can be made of the same material as the upholstery mat. This can simplify the production and / or logistics of the seat element. For example, no additional parts as fastening elements need to be connected to the upholstery mat in one production step. Instead, for example by means of thermoforming, the fastening elements can already be formed in the upholstery mat. This can save time, additional production steps, logistics complexity, in particular on account of fewer individual parts, and / or costs.In one embodiment, the upholstery mat can have a constant thickness, in particular in a manufacturing state. The cushion mat may be machined to give the cushion mat a specific shape. For example, the upholstery mat can be subjected to heat and / or pressure in a thermo tool in a mold. For example, the cushioning mat may be formed in a mold having a temperature of at least 140° C. and / or at least 150° C. and / or at least 160° C. For example, the cushioning mat can be formed in a forming tool with a temperature of at most 240° C. and / or at most 220° C. and / or at most 200° C. The upholstery mat can be plastically deformed at least in regions in the forming train, in particular have permanently assumed the shape after removal from the forming tool. In particular after the shaping, the upholstery mat can have local areas of different thickness.The upholstery mat can have at least two local regions with different densities. A region with a lower density can be plastically deformed.Regions with a lower density can be configured as folded edges. In particular, such regions of the upholstery mat can be arranged in the region of edges or undercuts or on edges of the carrier part. The upholstery mat can have regions of different sizes with different densities. Regions with a higher density than regions with a lower density can form support sections, for example.A density difference between the at least two local areas may be at least 5 kg / m3and / or at least 10 kg / m3and / or at least 15 kg / m3. A density difference between the at least two local regions may be at most 70 kg / m3and / or at most 50 kg / m3and / or at most 30 kg / m3. Higher density regions may be more easily compressible than lower density regions. The material of the upholstery mat can in particular not be a foam.The carrier part can be, in particular, a plastic injection molded part. The carrier part may comprise polyester-based plastic elastomers and / or polyamides and / or polyolefins and / or copolymers. The support part can be, for example, a support part of a seat region and / or a backrest and / or an armrest and / or a leg rest and / or a footrest of a motor vehicle seat.The fibers of the upholstery mat, which fibers are arranged in an in particular non-directional manner, can be made of polyester and / or of a polyester-based elastomer and / or of polyolefin or comprise one or more of these materials. The fibers may be made of a material containing a thermoplastic polymer. The fibers may, for example, comprise a material or consist of a material which contains at least one thermoplastic polymer.The fibers can be referred to as "endless" because their length can be much greater than their diameter. For example, the ratio between the length of the fibers and their diameter may be at least 100, preferably 500, and more preferably 1000. In addition, the diameter of the fibers can be between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm. The fibers can be present as a fiber entanglement. The fiber entanglement can be referred to as "three-dimensional", especially since the thickness of the obtained fiber entanglement is not negligible, since it is preferably significantly larger than the diameter of the fibers. More specifically, the thickness of the obtained fibril is at least 10 times, preferably at least 30 times, more preferably at least 50 times larger than the diameter of the fibers of the fibril.The fiber entanglement may consist of or comprise molten fibers, the fibers forming loops welded together. The fiber entanglement may have a bulk density of less than 30 kg / m3. Alternatively, the fibrous randomizer may have a bulk density of greater than or equal to 30 kg / m3, preferably greater than or equal to 35 kg / m3, more preferably greater than or equal to 45 kg / m3, and / or less than or equal to 70 kg / m3, preferably less than or equal to 55 kg / m3.Preferably, the space between the fibers of the fiber strand forming the padding is left open and filled only with air or other ambient gas. In other words, it may be advantageous not to fill the space between the fibers of the fiber entanglement with a liquid material in the form of a gel or a liquifiable solid, which is poured, for example, between the fibers. By keeping the space between the fibres free, a particularly breathable padding can be obtained, since the space between the fibres promotes the air circulation in the padding. In particular, such a cushioning mat can have a better breathability than a cushioning part, in particular made of polyurethane foam. Such a cushioning mat can also have the advantage that it absorbs significantly less moisture than a cushioning part made of polyurethane foam. The upholstery mat can have a substantially cuboidal shape. The fiber strand can have a thickness of more than or equal to 60 mm and / or less than or equal to 200 mm.The cushioning mat can be elastically folded around several edges of the carrier part. For this purpose, the upholstery mat can have a plurality of regions with one or more flap / s which is / are folded around the corresponding edge.The upholstery mat can have cuts, in particular in order to be foldable along the shape of the carrier part.In addition, the seat element may have a cover which is arranged on a side of the upholstery mat which is applied to the carrier part. The cover may comprise fabric and / or nonwoven and / or woven fabric and / or felt and / or leather and / or artificial leather.Further layers can be arranged between the cover and the upholstery mat and / or between the carrier part and the upholstery mat, for example in the form of a knitted spacer fabric.The seat element can be, in particular, a seat back, a seat cushion, a headrest, an armrest or a leg rest.The present disclosure further relates to a method for manufacturing a seat member as described above. The method typically comprises the following stepsproviding a cushioning mat according to the above description, wherein the cushioning mat is in particular made of an elastic material comprising non-directionally arranged fibers,providing a support member as described aboveplacing the upholstery mat on the support part in such a way that the first side of the upholstery mat is arranged at least in regions on the first side of the support part and is folded around a first edge of the support part, in particular elastically, so that the first side of the upholstery mat is also arranged at least in regions on the second side of the support part, in particular and fixed in the elastically folded form.According to one embodiment, the method of forming the cushion mat may include one or more of the steps of:extruding a material, in particular comprising at least one thermoplastic polymer, through an extrusion die comprising a plurality of die holes to form a curtain of molten fibers;forming a strand of molten fibers, the fibers forming loops welded together;cooling of the fiber strand.The curtain of molten fibres can be guided between two oppositely directed guide members. A fiber pile can be formed upstream of the two guide elements, so that a entanglement of fibers is formed, which form loops welded to one another.Before the upholstery mat is fastened to the support part arranged on the latter, the upholstery mat can be shaped and / or cut to size. In particular, the upholstery mat can be trimmed and / or shaped in a mold, in particular shaped by means of heat and / or pressure, in particular at temperatures and / or pressures described above.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 showFIGS. 1 ato 1 e show an exemplary embodiment of a vehicle seat seat cushion in various perspectives, FIGS. 2 ato 2 e show an exemplary embodiment of a vehicle seat backrest in various perspectives, FIG. 3 shows a schematic illustration of a vehicle seat backrest and an associated upholstery mat, FIG. 4 is a schematic illustration of an upper portion of an exemplary vehicle seat back with a cushion mat having fasteners, FIG. 5 is a schematic illustration of an upper portion of an exemplary vehicle seat back having a cushion mat having flaps and folding regions, FIG. 6 is a further schematic illustration of an upper portion of a vehicle seat backrest with a cushion mat having flaps, FIG. 7 is a schematic flow diagram visualizing an exemplary method of manufacturing a seat element.Features described with respect to an embodiment of a figure can be applied to an embodiment of another figure unless explicitly described in the opposite sense. Repetitive features are denoted by the same or similar reference numerals in the following description.FIG. 1 shows a schematically illustrated seat cushion 100 for a vehicle seat for a motor vehicle. In this case, FIG. 1 ashows the seat cushion 100 in a perspective view. FIG. 1 bshows the seat cushion 100 in a plan view. FIG. 1 cshows the seat cushion 100 in a view from below. FIG. 1 d shows a side view of the seat cushion 100. FIG. 1 eviscerates a section in the xz plane through the seat cushion 100. The seat cushion 100 comprises a support part 1 and a cushion mat 2. the support part 1 has a first side 11 and a second side 12. When the seat cushion 100 is mounted on a vehicle, the first side 11 corresponds to the side where a vehicle occupant sits down, while the second side 12 corresponds to a lower side facing the vehicle floor. The first side 11 is facing away from the observer in FIG. 1 a. The upholstery mat 2 has a first side 21 and an opposite second side 22. The first side 21 lies flat on the first side 11 of the carrier part 1. Furthermore, regions of the upholstery mat 2 project beyond the first side 11 of the carrier part and are folded around edges of the carrier part 1. In some areas, the first side 21 of the upholstery mat 2 is thus also located on the second side 12 of the support part 1. The upholstery mat 2 can be elastically folded around the edges of the carrier part and fixed in this position. The fixing can be effected, for example, by means of fastening means 4, which are described separately later. FIGS. 1 cand 1 edesignate regions 3 in which the cushioning mat 2 is folded around edges of the carrier part 1. In the sectional illustration of FIG. 1 e, it can be seen that the upholstery mat 3 surrounds undercuts of the carrier part 1 in this case. In FIG. 1 e, an upper tip of the triangle 31 marks a folding edge 23 of the upholstery mat 2, along which the upholstery mat 2 is folded. In FIG. 1 d, a further folding edge 23 is drawn, which extends between the triangles 31. In the region of the folded edge 23, the upholstery mat 2 can have a higher density than in a region surrounding the folded edge 23.FIG. 2 shows a schematically illustrated backrest 200 for a vehicle seat for a motor vehicle. In this case, FIG. 2 ashows the backrest 200 in a rear view. FIG. 2 bshows the backrest 200 in a perspective view obliquely from below. FIG. 2 cshows the backrest 200 in a sectional view in a section parallel to the xy plane from below. FIG. 2 d shows a side view of the backrest 200. FIG. 2 edisplays a section parallel to the yz plane through the backrest 200. The backrest 200 comprises a support part 1 and a cushioning mat 2. the support part 1 has a first side 11 and a second side 12. When the seat back 200 is installed in a vehicle, the first side 11 corresponds to the side facing a vehicle occupant, while the second side 12 corresponds to a rear side facing away from an occupant seated in the vehicle seat. The first side 11 is facing away from the observer in FIG. 2 a. The upholstery mat 2 has a first side 21 and an opposite second side 22. The first side 21 lies flat on the first side 11 of the carrier part 1. Furthermore, regions of the upholstery mat 2 project beyond the first side 11 of the carrier part and are folded around edges of the carrier part 1. In some areas, the first side 21 of the upholstery mat 2 is thus also located on the second side 12 of the support part 1. The upholstery mat 2 can be elastically folded around the edges of the carrier part and fixed in this position. The fixing can be effected, for example, by means of fastening means 4, which are described separately later. FIGS. 2 aand 2 edesignate regions 3 in which the cushioning mat 2 is folded around edges of the carrier part 1. In the sectional illustration of FIG. 2 e, it can be seen that the upholstery mat 3 engages around undercuts of the carrier part 1. The triangles 31 each mark a folding edge 23 of the upholstery mat 2, along which the upholstery mat 2 is folded around the carrier part 1. In the region of the folded edge 23, the upholstery mat 2 can have a higher density than in a region surrounding the folded edge 23.The upholstery mat 2 of the seat cushion according to FIG. 1 and the upholstery mat 2 of the backrest of FIG. 2 each have regions with different thicknesses. For example, the respective cushioning mat 2 can be preformed in a molding tool, so that it is adapted to the shape of the carrier element 1 and / or has support sections. The upholstery mat 2 can be glued to the carrier part 1 at least in areas.FIG. 3 shows a schematic illustration of a vehicle seat backrest in a perspective view. The backrest 300 has a support part 1 and a cushioning mat 2. The upholstery mat 2 is arranged on the support part 1, wherein a first side 21 of the upholstery mat 2 is arranged on a first side 11 and a second side 12 of the support part 1 opposite the first side 11. For this purpose, the upholstery mat 2 has flaps 24 which are each folded around an edge of the carrier part 1. In particular, the upholstery mat 2 can have four flaps, wherein a first flap 24 is folded around the carrier part in the upper region of the backrest, two opposite, lateral flaps 24 are folded around lateral edges of the carrier part 1 and a lower flap 24 is folded around a lower edge of the carrier part 1. In FIG. 3 b, the upholstery mat 2 is shown in an unfolded state. The upholstery mat 2 can be transported, for example, in a folded-apart state, which can facilitate logistics.FIG. 4 shows an upper portion of a backrest 400 of a motor vehicle seat, wherein the backrest 400 has a carrier part 1 and a cushioning mat 2 arranged thereon. The arrangement of the upholstery mat 2 on the support part 1 corresponds substantially to the arrangement of FIGS. 3 and 2. an exemplary fastening is visualized in FIG. 4. The flaps 24 each have at least one outer edge, the shape of which corresponds to the shape of the respectively adjacent outer edge of the adjacent flap 24. In this case, the outer edges have, in particular, projections 241 with undercuts which engage in corresponding receiving recesses 242. A positive connection can thus be formed between two adjacent flaps. The flaps 24 can be elastically folded under tension around the edges of the carrier part 1 and can be held in the folded form by the form fit between the projections 41 and receiving recesses 42. The projections 41 and receiving recesses 42 can be parts of fastening means 4. The fastening means 4, for example in the form of the projections 41 and receiving recesses 42, can be separate parts which are fastened to the flaps 24 or, preferably, are formed integrally with the flaps 24 and from the same material as the flaps 24. Alternative fastening means 4 are, for example, eyes and / or hooks and / or rails and / or clamps.FIGS. 5 and 6 each show an upper portion of a backrest 500 or 600 of a motor vehicle seat, wherein the backrest 500 or 600 each has a carrier part 1 and a cushioning mat 2 arranged thereon. The arrangement of the upholstery mat 2 on the support part 1 corresponds substantially to the arrangement of FIGS. 2, 3 and 4. In FIG. 5, folding regions are shown, which in particular have a smaller thickness than the surrounding regions of the flap 24. Along these folding regions 3, the flaps 24 are folded around the carrier part 1. The folding direction is again illustrated in FIG. 6 by the arrows.The upholstery mat 2 is formed by a fiber entanglement. The upholstery mat 2 comprises a three-dimensional ("3D") entanglement of continuous fibers. The ratio between the length of the fibers and their diameter is at least 100, preferably 500, and more preferably 1000. The diameter of the fibers is between 0.3 mm and 1.5 mm. The fiber entanglement is referred to as "three-dimensional" because the thickness of the obtained fiber entanglement is not negligible because it is preferably significantly larger than the diameter of the fibers. More specifically, the thickness of the obtained fiber strand is at least 50 times larger than the diameter of the fibers of the fiber strand. The fibers here consist, for example, of a material which contains at least one thermoplastic polymer. For example, the fibers are made of a material containing at least 95 wt% polyethylene terephthalate (or PET). For example, the fibers are made of a material comprising:95% to 99% by weight of a first polymer from the polyester family, such as PET; and1 wt % to 5 wt % of a second polymer from the family of polyesters, such as polytrimethylene terephthalate (or PTT) or polybutylene terephthalate (or PBT). The material may be known in particular under the trade name "Auraloop".The seat element can also comprise, in addition to the upholstery mat 2, a covering which is intended to cover the upholstery mat 2. This cover may be made of a single piece or of several pieces sewn together. The latter solution is preferred in order to adapt the shape of the trim cover as closely as possible to the geometry of the upholstery 2. Thus, the wrinkles of the trim covering the cushion mat 2 can be avoided as much as possible.The cover can be fastened to the upholstery mat 2 and / or the support part 1 by any means accessible to the skilled person.FIG. 7 visualizes an exemplary manufacturing method for manufacturing a seat element according to the preceding figures.First, in a first step, shown in FIG. 7 a, the fiber mat 2 is produced as a mat band and shortened to form a fiber mat section. In this method step, a preform of the fiber mat can already be shaped, for example by rolling. In a subsequent method step 2, shown in FIG. 7 b, the fiber mat 2 is placed in a mold and heated there, for example, in a mold and / or pressurized. The fiber mat 2 can be further shaped in this step, in particular plastically deformed, and permanently assume the shape predefined by a tool shape. For example, support portions and portions with increased density may be formed. The fiber mat can additionally or alternatively be cut to size. After removing the fiber mat 2 from the forming tool, the fiber mat is in a formed, unfolded state and can be packed and transported. The fiber mat 2 can be applied to a carrier part 1 in a further step (shown in FIG. 7 c ). In particular, the fiber mat 2 can be folded around edges, in particular also around undercuts, of the carrier part 1, as has already been described above with reference to the preceding figures. The fibre mat 2 can be fixed in the folded state by means of fastening means 4 of the type described above. Subsequently, a trim may be applied to the upholstery mat.

Claims

Seat element for a vehicle seat, comprising - at least one support part (1) having a first side (11) and a second side (12) opposite the first side (11), and - a planar cushioning mat (2) formed in one piece and having a first side (21) and a second side (22) opposite the first side (21), wherein the cushioning mat (2) is produced from an elastic material comprising fibres arranged in an undirected manner, characterized in that the first side (21) of the cushioning mat (2) is arranged at least in regions on the first side (11) of the support part (1) and is elastically folded around a first edge of the support part (1), such that the first side (21) of the cushioning mat (2) is also arranged at least in regions on the second side (12) of the support part (1) and is fixed in the elastically folded form.Seat element according to claim 1, wherein the upholstery mat (2), in particular in regions arranged on the second side (12) of the carrier part, comprises fastening elements (4) which fix the upholstery mat (2) in its elastically folded state.Seat element according to the preceding claim, wherein the fastening elements (4) engage in a form-fit manner in order to hold the upholstery mat (2) in its elastically folded state.Seat element according to one of the two preceding claims, wherein the fastening elements (4) are formed integrally with the upholstery mat (2).Seat element according to one of the preceding claims, wherein the upholstery mat (2) has at least two local areas with different densities.Seat element according to any one of the preceding claims, wherein the non-directionally arranged fibres are made of polyester and / or of a polyester-based elastomer and / or of polyolefin or comprise one or more of these materials.Seat element according to any one of the preceding claims, wherein a ratio between the length of the fibres and their diameter is at least 100, preferably 500 and more preferably 1000, and / or wherein the diameter of the fibres is between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm.Seat element according to one of the preceding claims, wherein the upholstery mat (2) is elastically folded around a plurality of edges of the carrier element (1).Seat element according to one of the preceding claims, wherein the upholstery mat (2) has incisions.Method for producing a seat element according to one of the preceding claims, comprising the steps of - providing a cushioning mat (2) produced from an elastic material comprising fibres arranged in an undirected manner - providing a carrier element (1) - placing the cushioning mat (2) on the carrier part (1) in such a way that the first side of the cushioning mat (2) is arranged at least in regions on the first side (11) of the carrier part (1) and is elastically folded around a first edge of the carrier part (1), such that the first side of the cushioning mat (2) is likewise arranged at least in regions on the second side (12) of the carrier part (1) and is fixed in the elastically folded form.

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