Cushions for a headrest and methods for their manufacture

Abstract

The invention relates to a headrest for a motor vehicle and methods for its manufacture, comprising a headbox having a front side facing a passenger and a rear side facing away from the passenger, a cushion surrounding the headbox at least at its front and rear, and a cover surrounding the cushion, wherein the cushion is constructed in two parts and forms a front cushion half and a rear cushion half, both cushion halves being connected to each other by means of a film hinge, the rear cushion half having an inner surface corresponding to the contour of the rear of the headbox, and the front cushion half having an inner surface corresponding to the contour of the front of the headbox.

Description

[0001] The invention relates initially to a headrest for a motor vehicle, with a headbox having a front side facing a passenger and a rear side facing away from the passenger, with a cushion that surrounds the headbox at least on its front and rear sides and with a cover that surrounds the cushion.

[0002] The invention also relates to a method for manufacturing such a headrest.

[0003] Headrests of this type are known, for example, from DE 11 2010 005 658 B4. They serve, on the one hand, to increase seating comfort for passengers in motor vehicles. On the other hand, headrests have a significant safety function in the event of a vehicle collision. Headrests catch the passenger's head as it moves due to centrifugal forces and gently dissipate the impact forces.

[0004] Headrests typically feature a headbox, a plastic injection-molded component. The headbox is usually mounted to the vehicle seat using two anchor rods. This essentially inelastic, load-bearing component is then surrounded by padding. The padding, being resilient, is designed to absorb and dampen impact forces. A cover is usually placed over the padding. This cover serves two purposes: firstly, it makes the headrest visually appealing and matches the rest of the vehicle's interior; secondly, it protects the padding and secures it to the headbox.

[0005] It is known from the state of the art, which is not documented in print, and is currently standard practice throughout the industry to manufacture the cushion from polyurethane. This material is easy to handle in the production process, results in a foam body with the appropriate elasticity values ​​when cured, and is durable and dimensionally stable.

[0006] From the prior art, which is also not documented in print, it is known to mix natural fibers, in particular coconut fibers, with rubber and to press them into a headrest cushion using a suitable mold.

[0007] The latter example has the significant advantage over the use of polyurethane foam of using naturally occurring, easily disposed-of materials, whereas polyurethane or objects made of polyurethane must be disposed of separately and in an environmentally friendly manner at the end of their service life.

[0008] Numerous stakeholders demand resource-efficient product manufacturing and simple product disposal, preferably through recycling. Particularly in the industrial production of mass-produced goods, the limited availability of natural raw materials poses a problem, which is why the aforementioned solution of manufacturing headrest cushions from coconut fibers has only seen limited adoption.

[0009] The object of the invention is therefore to provide a novel headrest that meets the requirements for disposal and recycling, as well as to demonstrate a method for manufacturing a suitable headrest cushion.

[0010] The problem of the invention is initially solved by a headrest with the features of claim 1, in particular with its characterizing features, according to which the cushion is constructed in two parts and forms a front cushion half and a rear cushion half, both cushion halves are connected to each other by means of a film hinge, the rear cushion half has an inner surface that corresponds to the contour of the back of the headbox and the front cushion half has an inner surface that corresponds to the contour of the front of the headbox.

[0011] The key advantage of the cushion of the headrest according to the invention lies in its particularly easy assembly and disassembly. The proposed two-part design of the cushion, in conjunction with the arrangement of the cushion halves against each other via a film hinge, allows the cushion halves to be folded together to accommodate the headrest, thus accommodating the headrest between them.

[0012] Compared to sliding on a polyurethane cushion with a cavity for the headrest, this mounting method is considerably simpler. However, the main advantage of the headrest according to the invention lies in its disposal. The cushion can be easily detached and separated from the headrest, so that the process of separating different materials, which may be necessary for recycling, can be carried out without much effort.

[0013] It is therefore intended that the film hinge is formed from the upholstery material itself.

[0014] This ensures that only one and the same material is used for the cushion, which simplifies its disposal or its return to the material cycle.

[0015] The invention proposes to achieve the required resilience of the cushion by layering the fibers of the nonwoven fabric or fleece in layers and arranging the layers essentially parallel to each other.

[0016] A nonwoven fabric possesses sufficient inherent elasticity due to its manufacturing process. Depending on the manufacturing method, particularly the arrangement of the individual nonwoven fibers, the density and elasticity can be influenced, allowing for selection based on the specific requirements of the cushion.

[0017] A particularly preferred embodiment is one in which the layers are oriented essentially orthogonally to the front or back of the headbox.

[0018] This specific orientation of the nonwoven fabric results in excellent resilience at a suitable density. In this way, sufficient cushioning travel in the event of a vehicle collision is achieved, along with a corresponding resilience characteristic, particularly a progressive one.

[0019] The thermal pressing process used to manufacture such a cushion sufficiently cross-links the outer and inner fiber ends to give the cushion dimensional stability.

[0020] It is intended that the nonwoven fabric consists partly, and in particular entirely, of recycled material. In a preferred embodiment, the nonwoven fabric is made of a thermoplastic material, for example polypropylene, and contains at least 20 percent, preferably 30 percent, and in particular 40 to 50 percent, of recycled material. However, it is particularly preferred that the nonwoven fabric be made of polyester, since this material is also used in the manufacture of the headrest cover. This material uniformity facilitates the recycling of the headrest at the end of its service life.

[0021] The use of recycled materials, especially recycled plastic, is essential from a sustainability perspective. Furthermore, it is possible to integrate material scraps generated during the production of the headrest itself into the nonwoven fabric production via appropriate recycling streams, thus creating corresponding material cycles.

[0022] The object of the invention is then achieved by a method for manufacturing a cushion for arrangement on the headboard of a headrest of a motor vehicle according to one of claims 1 to 7, in particular if the method according to dependent claim 8 comprises the following steps: a) Production of a layered nonwoven fabric or nonwoven material, b) Inserting the fleece into a mold consisting of two mold parts, in particular two mold halves, the negative contour of which corresponds to the positive contour of the cushion to be produced, c) Closing the mold and pressing the nonwoven fabric into the desired cushion shape under the influence of heat, d) Removal of the fleece formed into a cushion from the mold.

[0023] The invention recognizes that nonwovens are not only ideally suited for manufacturing a cushion for a motor vehicle headrest for the reasons already mentioned above. Furthermore, the use of nonwovens compared to previously used polyurethanes makes it possible to achieve a significant weight reduction in the cushion.

[0024] Furthermore, when using nonwovens or fleeces, it is particularly easy to reuse the offcuts generated during the production of, for example, upholstery covers. These offcuts can be easily processed into shredded wool and then further processed into a nonwoven or fleece fabric, which can then be used to manufacture the upholstery. In this way, sustainable material cycles can be created.

[0025] Particularly good elasticity values ​​of the padding with at the same time appropriate density of the nonwoven fabric can be achieved if the nonwoven fabric is inserted into the mold with a layering arranged essentially vertically to the mold surface or with a layering aligned parallel to one direction of movement of the two mold parts.

[0026] For this, it is necessary that the thickness of the fleece or nonwoven fabric - measured orthogonally to its layering - corresponds at least to the height of the cushion part to be produced.

[0027] The cushion can be manufactured particularly efficiently by producing both cushion parts simultaneously in a single pressing process, with the first cushion part forming the front half and the second cushion part forming the rear half. The pressing process creates a material-bonded hinge that secures the front and rear cushion halves together and allows them to pivot relative to each other to form the cushion.

[0028] The design provides that one of the molded parts depicts the outer contour of a front and the outer contour of a back of the headbox, and the other molded part depicts the front and the rear outer contour of the cushion to be created.

[0029] A better understanding of the invention and its further advantages will become apparent from the following description of an exemplary embodiment. It shows: Fig. 1 a schematic representation of a two-part form for the production of the cushion of a headrest including the fleece to be inserted, Fig. 2. that with the form according to Fig. 1 manufactured, two-piece upholstery part, Fig. 3 the upholstered part after Fig. 2 in compound form, Fig. 4 a headrest according to the invention with the upholstered part according to Fig. 3.

[0030] In the figures, a headrest according to the invention is provided with the reference numeral 10.

[0031] In Fig. Figure 1 shows a mold 11, consisting of a first mold half 12 and a second mold half 13. The mold 11 serves to produce a cushion 14 for the headrest 10 from a nonwoven fabric 15. For this purpose, the nonwoven fabric 15 is placed between the mold halves 12 and 13, whereupon the mold halves 12 and 13 are moved towards each other along a direction of movement B. This presses the nonwoven fabric 15 into the cavity of the mold 11, which is formed between the mold halves 12 and 13.

[0032] The nonwoven fabric 15 is made of synthetic fibers, preferably thermoplastic, in particular polypropylene or polyester, and is heated when the mold 11 is closed, i.e., when the nonwoven fabric 15 is compressed. This can be done by heating the mold halves 12 and 13. However, it is also possible to introduce the necessary energy into the nonwoven fabric 15 using vibration techniques, so that the required temperature for forming the nonwoven fabric 15 is generated by friction.

[0033] The nonwoven fabric 15 has a layered structure, meaning that the fibers forming the nonwoven fabric 15 form individual layers L, which are in Fig. The layers are symbolized by corresponding lines. Naturally, the layers are interconnected, so that the fleece 15 is a correspondingly stable structure.

[0034] The layers L of the nonwoven fabric 15 are arranged essentially orthogonally to the shaping inner surface of the mold halves 12 and 13.

[0035] In the present case, in which the mold halves 12 and 13 are moved vertically towards each other for the shaping pressing of the nonwoven fabric 15, the individual layers L of the layered nonwoven fabric 15 are aligned parallel to the direction of movement B of the mold halves 12 and 13.

[0036] Now, let's consider the headrest 10 in Fig. Figure 1, which is shown there in its entirety – but without reference – shows that the cushion 14 is mounted on a headrest 17. The headrest 17 carries two anchor rods 18, by means of which the headrest can be attached, for example, to a passenger seat in a vehicle.

[0037] The headrest 10 forms a front side V and a back side R, with the front side V pointing towards a passenger not shown here and the back side R of the headrest 10 being the side of the headrest furthest from the passenger.

[0038] The headbox 17 has a headbox contour K which - apart from its side surfaces - is defined in particular by the surface areas facing forward and backward.

[0039] The dividing line T is in Fig. 4 indicates that the cushion 14 is made up of two parts and has a front cushion half 19 and a rear cushion half 20.

[0040] Fig. Figure 4 also shows that the front cushion half 19, with its inner surface 21, essentially accommodates the front headboard contour K, whereby in a preferred embodiment it is not necessary for every contour section of the headboard 17 to be accommodated. To fulfill this feature, it is sufficient if the inner surface 21 of the front cushion half 19 is designed such that it rests against the corresponding surface portions of the headboard contour K provided for bearing.

[0041] The inner surface 22 of the rear cushion half 20 is designed in the same way. This surface also incorporates the headboard contour K – in this case, the rear one – and this feature is also fulfilled here if the inner surface 22 of the rear cushion half 20 is designed to rest against the surface areas of the back of the headboard intended for bearing against it.

[0042] Fig. Figure 4 further shows that the cushion 14 has a cushion contour P, which is formed by the outer surface of the front cushion half 19 and the rear cushion half 20, respectively, facing the front V and rear R. Any lateral cushion parts are disregarded here.

[0043] If we now turn back to the Fig. From this, it can be seen that the cavity of the first mold half 12 is divided into two parts, and a first cavity part 23 defines the section of the cushion contour P assigned to the front cushion half 19. The second cavity part 24 of the first mold half 12, on the other hand, defines the part of the cushion contour P assigned to the rear cushion half 22. In other words, only the first mold half 12 is the part of the mold 11 by which the cushion contour P is defined in its shape.

[0044] The second mold half 13 forms a third cavity part 25 and a fourth cavity part 26. The third cavity part 25 and the fourth cavity part 26 define the headbox contour K, wherein the third cavity part 25 defines the inner surface 21 of the front cushion half 19 and the fourth cavity part 26 defines the inner surface 22 of the rear cushion half 20.

[0045] It is therefore sufficient to include the Fig. 1 to use the form 11 shown in order to form both the front cushion half 19 and the rear cushion half 20 in one pressing operation.

[0046] The first mold half 12 forms a separating wedge 27 which, in conjunction with the opposing mold surface of the second mold half 13, separates the front cushion half 19 and the rear cushion half 20 from each other. The separating wedge 27 can be designed such that two separate, independent cushion halves 19 and 20 are actually formed.

[0047] Fig. Figure 2 shows the cushion 14 after demolding. Clearly visible here are the outer cushion contour P, created by mold 11 and pointing downwards in the plane of the paper, formed by the front and rear cushion halves 19 and 20, as well as the inward-pointing headboard contour K, which faces the viewer in the plane of the drawing and is also formed by the front and rear cushion halves 19 and 20.

[0048] Fig. Figure 2 also shows the most preferred embodiment of the cushion 14. In this embodiment, the separating wedge 27 is slightly spaced from the opposite mold surface when the mold 11 is closed. This creates a hinge S, particularly preferably a film hinge S, which is integrally formed with the cushion halves 19, 20 and arranges the cushion halves 19 and 20 together for simplified assembly.

[0049] How Fig. Figure 3 shows that the cushion can be raised by pivoting the inner surfaces 21 and 22 of the cushion halves 19 and 20 towards each other. If one now pulls Fig. Adding 4, it can be clearly seen that the cushion 14 formed in this way can be folded around the headbox 17 and the assembly effort is thus considerably reduced.

[0050] If one imagines that only the cover is intended to firmly anchor the cushion 14 to the headboard, a particularly simple and easy-to-assemble headrest is created.

[0051] The use of a nonwoven fabric 15 for the production of the cushion has the advantages mentioned at the outset. The specific design, particularly with regard to the recycling of certain residual materials generated during production and the easy separability of the individual components of the headrest, improves the recyclability of the raw materials used in the headrest at the end of its service life. Reference symbol list 10 Headrest 11 Form 12 first half of the mold 13 second half of the form 14 cushions 15 fleece 16 Outer contour 17 Headbox 18 Anchor rod 19 front cushion half 20 rear cushion half 21 Inner surface of the front half of the cushion 19 22 Inner surface of the rear upholstery half 20 23 first cavity part 24 second cavity part 25 third cavity part 26 fourth cavity part 27 Separating wedge B Direction of movement K headbox contour L location P cushion contour V Front R Back S hinge / film hinge T dividing line QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 11 2010 005 658 B4

[0003]

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