Upholstery part for a vehicle as well as seat cushion for a vehicle seat

Abstract

A cushioning component (100) for a vehicle is proposed. The cushioning component comprises a first layer (10), a second layer (12), and at least one functional intermediate layer (14) arranged between them. The first layer (10) and the second layer (12) are made of a vertical nonwoven fabric comprising a thermoplastic material. The at least one functional intermediate layer (14) comprises the same thermoplastic material as the first layer (10) and the second layer (12). The at least one functional intermediate layer (14) has a material structure selected from the group consisting of yarns, woven fabrics, knitted fabrics, horizontal nonwovens, and films.

Description

[0001] The invention relates generally to the field of upholstery components. Specifically, the invention relates to an upholstery component for a vehicle and a seat cushion for a vehicle seat.

[0002] For recycling reasons, the use of vertical nonwovens, such as PET nonwovens, as a replacement material for polyurethane foam in seat cushions is increasingly being pursued. However, to achieve the current performance level in all comfort-relevant properties, a construction consisting of one or more layers of vertical nonwovens is insufficient.

[0003] The object of the present invention is to address the challenges described above and, in particular, to at least partially overcome the disadvantages of the prior art. Specifically, the invention aims to provide an improved upholstery component for a vehicle. Furthermore, the invention aims to provide an improved seat cushion for a vehicle seat.

[0004] The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description.

[0005] A first aspect of the present disclosure relates to a cushioning component for a vehicle. The cushioning component comprises a first layer, a second layer, and at least one functional intermediate layer arranged between them. The first layer and the second layer are made of a vertical nonwoven fabric comprising a thermoplastic material. The at least one functional intermediate layer comprises the same thermoplastic material as the first layer and the second layer. The at least one functional intermediate layer has a material structure selected from the group consisting of fibers, yarns, woven fabrics, knitted fabrics, warp-knitted fabrics, horizontal nonwovens, and films.

[0006] A cushioning component is proposed, which may consist of a multi-layered structure. The cushioning component preferably comprises two or more layers of a vertical nonwoven fabric, which is preferably made predominantly of a thermoplastic material, such as polyethylene terephthalate (PET). The cushioning component may include several layers of a vertical nonwoven fabric. A vertical nonwoven fabric can be defined as a nonwoven fabric in which the fibers are oriented predominantly perpendicular to the surface of the respective layer and / or to the surface of the cushioning component. A vertical nonwoven fabric may also be called a V-nonwoven or V-lap nonwoven. The first and second layers may form the two outer layers of the cushioning component.Preferably, at least one functional intermediate layer is located between these two vertical nonwoven layers. This intermediate layer consists primarily of the same thermoplastic material as the first and second layers. The functional intermediate layer can have a special material structure that differs, in particular, from the material structure of the first and second layers. The intermediate layer can consist of mono- or multifilament fibers, yarns, woven fabrics, knitted fabrics, warp-knitted fabrics, horizontal nonwovens, or even films. The use of such a functional intermediate layer, which can be made from the same base material as the outer vertical nonwovens, can serve to specifically improve the performance and comfort properties of the upholstery component. The at least one functional intermediate layer can also serve to provide the upholstery component with increased stability.At least one intermediate layer can be described as a stabilizing intermediate layer.

[0007] The at least one functional intermediate layer can serve, either alternatively or additionally, to improve the pressure absorption capacity of the upholstery component in the direction perpendicular to the surface of the upholstery component, or to the surface of the first and / or second layer. By using the functional intermediate layer, the ability of the upholstery component to absorb energy under load and release this energy in a controlled manner when the load is removed can be improved. Such elastic deformation behavior transversely, or essentially perpendicularly, to the surface of the first and / or second layer can be crucial for the seating comfort of a vehicle seat.

[0008] By using such an intermediate layer, the cushioning component can be improved in terms of compression, energy absorption and / or rebound.

[0009] According to one embodiment, the at least one functional intermediate layer has a lesser thickness than the first and / or second layer. This thickness extends substantially perpendicular to the surface of the first and / or second layer. This means that the thickness of the functional intermediate layer can be less than the thickness of the two outer vertical nonwoven layers. The thickness extends substantially perpendicular to the surface of the cushioning element. The functional intermediate layer can have a smaller extent in height or in the Z-direction of the cushioning element than the two nonwoven layers above and below it.

[0010] The invention is based on the finding that the targeted use of such a thinner functional intermediate layer between the two vertical nonwoven fabric layers can make it possible to provide a recyclable cushioning component with high comfort requirements.

[0011] According to one embodiment, the cushioning component has a plurality of functional intermediate layers. For example, the cushioning component can have three functional intermediate layers, all made of the same thermoplastic material. The three intermediate layers can each have different material structures. For instance, a first intermediate layer can be a knitted fabric, a second layer a woven fabric, and a third layer a thin film. By using a predefined combination of two or three different material structures in the intermediate layers, the deformation behavior and the energy absorption and release capacity of the cushioning component in the Z-direction can be better coordinated and optimized.

[0012] For example, the desired seating comfort, previously only achievable with polyurethane foam, can now also be achieved with this recyclable, multi-layered upholstery component. Varying the intermediate layers allows for targeted fine-tuning of the upholstery's mechanical properties.

[0013] According to one embodiment, the thermoplastic material belongs to the group of polyolefins and / or polyesters. The thermoplastic material of the intermediate layers and the outer nonwoven layers preferably consists of polyethylene (PE) or polyethylene terephthalate (PET). Alternatively, polytrimethylene terephthalate (PPT) or polybutylene terephthalate (PBT) can be considered. Polyethylene is a very cost-effective and widely used standard plastic. It generally exhibits high impact strength, flexibility, and chemical resistance. Furthermore, PE is very easy to recycle, which can benefit the circular economy and sustainability of the cushioning component. Polyethylene terephthalate, or PET for short, is also a very common and recyclable plastic. PET exhibits high strength, stiffness, and dimensional stability. In addition, PET is very resistant to oils, greases, and solvents, which can be advantageous for use in the cushioning component.

[0014] According to one embodiment, the at least one functional intermediate layer is bonded to the first layer and / or the second layer. This means that the intermediate layer is preferably firmly and permanently bonded to the first and / or second layer. The bond can be achieved by applying and fusing the functional intermediate layer to the two nonwoven layers. Alternatively, the intermediate layer can be injected with the nonwoven layers using a multi-component injection molding process. Such a strong bond of the functional intermediate layer allows shear forces and tensile loads to be reliably transmitted across the interfaces between the layers. The cushioning component can be thermoformed, for example, under additional pressure. The cushioning component can have a three-dimensional structure and / or shape.The upholstery may have compressed sections and / or zones.

[0015] If the upholstered part has several functional intermediate layers, these intermediate layers can be bonded together with each other using fabric.

[0016] A second aspect of the present disclosure relates to a seat cushion for a vehicle seat. The seat cushion comprises at least one cushioning element, as described above and / or below. Such a seat cushion can improve seating comfort. The comfort-relevant parameters can be specifically improved by using a cushioning element, as described above and / or below. The comfort-relevant parameters of the cushioning element include, for example: rebound, pressure distribution, relaxation, and hysteresis. The seat cushion can comprise several cushioning elements.

[0017] All benefits, revelations and / or explanations described above and / or below in relation to one aspect of the present revelation apply equally to all other aspects of the present revelation.

[0018] An embodiment of the invention is described below with reference to the Fig. 1 described. Fig. Figure 1 shows a cushion part according to an exemplary embodiment.

[0019] Similar, similar-looking, identical, or equally effective elements are in Fig. 1. provided with similar or identical reference symbols. Fig. Figure 1 is merely schematic and not to scale.

[0020] Fig. Figure 1 schematically shows a cushioning element 100 according to an embodiment for a vehicle, and in particular for a vehicle seat. The cushioning element 100 has a first layer 10 and a second layer 12. The first layer 10 and the second layer 12 consist of a vertical nonwoven fabric. The vertical nonwoven fabric is preferably made of a thermoplastic material, such as PE or PET. The vertical nonwoven fabric of the first layer 10 and / or the second layer 12 preferably has predominantly fibers made of a thermoplastic material, which are oriented substantially perpendicular to the surface of the first layer 11 and / or to the surface of the second layer 12. One or more functional intermediate layers 14, 14' can be arranged between the two layers 10, 12. The cushioning element 100 of Fig.Figure 1 has, by way of example, two intermediate layers 14, 14'. Both intermediate layers 14, 14' can serve to increase the restoring force F of the cushioning part 100 and / or to improve the stability of the cushioning part 100. In the context of this disclosure, the restoring force F can denote the force that counteracts a force acting on the cushioning part 100. The two intermediate layers 14, 14' are preferably made of the same thermoplastic material as the two layers 10, 12.

[0021] The intermediate layers 14 and 14' are preferably bonded to the two layers 10 and 12. This can be achieved by thermoforming the cushioning part 100. In principle, the bonded connection of the intermediate layers 14 and 14' to the further layers 10 and 12 can be created by applying heat.

[0022] In summary, a padding component 100 for a vehicle, particularly for a vehicle seat, can be proposed, which has a multi-layered structure. In addition to the outer vertical PET nonwovens (layers 10, 12), this structure can also include suitable functional intermediate layers 14, 14'. These intermediate layers 14, 14', which can be made of the same thermoplastic material as the vertical nonwoven, can further enhance the performance of the padding component 100 with regard to comfort properties. Various material structures are suitable for the intermediate layers 14, 14', such as yarns, woven fabrics, knitted fabrics, or films.

[0023] It should be further noted that the terms "comprising" and "comprising" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features and steps described with reference to one of the above embodiments may also be used in combination with other features and steps of other embodiments described above. Reference numerals in the claims are not to be considered limitations. Reference symbol list 100 upholstery parts 10 first shift 11 Surface of the first layer 12 second shift 13 Surface of the second layer 14 functional intermediate layers F Restoring force

Claims

Upholstery part (100) for a vehicle, comprising a first layer (10), a second layer (12) and at least one functional intermediate layer (14) arranged between them, wherein the first layer (10) and the second layer (12) are made of a vertical nonwoven fabric comprising a thermoplastic material, wherein the at least one functional intermediate layer (14) comprises the same thermoplastic material as the first layer (10) and the second layer (12), and wherein the at least one functional intermediate layer (14) has a material structure selected from the group consisting of fibers, threads, woven fabrics, knitted fabrics, warp-knitted fabrics, horizontal nonwovens and films. Upholstery part (100) according to claim 1, wherein the at least one functional intermediate layer (14) has a lesser thickness than the thickness of the first layer and / or the second layer, wherein the thickness extends substantially perpendicular to the surface (11, 13) of the first layer (10) and / or the second layer (12). Upholstery part (100) according to one of the preceding claims, comprising a plurality of functional intermediate layers (14, 14'). Upholstery part (100) according to one of the preceding claims, wherein the thermoplastic material belongs to the group of polyolefins and / or polyesters. Upholstery part (100) according to one of the preceding claims, wherein the at least one functional intermediate layer (14) is bonded to the first layer (10) and / or to the second layer (12). Seat cushion for a vehicle seat comprising at least one cushion part (100) according to one of claims 1 to 5 .

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