RECYCLABLE FOAM COMPOSITE

Abstract

A composite component comprises an outer skin formed from a thermoplastic polyurethane (TPU) elastomer in a thermoforming mold into the desired shape, a mesh reinforcement layer formed from a mixture of TPU and polyester fibers and applied to an inner surface of the outer skin, and padding formed from a TPU foam and applied to the inner surface of the outer skin, comprising a liquid TPU foam poured into the desired shape of the outer skin, a plurality of gas-filled TPU beads fused together at contact points of the outer surfaces of adjacent beads, or a TPU foam molded into a desired shape, or TPU foam cut into the desired shape from a bulk piece of TPU foam.

Description

INTRODUCTION

[0001] The present invention relates to a seat cushion for a vehicle seat. The present invention generally relates to a composite component made of thermoplastic polyurethane (TPU), wherein all subcomponents of the composite component consist of TPU and are therefore suitable for uniform recycling in a closed loop with fully recoverable content.

[0002] German patent application DE 10 2008 050 183 A1 discloses a seat cushion for a vehicle seat according to the preamble of claim 1. German patent applications WO 1994 / 020 568 A1, DE 203 21 141 U1, the internet sources “TPU materials for textile applications”, https: / / www.kgk-rubberpoint.de / roh-zusatzstoffe / tpu-materialien-fuer-textile-anwendungen-1.html, and “Foam in Place Method”, https: / / web.archive.org / web / 20230922082216 / https: / / www.toyotaboshoku.com / global / development / production / foam_in_place / , and the excerpt from the product catalog “Evonik Product Story - In the car seat on the journey to monomaterials” show related seat cushions or materials and methods for manufacturing such a cushion. BACKGROUND OF THE INVENTION

[0003] Modern vehicle seats generally consist of an outer skin (cover) made of vinyl, fabric, leather, etc., and a foam cushion made of a thermosetting polyurethane that is not suitable for closed-loop recycling. Therefore, for recycling, such a seat must be mechanically separated into the outer skin and the non-homologous thermosetting polyurethane (foam cushion).

[0004] Therefore, one object of the invention is to provide a seat cushion with a composite component, the parts of which consist of TPU and are suitable for uniform recyclability in a closed loop with fully recoverable content. SUMMARY

[0005] The aforementioned problem is solved by the features of claim 1. Advantageous further developments result from the dependent claims.

[0006] A seat cushion for a vehicle seat comprises an outer skin formed from a thermoplastic polyurethane (TPU) elastomer and padding formed from a TPU foam, wherein the outer skin and padding are suitable for uniform recycling in a closed loop with fully recoverable content.

[0007] The outer skin comprises a mesh reinforcement layer made of TPU fibers.

[0008] According to another aspect, the TPU fibers of the mesh reinforcement layer comprise a mixture of TPU fibers and polyester fibers.

[0009] According to another aspect, the outer skin further comprises at least one fastening clip made of TPU, which is suitable for attaching the outer skin to a frame of the vehicle seat, wherein the outer skin, the at least one fastening clip and the padding are suitable for uniform recyclability in a closed loop with fully recoverable content.

[0010] According to another aspect, the seat pad further comprises at least one seam made of TPU fibers suitable for joining two separate pieces of TPU skin to form the outer skin, seams made of TPU fibers suitable for attaching the outer skin to the padding, and at least one lashing clip made of TPU suitable for attaching the outer skin to the padding.

[0011] The outer skin is formed into a desired shape within a thermoformable mold, and the padding is applied to an inner surface of the outer skin within the desired shape.

[0012] According to another aspect, the padding includes liquid TPU foam, which is poured into the desired shape of the outer skin, whereby the liquid TPU foam expands in the desired shape and hardens into a solid foam structure.

[0013] According to another aspect, the padding comprises a multitude of gas-filled TPU beads that are fused together at the contact points of the outer surfaces of adjacent beads, with the desired shape of the outer skin being filled with gas-filled TPU beads and vapor being applied to the gas-filled TPU beads, causing the outer surfaces of the gas-filled TPU beads to melt and adjacent beads to fuse together, forming a solid foam structure upon cooling.

[0014] According to another aspect, the padding comprises either TPU foam that is molded into a desired shape, or TPU foam that is cut into the desired shape from a bulk piece of TPU foam, and the padding is applied by placing the TPU foam of the desired shape within the corresponding desired shape of the molded TPU outer skin.

[0015] The seat pad further comprises a second skin formed from a TPU elastomer, which is heat-welded to the inner surface of the outer skin after the padding has been applied, the outer skin and the second skin defining a bubble that encapsulates the padding within it.

[0016] According to several aspects of the present disclosure, a method for forming a seat cushion for a vehicle seat comprises forming an outer skin comprising a thermoplastic polyurethane (TPU) elastomer within a thermoforming mold into a desired shape and applying a padding comprising a TPU foam to an inner surface of the outer skin within the desired shape, wherein the outer skin and the padding are suitable for uniform recycling in a closed loop with fully recoverable content.

[0017] According to another aspect, the process also includes applying a mesh reinforcement layer made of TPU fibers to an inner surface of the outer skin before applying the padding.

[0018] According to another aspect, applying a mesh reinforcement layer to an inner surface of the outer skin before applying the padding also includes forming the mesh reinforcement layer from a mixture of TPU fibers and polyester fibers.

[0019] According to another aspect, the method further includes attaching the outer skin to a frame of the vehicle seat with at least one TPU fastening clip, wherein the outer skin, the at least one fastening clip and the foam filler are suitable for uniform recyclability in a closed loop with fully recoverable content.

[0020] According to another aspect, the method further comprises at least one step consisting of joining two separate TPU skin pieces to form the outer skin with seams made of TPU fibers before applying the padding, attaching the outer skin to the padding with seams made of TPU fibers after applying the padding, and attaching the outer skin to the padding with at least one TPU lashing clip after applying the padding.

[0021] According to another aspect, the application of padding comprising TPU foam to an inner surface of the outer skin in the desired shape further includes pouring liquid TPU foam into the desired shape of the outer skin and allowing the liquid TPU foam to expand within the desired shape and cure into a solid foam structure.

[0022] According to another aspect, applying padding comprising TPU foam to an inner surface of the outer skin in the desired shape further includes filling the desired shape of the outer skin with a multitude of gas-filled TPU beads, applying vapor to the multitude of gas-filled TPU beads, fusing the multitude of gas-filled TPU beads together at contact points of outer surfaces of adjacent beads, and forming a solid foam structure upon cooling.

[0023] According to another aspect, the method comprises, prior to applying the padding, molding TPU foam into a desired shape or cutting TPU foam into the desired shape from a bulk piece of TPU foam, and wherein applying padding comprising TPU foam to an inner surface of the outer skin in the desired shape further comprises placing the TPU foam in the desired shape within the corresponding desired shape of the molded TPU outer skin.

[0024] According to another aspect, the process further includes applying a second skin made of a TPU elastomer to the inner surface of the outer skin after the padding has been applied, and heat-welding the second skin to the inner surface of the outer skin, wherein the outer skin and the second skin define a bubble that encapsulates the padding therein.

[0025] Further areas of application will become apparent from the description given herein. It is understood that the description and the specific examples serve only for illustrative purposes. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings described herein are for illustrative purposes only. Fig. Figure 1 is a perspective view of a composite component according to an exemplary embodiment, wherein the composite component is a seat cushion for a vehicle seat; Fig. 2 is a perspective view of the seat cushion made of Fig. 1, in which part of the seat cushion is shown in cross-section; Fig. 3 is an enlarged part of Fig. 2, as by the part of Fig. 2 displayed, marked with “ Fig. 3"; Fig. Figure 4 is a schematic exploded view of an outer skin, a reinforcement layer and a seat cushion made of Fig. 1 to Fig. 3; Fig. Figure 5 is a schematic view of the outer skin with the reinforcing layer glued to an inner surface of the outer skin; Fig. 6 is an enlarged view of Fig. 1, as by the part of Fig. 1 displayed, marked with “ Fig. 6"; Fig. Figure 7A is a schematic perspective view illustrating the application of liquid TPU foam to the inside of the outer skin; Fig. 7B is a side view of Fig. 7A; Fig. 7C is a side view of the outer skin after the liquid TPU foam has expanded and hardened inside it; Fig. Figure 8A is a schematic side view of the outer skin, where the padding comprises a variety of gas-filled TPU beads; Fig. 8B is an enlarged view of two gas-filled TPU beads fused together at a contact point; Fig. Figure 9 is a schematic representation illustrating the application of padding comprising a TPU foam block on the outer skin; Fig. Figure 10A is a schematic representation illustrating the application of a second skin to the outer skin after the padding has been applied; Fig. Figure 10B is a schematic representation, with the second skin applied to the inner surface of the outer skin; Fig. Figure 10C is a schematic representation, where the second skin has been heat-welded to the inner surface of the outer skin; and Fig. Figure 11 is a flowchart illustrating a method according to an exemplary embodiment of the present disclosure.

[0027] The figures are not necessarily to scale, and some features may be larger or smaller to show details of certain components. In some cases, known components, systems, materials, or processes have not been described in detail so as not to obscure the present disclosure. DETAILED DESCRIPTION

[0028] The following description is for illustrative purposes only. It is understood that in the drawings, corresponding reference numerals denote identical or corresponding parts and features. As used herein, the term "module" refers to any hardware, software, firmware, electronic control component, processing logic, and / or processor device, individually or in any combination, including, but not limited to: application-specific integrated circuits (ASICs), electronic circuits, processors (common, dedicated, or group), memory executing one or more software or firmware programs, combinational logic circuits, and / or other suitable components providing the described functionality.Although the figures shown herein represent an example with specific arrangements of elements, actual embodiments may include additional intervening elements, devices, features, or components. It is also understood that the figures are for illustrative purposes only and are not necessarily drawn to scale.

[0029] The term "vehicle" as used herein is not limited to automobiles. Although the technology presented here is primarily described in the context of automobiles, it is not limited to automobiles. The concepts can be used in a wide variety of applications, such as in connection with aircraft, watercraft, other vehicles, and consumer electronics components.

[0030] With reference to Fig. 1, Fig. 2 and Fig. 3, a seat cushion 10 for a vehicle seat 12 comprises an outer skin 14 made of a thermoplastic polyurethane (TPU) elastomer and padding 16 made of TPU foam. Since both the outer skin 14 and the padding 16 are made of TPU, they are suitable for uniform recycling in a closed loop with fully recoverable content.

[0031] In closed-loop recycling, also known as primary recycling, used plastic is endlessly recycled into new items of the same quality and type. For example, beverage bottles are turned back into beverage bottles. Continuous mechanical recycling of plastics without loss of quality is challenging due to cumulative polymer degradation and the risk of pollutant accumulation. Very few materials can be recycled in a closed loop. TPU materials (elastomers, foams, etc.) are recyclable in a closed loop.

[0032] In open-loop recycling, also known as secondary recycling or downcycling, the quality of the plastic decreases with each recycling process, eventually rendering the material unrecyclable. This is the most common type of recycling. A typical example is the recycling of PET bottles into nonwovens or other fibers, which accounts for the majority of PET recycling. Thermoset polymers, such as thermosetting polyurethane, typically used for foam padding in vehicle seats, do not melt. Technologies have been developed for the mechanical recycling of thermoset polymers, in which the material is usually broken down into small particles (crumbs) that can then be mixed with a binder to form a composite material. For example, thermosetting polyurethanes can be recycled as re-solidified granular foam (chip foam). Life cycle assessments show that recycling is environmentally beneficial.Recycling can reduce the demand for virgin plastic. However, if it is used to manufacture items that would not otherwise be produced, as in open-loop recycling, it does not displace production and offers little to no environmental benefit. Recycling of alternative thermosetting polyurethanes can be achieved through glycolysis, hydrolysis, aminolysis, pyrolysis, etc., which break down the polyurethane chemical chains and allow the product to be used as a raw polyol. Glycolysis involves treating thermosetting polyurethane with a glycol, hydrolysis involves treatment with phosphoric acid esters, and aminolysis utilizes low-weight alkanolamines. A disadvantage of this recycling process is that the resulting polyol is only suitable for products and applications with high or medium stiffness.Another problem with processes like glycolysis, hydrolysis, aminolysis, and pyrolysis is a side reaction that produces a secondary, undesirable product: methylenedianiline (MDA), an aromatic and carcinogenic amine. Furthermore, items such as car seats, which may consist of a thermoplastic outer skin and a foam cushion made of thermosetting polyurethane, must be disassembled for recycling, and even then, only some parts, such as the thermoplastic outer skin, can be recycled in a closed loop.

[0033] Thermoplastic polyurethane (TPU) is a polyurethane-type plastic with many properties, including elasticity, transparency, and resistance to oil, grease, and abrasion. Technically, it is a thermoplastic elastomer composed of linear segmented block copolymers made up of hard and soft segments. TPU is a block copolymer consisting of alternating sequences of hard and soft segments or domains formed by the reaction of (1) diisocyanates with short-chain diols (so-called chain extenders) and (2) diisocyanates with long-chain diols. By varying the ratio, structure, and / or molecular weight of the reactive compounds, a vast variety of TPUs can be produced. This allows polyurethane chemists to tailor the polymer structure to achieve the desired end properties of the material.

[0034] A TPU resin consists of linear polymer chains in block structures. These chains contain relatively long, low-polarity segments (so-called soft segments) alternating with shorter, high-polarity segments (so-called hard segments). Both types of segments are linked by covalent bonds, effectively forming block copolymers. The miscibility of the hard and soft segments in TPU depends on the differences in their glass transition temperatures (Tg), which occur at the onset of micro-Brown segment motion and can be identified by dynamic mechanical spectra. For an immiscible TPU, the loss modulus spectrum typically shows two peaks, each corresponding to the Tg of one component.If the two components are miscible, the TPU is characterized by a single broad peak value, the position of which lies between the two original Tg peak values ​​of the pure components.

[0035] The polarity of the hard units creates a strong attraction between them, leading to a high degree of aggregation and order in this phase and forming crystalline or pseudocrystalline regions within a soft and flexible matrix. This so-called phase separation between the two blocks can be more or less significant depending on the polarity and molecular weight of the flexible chain, the production conditions, and other factors. The crystalline or pseudocrystalline regions act as physical cross-links, which are responsible for TPU's high elasticity, while the flexible chains give the polymer its elongation properties.

[0036] These "pseudo-crosslinks" disappear under the influence of heat, making classic extrusion and injection molding processes applicable to these materials. Consequently, TPU scrap can be recycled (closed-loop recyclability). TPU has applications in many areas, including vehicle dashboards, steering wheels, power tools, sporting goods, medical devices, drive belts, shoes, inflatable rafts, fire hoses, and a wide variety of extruded film, sheet, and profile applications. TPU is also a popular material for flexible outer casings of devices such as mobile phones and keyboard protectors. TPU is known for its applications in sheathing wires and cables, hoses and pipes, in adhesive and textile coating applications, and as an impact modifier for other polymers. It is also used in high-performance films, such as...in high-impact glass structures. TPU is the thermoplastic elastomer used in fused deposition modeling (FFD) 3D printing. Because it does not warp and requires no primer, it is an ideal filament for 3D printers when objects need to be flexible and elastic. Since TPU is a thermoplastic, it can be melted by the 3D printer's hot end, printed, and then cooled into a flexible solid. TPU's performance and adaptability in various applications can largely be attributed to its hardness, represented by the Shore A scale. TPU powders are also used for other 3D printing processes, such as selective laser sintering (SLS) and inkjet 3D printing. It is also used in large vertical injection molding or extrusion molding machines for direct printing, eliminating the intermediate steps of filament extrusion or powder preparation.Recently, TPU foams have been developed that provide a wider application for TPU and enable systems and processes according to the features of the present disclosure.

[0037] Thus, the seat cushion 10 of the vehicle seat 12, which is in Fig. 1, Fig. 2 and Fig. As shown in Figure 3, the advantage of this arrangement is that it allows the production of a composite component (seat cushion 10) comprising an outer skin 14 made of a TPU elastomer, as is known in the industry, and a foam cushion 16 made of TPU foam, which until recently was unavailable. The advantage of this arrangement is that the composite seat cushion 10, comprising both the outer skin 14 and the foam cushion 16, can be removed from the frame 18 of the vehicle seat 12 and recycled as a unit in a closed loop. This provides economic and environmental benefits, thereby increasing the overall recyclability of the seat cushion 10 and reducing the preparation and sorting required for recycling conventional seat cushions.

[0038] With reference to Fig. 4 and Fig. 5, in an exemplary embodiment, the outer skin 14 comprises a mesh reinforcement layer 20 formed from TPU fibers 20A. The mesh reinforcement layer 20 is bonded to an inner surface 22 of the outer skin 14, as shown in Fig. Figure 5 shows the reinforcement layer 20 positioned adjacent to the padding 16 when the padding 16 is attached to the outer skin 14. In another exemplary embodiment, the TPU fibers 20A of the mesh reinforcement layer 20 comprise a mixture of TPU fibers 20A and polyester fibers 20B. Known and currently used TPU outer skins employ woven reinforcement fibers that are not capable of being recycled in a closed loop and cannot be separated from the TPU outer skin, thus preventing closed-loop recycling of the TPU outer skin. The reinforcement layer 20, made of TPU and / or polyester fibers 20A, 20B, can be recycled together with the outer skin 14 and the padding 16 as a unit in a closed loop, thereby enabling the seat cushion 10 to be manufactured entirely from recyclable materials.

[0039] With renewed reference to Fig. 3, in another exemplary embodiment, the outer skin 14 further comprises at least one TPU fastening clip 24 adapted to attach the outer skin 14 to a frame 18 of the vehicle seat 12. The at least one fastening clip 24 is attached to an edge 14A of the outer skin 14 and secures the outer skin to the frame 18 of the vehicle seat 12. The at least one fastening clip 24 can be attached to the edge 14A of the outer skin 14 by heat welding, or the at least one fastening clip 24 can be sewn to the edge 14A of the outer skin 14 with a thread made of TPU fibers. When the seat cushion 10 reaches the end of its service life, the entire seat cushion 10, including the outer skin 14, the at least one fastening clip 24, and the foam padding 16, is thus suitable for uniform recycling in a closed loop with fully recoverable content.

[0040] In another exemplary embodiment, the seat cushion 10 further comprises at least one of 1) seams 26 made of TPU fibers and suitable for joining two separate pieces of the TPU skin 14B to form the outer skin 14, 2) seams 26 made of TPU fibers and suitable for attaching the outer skin 14 to the padding 16, and 3) at least one lashing clip 28 made of TPU and suitable for attaching the outer skin 14 to the padding 16. With reference to Fig. 6, seams 26 made of TPU fibers are used to join two pieces of TPU elastomer 14B together, thus forming the outer skin 14 of the seat cushion 10. Additionally, such seams 26, which use TPU fibers, can extend into the padding 16 behind the outer skin 14, thereby attaching the outer skin 14 to the padding 16. In an exemplary embodiment, the seams 26, which are described in Fig. The seams 26 shown in Figure 6 join two separate pieces of TPU elastomer 14B skin together and extend into the padding 16 to form both the outer skin 14 and to attach the outer skin 14 to the padding 16. It is understood that such seams 26 can also be used solely for attaching the outer skin 14 to the padding 16.

[0041] With renewed reference to Fig. 3, at least one lashing clip 28 made of TPU is suitable for extending through the outer skin 14 and into the padding 16, wherein the at least one lashing clip 28 comprises features suitable for engaging with the outer skin 14 and the padding 16 in order to fasten the outer skin 14 to the padding 16. As shown, the at least one lashing clip 28 comprises a head section 30 suitable for engaging with an outer surface 32 of the outer skin 14, a shaft 34 with a sharp distal end 36 suitable for penetrating the outer skin 14 and the padding 16 when the at least one lashing clip 28 is pressed into the seat cushion 10, and features 38, such asBarbs or ribs extending radially outward from the shaft 34 and adapted to engage the padding 16 as soon as the at least one lashing clip 28 is pressed into position, and to secure the at least one lashing clip 28 in place, thereby attaching the outer skin 14 to the padding 16. It is understood that different versions of the at least one lashing clip 28 may be used without this deviating from the novelty of the present disclosure.

[0042] The outer skin 14 is thermoformed into a desired shape, and the padding 16 is applied to the inner surface 22 of the outer skin 14 in the desired shape. Thermoforming is a manufacturing process by which thermoplastic sheet materials are shaped into desired profiles / forms by applying heat and pressure / vacuum. Various thermoforming techniques include vacuum forming, pressure forming, and combined vacuum / pressure forming. Thermoforming is used in the production of both simple and relatively complex single-sheet parts, which are processed in a relatively low-stress process by avoiding sharp transitions in the mold profile.

[0043] Thermoforming is a simple process in which a heated thermoplastic sheet is stretched over a 3D profile former and then shaped in close accordance with its contours. A thermoplastic sheet is heated until it reaches the required viscous, rubbery, semi-solid state, generally well within the glass transition range. The temperature required for this is at the upper end of the glass transition range, weakening and allowing mobility, but not complete elimination, of the interchain bonds that form the crystalline matrix.

[0044] The heated plate is formed into a specific shape in two steps. First, the tool is lifted onto a movable table, which rises to meet the underside of the plate. This forces the heated polymer to conform to the tool's height, but not to the overall shape. Then, additional force is applied by a vacuum at the bottom, pressure at the top, or a combination of both. An upper tool component can also be used to assist in shaping specific areas. Thus, the heated TPU outer skin 14 is formed into the desired shape.

[0045] The formed outer skin 14 is cooled to return the TPU material to its solid state, retaining the desired shape as part of a now three-dimensional sheet. The vacuum or pressure is maintained during cooling to prevent mold relaxation as the TPU material returns to its rigidity. Upon completion of the thermoforming process, a 3D profile (or multiples thereof) remains, representing either a male or female mesh shape relative to the sheet's position. This incomplete part is removed from the thermoforming machine, either manually or automatically, and then proceeds to a trimming step, where excess material is cut away to achieve the final desired shape of the outer skin 14. It is understood that the above description is a non-limiting example of the thermoforming of the outer skin 14.The outer skin 14 can be thermoformed into the desired shape by other methods known in the industry without deviating from the novel aspects of the present disclosure.

[0046] With reference to Fig. 7A, Fig. 7B and Fig. 7C, in an exemplary embodiment, the padding 16 comprises a liquid TPU foam 40 which is cast or injected into the desired shape of the outer skin 14, as shown in Fig. 7A and Fig. 7B is shown. The liquid TPU foam 40 expands into the desired shape and hardens into a solid foam structure that defines the padding 16, as shown in Fig. 7C is shown.

[0047] With reference to Fig. 8A and Fig. 8B, in another exemplary embodiment, the padding 16 comprises a plurality of gas-filled TPU beads 42 which are fused together at the contact points of the outer surfaces of adjacent beads. With reference to Fig. 8A, the desired shape of the outer skin is filled with gas-filled TPU beads 42, and vapor is applied to the gas-filled TPU beads 42. The vapor melts the outer surfaces of the gas-filled TPU beads 42 and causes adjacent beads 42 to fuse together at the contact points 56, as shown in Fig. 8B shows that a solid foam structure is formed which corresponds to the desired shape of the outer skin 14 and, after cooling, defines the padding 16.

[0048] The gas-filled TPU beads 42 are pre-stretched with steam or other expansion agents. The expanded TPU beads 42 are then cooled, resulting in lightweight, closed-cell beads. Before the gas-filled TPU beads 42 are inserted into the desired shape of the thermoformed outer skin 14, the beads 42 can be further pre-stretched to achieve the desired density. After the desired shape of the outer skin 14 is filled with gas-filled TPU beads 42, as described in Fig. As shown in Figure 8A, steam and / or pressure is applied to the gas-filled TPU beads 42. The steam further expands the gas-filled TPU beads 42 and causes them to fuse together, creating a solid foam shape that corresponds to the desired shape of the outer skin 14. The seat pad 10, manufactured using gas-filled TPU beads 42, provides excellent insulation properties due to the gas trapped within the gas-filled TPU beads 42, is lightweight, and offers buoyancy and water resistance due to the closed-cell structure of the gas-filled TPU beads 42.

[0049] In another exemplary embodiment, the padding 16 comprises a block of TPU foam 44, which consists either of TPU foam that has been molded into a desired shape or of TPU foam that has been cut into the desired shape from a bulk piece of TPU foam. With reference to Fig. 9. The padding 16 is attached by placing the TPU foam block 44 in the desired shape within the corresponding desired shape of the thermoformed TPU outer skin 14, as indicated by arrows 46. After placement in the desired shape of the thermoformed outer skin 14, the TPU foam padding 16 can be bonded to the inner surface 22 of the thermoformed outer skin 14 by heat welding or other known methods.

[0050] In yet another exemplary embodiment, the seat cushion 10 further comprises a second skin 48, which is formed from a TPU elastomer and is heat-welded to the inner surface 22 of the outer skin 14 after the padding 16 has been applied. With reference to Fig. 10A, after the padding 16 has been applied to the thermoformed outer skin 14 in the desired shape by one of the methods discussed above, the second skin 48 is placed on the inner surface 22 of the outer skin 14, as shown by arrows 50. With reference to Fig. 10B, after the second skin 48 has been applied to the inner surface 22 of the outer skin 14, the second skin 48 is bonded to the inner surface 22 of the outer skin 14 by heat welding or other suitable methods, with reference to Fig. 10C defines the outer skin 14 and the second skin 48 a blister 52 that encapsulates the padding 16 within it.

[0051] Depending on the shape of the outer skin 14, the presence of the bladder 52 may or may not be visible when viewing the seat pad 10. Furthermore, the bladder 52, whose padding 16 consists of compressible / expandable TPU foam, can provide selective expansion using an external pump or mechanical means to offer selectively actuated functions, such as an adjustable support or massage system. The bladder 52 includes a vent 54 suitable for allowing air to escape from and enter the bladder 52, thus preventing it from behaving like a sealed balloon. The bladder 52 can be compressed under external pressure to provide a cushioning effect when the padding 16 inside is compressed, and is able to expand back to its original shape once the external pressure is removed.

[0052] Thus, a composite component, such as a seat cushion 10, according to the present disclosure, provides complex design features and functions while simultaneously being fully recyclable in a closed loop, with 100% of the materials used in the seat cushion 10 being recyclable. Furthermore, according to the teachings of the present disclosure, a composite component 10 does not need to be mechanically separated before recycling. For example, the seat cushion 10, which comprises the outer skin 14, the padding 16, the at least one fastening clip 24, the at least one lashing clip 28, the seams 26, and possibly a second skin 48 defining a bladder 52 therein, can be removed from the frame 18 of the vehicle seat 12 and recycled as a unit. The entire seat cushion 10 can be recycled into new TPU.

[0053] With reference to Fig.11, comprising a method 100 for forming a seat cushion 10 for a vehicle seat 12, starting at block 102, forming, within a thermoforming mold, an outer skin 14 comprising a thermoplastic polyurethane (TPU) elastomer into a desired shape, and, moving to block 104, applying a padding 16 comprising a TPU foam to an inner surface 22 of the outer skin 14, within the desired shape, wherein the outer skin 14 and the padding 16 are suitable for uniform closed-loop recycling with fully recoverable content.

[0054] In one exemplary embodiment, the method 100 further comprises, moving towards block 106, applying a mesh reinforcement layer 20, formed from TPU fibers 20A, to an inner surface 22 of the outer skin 14 before applying the padding 16. In another exemplary embodiment, the application of a mesh reinforcement layer 20 to an inner surface 22 of the outer skin 14 before applying the padding 16 at block 106 further comprises forming the mesh reinforcement layer 20 from a mixture of TPU fibers 20A and polyester fibers 20B.

[0055] In an exemplary embodiment, the method 100 further comprises, moving from block 104 to block 108, attaching the outer skin 14 to a frame 18 of the vehicle seat 12 with at least one fastening clip 24 made of TPU, wherein the outer skin 14, the at least one fastening clip 24 and the padding 16 are suitable for uniform recyclability in a closed loop with fully recoverable content.

[0056] In another exemplary embodiment, the method 100, moving from block 104 to block 110, further comprises at least one joining of two separate pieces of the TPU skin 14B to form the outer skin 14 with seams 26 made of TPU fibers, before the application of the padding 16, moving from block 104 to block 112, attaching the outer skin 14 to the padding 16 with seams 26 made of TPU fibers, after the application of the padding 16, and, moving from block 104 to block 114, attaching the outer skin 14 to the padding 16 with at least one lashing clip 28 made of TPU, after the application of the padding 16.

[0057] In an exemplary embodiment, the application of a padding 16 comprising a TPU foam to an inner surface 22 of the outer skin 14 within the desired shape at block 104 further comprises, moving towards block 116, pouring liquid TPU foam 40 into the desired shape of the outer skin 14 and, moving towards block 118, allowing the liquid TPU foam 40 to expand within the desired shape and to harden into a solid foam structure.

[0058] In an exemplary embodiment, the application of a padding 16 comprising a TPU foam to an inner surface 22 of the outer skin 14 within the desired shape at block 104 further comprises, moving towards block 120, filling the desired shape of the outer skin 14 with a plurality of gas-filled TPU beads 42, moving towards block 122, applying vapor to the plurality of gas-filled TPU beads 42, and, moving towards block 124, fusing the plurality of gas-filled TPU beads 42 together at contact points 56 of outer surfaces of adjacent beads 42 and forming a solid foam structure when cooled.

[0059] In another exemplary embodiment, the method 100 comprises, prior to the application of the padding at block 104, either, moving from block 106 to block 126, forming TPU foam into a desired shape, or, moving from block 106 to block 128, cutting TPU foam in the desired shape from a bulk piece of TPU foam, and wherein the application of a padding 16 comprising TPU foam to an inner surface 22 of the outer skin 14 within the desired shape at block 104 further comprises, moving to block 130, placing the TPU foam of the desired shape within the corresponding desired shape of the thermoformed TPU outer skin 14.

[0060] In another exemplary embodiment, the method 100 further comprises, moving from block 104 to block 132, applying a second skin 48, formed from a TPU elastomer, to the inner surface 22 of the outer skin 14 after the padding 16 has been applied, and, moving to block 134, heat-welding the second skin 48 to the inner surface 22 of the outer skin 14, wherein the outer skin 14 and the second skin 48 define a bubble 52 encapsulating the padding 16 therein.

[0061] A composite component (seat cushion 10) and the method 100 of the present disclosure offer several advantages. These include enabling a composite component, such as the seat cushion 10, to have complex design features and functions while being fully recyclable in a closed loop, with 100% recovery of the materials used in the seat cushion 10. Furthermore, according to the teachings of the present disclosure, a composite component 10 does not need to be mechanically separated before recycling. For example, the seat cushion 10, which comprises the outer skin 14, the padding 16, the at least one fastening clip 24, the at least one lashing clip 28, the seams 26, and possibly a second skin 48 defining a bladder 52 therein, can be removed from the frame 18 of the vehicle seat 12 and recycled as a unit. The entire seat cushion 10 can be recycled into new TPU.

Claims

[1] Seat cushion (10) for a vehicle seat (12), comprising: an outer skin (14) formed from a thermoplastic polyurethane (TPU) elastomer (14B); and a padding (16) formed from a TPU foam (40, 44); wherein the outer skin (14) and the padding (16) are suitable for uniform recyclability in a closed loop with fully recoverable content, wherein the outer skin (14) comprises a mesh reinforcement layer (20) formed from TPU fibers (20A), characterized by , that the outer skin (14) is formed into a desired shape within a thermoforming mold and the padding (16) is applied to an inner surface (22) of the outer skin (14) within the desired shape, wherein the seat pad (10) further comprises a second skin (48) formed from a TPU elastomer which is heat-welded to the inner surface (22) of the outer skin (14) after the padding (16) has been applied, wherein the outer skin (14) and the second skin (48) define a bladder (52) which encapsulates the padding (16) therein, wherein the bladder (52) includes a vent opening (54) which is suitable for allowing air to escape from and enter the bladder (52). [2] Seat cushion (10) according to claim 1, wherein the TPU fibers (20A) of the mesh reinforcement layer (20) comprise a mixture of TPU fibers (20A) and polyester fibers (20B). [3] Seat cushion (10) according to claim 1, wherein the outer skin (14) further comprises at least one fastening clip (24) made of TPU, which is suitable for attaching the outer skin (14) to a frame (18) of the vehicle seat (12), wherein the outer skin (14), the at least one fastening clip (24) and the padding (16) are suitable for uniform recyclability in a closed loop with fully recoverable content. [4] Seat cushion (10) according to claim 1, further comprising at least one of: Seams (26) made of TPU fibers and suitable for joining two separate TPU skin pieces to form the outer skin (14); seams (26) made of TPU fibers and suitable for attaching the outer skin (14) to the padding (16); and at least one lashing clip (28) made of TPU and suitable for attaching the outer skin (14) to the padding (16). [5] Seat cushion (10) according to claim 1, wherein the padding (16) comprises liquid TPU foam (40) which is poured into the desired shape of the outer skin (14), wherein the liquid TPU foam (40) expands in the desired shape and hardens to form a solid foam structure. [6] Seat cushion (10) according to claim 1, wherein the padding (16) comprises a plurality of gas-filled TPU beads (42) which are fused together at contact points (56) of the outer surfaces of adjacent beads, wherein the desired shape of the outer skin (14) is filled with gas-filled TPU beads (42) and vapor is applied to the gas-filled TPU beads (42), causing the outer surfaces of the gas-filled TPU beads (42) and adjacent beads (42) to fuse together, forming a solid foam structure upon cooling. [7] Seat cushion (10) according to claim 1, wherein the cushioning (16) comprises one of: TPU foam (40) that is molded into a desired shape; or TPU foam (44) cut into the desired shape from a bulk piece of TPU foam; and wherein the padding (16) is applied by placing the TPU foam (40, 44) of the desired shape within the corresponding desired shape of the molded TPU outer skin (14).

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