Vehicle seat and method for the assembly thereof

Abstract

The invention relates to a vehicle seat (1) comprising a structural frame (6), a backrest (2) and a seat part (3), wherein the backrest (2) has a lower part (8) and an upper part (7), wherein the upper part (7) has an upper cushion body (15) and a headrest (4) integrated therein and the lower part (8) has a support structure (11), a lower cushion body (9), supporting wires (19) for supporting the lower cushion part (9) and functional components (24). According to the invention, the lower part (8) of the backrest (2) has an upper fastening part (10a) and a lower fastening part (10b) and the lower part (8) is fixed on the structural frame (6) independently of the upper part (7) by means of these fastening parts (10a, 10b), the lower part (8) being fixed on the structural frame (6) in such a way that the lower part can be nondestructively detached.

Description

[0001] Vehicle seat and method for its assembly

[0002] The invention relates to a vehicle seat with a backrest, wherein a lower part of the backrest is of modular design, and to a method for assembling the vehicle seat.

[0003] Vehicle seats generally comprise several components, in particular a seat part, a backrest, and a headrest, which are attached to a structural frame of the vehicle seat. The seat part and the backrest each have a cushioned body with a continuous support surface for the seat occupant. The support surface is ergonomically shaped and attached to a supporting structure of the respective component. The headrest also has a correspondingly designed cushioned body. The individual components are then attached separately and independently of one another to the structural frame via the supporting structure.

[0004] When manufacturing the aforementioned components, in particular the upholstery, a specific shape is generally chosen, which, however, is not equally optimal in terms of ergonomics for every seat occupant. In particular, the stiffness or resilience of the upholstery material is predetermined and cannot be subsequently adjusted to the individual characteristics such as weight and dimensions of a different or changing seat occupant. Any functional components that may be present are also specified. US 6811227 B2 discloses a vehicle seat with a structural frame via which the vehicle seat is connected to the vehicle, as well as with a backrest and a seat part which are fixed to the structural frame. Additional dampers are installed in both the seat part and the backrest to increase comfort for the seat occupant.

[0005] US 7775603 describes a spring system for a seat part of a vehicle seat, wherein the spring system is fixed to the structural frame of the vehicle seat.

[0006] EP 3543124 discloses a cover for a vehicle seat, wherein the cover has cushioning bodies and functional components which can be fixed to a structural frame of a vehicle seat by means of a supporting structure.

[0007] US 10974634 B2 discloses a vehicle seat, wherein a holding structure is provided for the cushion body of the backrest, which allows replacement of the cushion body of the backrest attached to the holding structure.

[0008] Such designs sometimes even allow for the replacement of individual components of the vehicle seat, including the upholstery. This makes it possible to adapt a vehicle seat to the individual wishes and needs of a seat occupant. However, this requires the complete replacement of the respective components of the vehicle seat, which is usually quite complex and expensive, especially for vehicle seats where the headrest is integrated into the backrest.

[0009] The invention is therefore based on the object of providing a vehicle seat with a backrest that allows for easy and inexpensive individual adjustment of the backrest to the respective seat occupant. The object is also to provide a method for mounting the vehicle seat.

[0010] These objects are achieved by a vehicle seat and a method according to the independent claims. The subclaims describe preferred developments.

[0011] Thus, a vehicle seat is provided, comprising a structural frame, a backrest, and a seat part, wherein the backrest has a lower part and an upper part, wherein the upper part has an upper cushion body and a headrest integrated or accommodated therein, wherein the upper cushion body surrounds the headrest and is therefore not part of the headrest itself, and wherein the lower part has a supporting structure, a lower cushion body, support wires for supporting the lower cushion part, and functional components. The structural frame that holds the individual components of the vehicle seat preferably consists of metal struts or molded parts and is connected to the body of the vehicle in a well-known manner, for example via a rail system.According to the invention, it is provided that the lower part of the backrest has an upper fastening part and a lower fastening part and the lower part is fixed to the structural frame via these fastening parts independently of the upper part, wherein the lower part is fixed to the structural frame in a non-destructively detachable or non-destructively removable manner.

[0012] Advantageously, unlike the previously mentioned prior art vehicle seats, this creates the possibility of simply and easily arranging the crucial component of the backrest, the lower section, on the structural frame in an exchangeable manner. This allows a modular and prefabricated lower section, adapted to the respective seat occupant, to be provided, which can then be easily and tool-freely assembled without having to replace the entire backrest. In this way, the relevant lower section of the backrest, which is primarily subjected to stress by seat occupants of different weights and anatomies, can be adapted and provided separately, saving effort and costs. Subsequent replacement for a different occupant or a change in the occupant is also possible easily and tool-free.Preferably, the non-destructively detachable or removable fixation of the lower part is provided by a clip connection and / or a snap-in connection between the lower part and the structural frame. However, a snap-in connection, a clamp connection, or a combination of the aforementioned connection types is also possible. It is essential that the fixation is reversible, whereby reversible in this case means a non-destructive release of the fixation without special tools.

[0013] The lower area of ​​a backrest, which in the invention is formed by the lower part, is usually subject to particularly heavy loads, since the driver's seat occupant is permanently seated in this area. Consequently, this area is subject to increased stress and wear. This area also usually contains functional components that serve to improve comfort, so that these can also be specifically adjusted and / or replaced without replacing the entire backrest. In this case, it can preferably be provided that the lower part, as a modular, prefabricated unit, has the following functional components: a lumbar support and / or an adjustment system for the side bolsters and / or a massage system and / or a heating and / or ventilation system.In order to enable easy attachment to the modular base, it is preferably provided that the respective functional component is attached to a support mat, wherein the support mat is held by the support wires.

[0014] The upper part of the backrest, which consists of the headrest and an upper upholstered body, with the headrest being integrated or accommodated therein, is firmly attached to the structural frame, i.e. it cannot be easily detached or removed. The reason for this is that in such a vehicle seat with a headrest integrated into the upholstered body of the vehicle seat, this area, which is subject to less stress and requires less adjustment and which is defined in the invention by the upper part, generally does not need to be replaced. It can therefore generally remain on the backrest, thus saving effort and cost if the lower area (here the lower part) of the backrest needs to be adjusted or replaced.Preferably, the lower part should occupy between 65% and 75% of the backrest's surface area, and the separate, unconnected upper part should occupy between 25% and 35% of the backrest's surface area. It has been found that the highest and lowest stresses and signs of wear are expected on these areas of the backrest, and the functional components are located in this area.

[0015] The upper part is therefore not only formed by the headrest, but in such an integrated vehicle seat also forms a support surface for the occupant (not just for the head). Accordingly, it is preferably provided that the lower cushioning body of the lower part and the upper cushioning body of the upper part are separated from one another by a dividing line when the vehicle seat is in the assembled state, so that the lower cushioning body of the lower part and the upper cushioning body of the upper part form a support surface interrupted only by the dividing line, against which an occupant can rest their back. A dividing line does not mean that there is an air gap between the two cushioning bodies. Rather, this dividing line is to be understood as an area where the lower cushioning body and the upper cushioning body touch to form a continuous support surface.The upper part can also be manufactured more easily due to the two-part design, as it consists of fewer components that require adjustment or adaptation, and this can then be done automatically. Therefore, only a targeted adjustment of the lower part is provided within the framework of a modular design, not the entire backrest. Thus, such a two-part backrest design, in which only the modular lower part can be easily removed without tools, can shorten manufacturing and assembly times. Furthermore, due to its simplicity, manufacturing and assembly can be automated.

[0016] The structural frame of the vehicle seat preferably consists of metal struts or molded parts and is connected to the vehicle body in a well-known manner, for example via a rail system. Preferably, the structural frame comprises an upper cross member in a backrest region, to which the lower part is non-destructively detachably or removably attached to the structural frame via the upper fastening part, and a lower cross member, to which the lower part is non-destructively detachably or removably attached to the structural frame via the lower fastening part. Furthermore, preferably, the upper part of the backrest is attached to the upper cross member independently of the lower part and / or without shared fastening means.

[0017] Accordingly, an independent fastening of the two parts is achieved via the stabilizing and structural cross members, which simplifies the connection and enables secure holding of the lower part and also the upper part. In this case, it is preferably provided that the respective cross member has an area that is designed to complement the respective fastening part on the lower part in order to achieve the detachable or removable connection in a simple manner. For this purpose, it can be provided, for example, that the upper fastening part is formed by a nose that is fastened to the supporting structure of the lower part, preferably projecting upwards, and that is held on the upper cross member of the structural frame, in particular engaging in a holder fastened to the upper cross member.Furthermore, it can then be provided that the lower fastening part is formed by a hook-shaped section or a rear engagement on the supporting structure of the lower part, wherein the hook-shaped section is held on the lower cross member of the structural frame, in particular resting against a contact surface of the lower cross member and / or engaging around it in a hook-like manner. In addition, it can be provided that a locking element is arranged on the hook-shaped section, which engages into the lower cross member in order to fix the lower part to the structural frame in a non-destructively detachable or removable manner.

[0018] The supporting structure of the lower part is then preferably designed in such a way that the lower part is dimensionally stable and can withstand the forces that occur during use of the vehicle seat. Materials such as metal struts and / or plastic parts can be used for the supporting structure. For example, the supporting structure consists of a plastic frame onto which the lower cushion body is stretched. This also allows for secure attachment of the respective fastening components, so that the lower part can be securely held to the structural frame.

[0019] It is preferably further provided that at least some of the support wires of the lower part are held on the upper cross member and / or on the lower cross member of the structural frame, wherein ends of the respective support wire preferably engage in receptacles, for example holes, in the upper cross member and / or in the lower cross member. The respective support wire is, for example, part of a spring system of the backrest, which in turn interacts with the lower upholstery body at the rear, for example also via the support mat. By attaching it to the structural frame, the stability and durability of the lower part is improved and the spring system is improved. When assembling the lower part, the ends of the support wires can automatically thread into or engage the receptacles or openings, which simplifies assembly.

[0020] According to the invention, a method for assembling the vehicle seat according to the invention is also provided, comprising at least the following steps:

[0021] - Providing a structural frame with a backrest area and a seat part area;

[0022] - Providing a seat part and attaching the seat part to the seat part area;

[0023] - Providing an upper part with an upper cushion body and a headrest integrated or accommodated therein, the upper cushion body surrounding the headrest, and attaching the upper part to the backrest area;

[0024] - Providing a lower part independently of the upper part, preferably a modular, prefabricated lower part, and fixing the lower part to the backrest region, wherein the lower part and the upper part together form the backrest and the lower part is fixed to the backrest region of the structural frame independently of the upper part by

[0025] - the lower part is fixed to the top of the structural frame by means of an upper fastening part by a vertically oriented movement, and then

[0026] - the lower part is fixed to the underside of the structural frame in a non-destructively detachable or non-destructively removable manner by pivoting the lower part around the upper fastening part by means of a lower fastening part.

[0027] The same explanations and advantages apply to the method according to the invention as to the vehicle seat according to the invention. The embodiments of the method and vehicle seat can be combined with one another. The individual steps of the method do not necessarily have to be carried out in this order. For example, the lower part and then the upper part or the seat part can be attached to the structural frame. However, it is advantageous if the structural frame with at least the assembled upper part is manufactured first and then the lower part is assembled (before or after the seat part). In this way, the modular and prefabricated lower part can be manufactured in a JIT plant and then mounted to the separately manufactured structural frame with the upper part already firmly attached to it.

[0028] Preferably, it can also be provided that a vehicle seat with a previously assembled seat part and upper part is fitted with a new lower part, for example, due to a defect or a desired change in the configuration (conversion) of the lower part. Removal of the lower part is easily possible by performing the steps for assembling the lower part in reverse order.

[0029] In particular, it is provided that for assembly the upper fastening part is formed by a nose which is brought into engagement with a holder on an upper cross member of the structural frame by the vertically oriented movement of the lower part, and / or the lower fastening part is formed by a hook-shaped section of the supporting structure of the lower part which is brought to bear on and / or to encompass a contact surface on a lower cross member of the structural frame by the pivoting of the lower part around the upper fastening part, in particular is additionally latched.

[0030] The invention is explained in more detail below with reference to the accompanying drawings. Figure 1 shows an exploded view of a vehicle seat according to the invention;

[0031] Figure 2 shows a seat frame of the vehicle seat according to Figure 1;

[0032] Figure 3A is a side view of the vehicle seat shown in Figure 1 during the fixing of a lower part of the backrest;

[0033] Figure 3B is a side view of the vehicle seat shown in Figure 1 with the lower part of the backrest fully fixed; and

[0034] Figure 4 is a rear view of the vehicle seat shown in Figure 1.

[0035] Figure 1 shows a vehicle seat 1 in an exploded view, wherein the vehicle seat 1 has a backrest 2, a seat part 3, and a structural frame 6, via which the backrest 2 is pivotally connected to the seat part 3. The structural frame 6 is divided, as shown in Fig. 2, into a backrest area A, which supports the backrest 2, and a seat part area B, which supports the seat part 3.

[0036] As shown exploded in Fig. 1, the backrest 2 has an upper part 7 made up of several components, wherein the upper part 7 in the illustrated embodiment has a headrest 4, a belt outlet 5 and an upper cushion body 15 in which the headrest 4 is accommodated or integrated. Furthermore, a curtain fastening (not shown) can also be provided as a component of the upper part 7. The integrated headrest 4 is, for example, a 4-way headrest. The aforementioned components of the upper part 7 are each firmly attached to the backrest area A of the structural frame 6 and thereby form a firmly fixed unit. Furthermore, the backrest 2 has a headrest 4 which is independent of the upper part 7, separate from it ora non-connected lower part 8 with a structural support structure 11, for example in the form of a plastic frame, a lower cushion body 9 with side cheeks 17, an upper fastening part 10a in the form of a nose 18, and a lower fastening part 10b in the form of a hook-shaped section 23 with a locking element 23a or a rear grip. A cover 9a can also be pulled over the lower cushion body 9.

[0037] To achieve a cushioning effect, support wires 19 (indicated by dashed lines in Fig. 1) are suspended or attached to the supporting structure 11 of the lower part 8, which additionally hold a support mat 22 (indicated by dashed lines in Fig. 1). The support wires 19 and the support mat 22 are positioned flat behind the lower cushion body 9 and can thus absorb shocks.

[0038] The lower part 8 can be configured modularly and assembled in a JIT (Just in Time) factory as a modular unit, whereby this modular unit can then be clipped and / or snapped into place without tools onto the backrest area A of the structural frame 6 via the fastening parts 10a, 10b, as explained later. In addition, non-destructive removal of the modular lower part 8 is also possible if replacement of the lower part 8 is desired, for example in the event of a defect or if a different configuration is desired. Additional functional components 24 can be attached to the modular lower part 8, for example a lumbar support 24a (only schematically shown in Fig. 1) and / or side bolsters 17 with an automatic adjustment system 24b (only schematically shown in Fig. 1) and / or a massage system 24c (only schematically shown in Fig. 1) and / or a heater 24d (in Fig.1 only schematically shown) and / or ventilation 24e (only schematically shown in Fig. 1). Furthermore, a belt buckle 14 is attached to the structural frame 6 in the seat part area B, and armrests 12 are attached to the backrest area A. In order to enable easy attachment and non-destructive removal of the lower part 8 on or from the structural frame 6, the latter has an upper cross member 6a and a lower cross member 6b in the backrest area A. According to Fig. 2, a holder 21 or a receptacle is arranged on the upper cross member 6a, into which the nose 18 (upper fastening part 10a) on the lower part 8 or on the supporting structure 11 can engage. Furthermore, receptacles 20 in the form of holes are provided on the upper cross member 6a, into which the support wires 19 can be hung or fastened with their ends. The lower cross member 6b has a contact surface 25, against or around which the hook-shaped section 23 (lower fastening part 10b) can be placed.

[0039] Figures 3A and 3B illustrate the process for assembling the vehicle seat 1, in particular the installation of the lower part 8 of the backrest 2 to the structural frame 6:

[0040] First, the modularly constructed lower part 8 is provided with the respective functional components 24. The upper fastening part 10a on the lower part 8, which here has the shape of a lug 18, is positioned behind the holder 21 by a movement in the vertical direction z, for example, hooked under. This state, in which the upper fastening part 10a is hooked under, is shown in Figure 3A.

[0041] The lower part 8 is then pivoted about the holder 21 or the upper fastening part 10a and the lower fastening part 10b or the hook-shaped section 23 is thereby brought in the longitudinal direction x towards the lower cross member 6b. From a certain pivoting, the hook-shaped section 23 rests on the contact surface 25 on the lower cross member 6b and the locking element 23a locks, for example, into an opening or the like on the lower cross member 6b. This state is shown in Figure 3B. The lower part 8 is thus detachably fastened to the backrest area A of the structural frame 6. In this state, the lower cushion body 9 and the upper cushion body 15 form a support surface which is separated only by a dividing line L between the lower part 8 and the upper part 7 or between the two cushion bodies 9, 15 by a slot.

[0042] Finally, as shown in Figure 4, a panel 13 on the back of the backrest 2 can be closed by means of a zipper 16, so that the back is also closed.

[0043] To remove the lower part 8, it is pulled away from the lower cross member 6b in the longitudinal direction x, for example, after manually grasping the lower part 8. The locking element 23a then releases when a corresponding pulling force is exerted, and the lower part 8 can be pivoted about the upper fastening part 10a or the holder 21 by a pivoting movement. From a certain pivoting angle, the nose 18 can be freed from the holder 21 by a downward movement (z) of the lower part 8, and the lower part 8 can be removed and replaced with a new or repaired lower part 8. This process is carried out without tools and is non-destructive.

[0044] List of reference symbols

[0045] 1 vehicle seat

[0046] 2 backrest

[0047] 3 Seat part

[0048] 4 headrest

[0049] 5 Belt outlet

[0050] 6 structural frames

[0051] 6a upper cross member b lower cross member

[0052] 7 Top

[0053] 8 Lower part

[0054] 9 lower cushion body

[0055] 10a upper fastening part

[0056] 10b lower fastening part

[0057] 11 Supporting structure

[0058] 12 Armrest

[0059] 13 aperture

[0060] 14 Belt buckle

[0061] 15 upper cushion body

[0062] 16 zipper

[0063] 17 side panels

[0064] 18 Nose

[0065] 19 Support wire

[0066] 20 recordings

[0067] 21 Bracket

[0068] 22 Support mat

[0069] 23 hook-shaped section

[0070] 23a locking element

[0071] 24 functional element

[0072] 24a Lumbar support

[0073] 24b adjustment system

[0074] 24c massage system

[0075] 24d heating

[0076] 24e Ventilation

[0077] 25 contact surface

[0078] A backrest area

[0079] B Seating area

[0080] L dividing line x longitudinal direction z vertical direction

Claims

Patent claims 1. A vehicle seat (1) comprising a structural frame (6), a backrest (2), and a seat part (3), wherein the backrest (2) has a lower part (8) and an upper part (7), wherein the upper part (7) has an upper cushion body (15) and a headrest (4) integrated or accommodated therein, wherein the upper cushion body (15) surrounds the headrest (4), and wherein the lower part (8) has a supporting structure (11), a lower cushion body (9), support wires (19) for supporting the lower cushion part (9), and functional components (24), characterized in that the lower part (8) of the backrest (2) has an upper fastening part (10a) and a lower fastening part (10b), and the lower part (8) is fixed to the structural frame (6) independently of the upper part (7) via these fastening parts (10a, 10b), wherein the lower part (8) can be removed or removed non-destructively. is removably fixed to the structural frame (6).

2. Vehicle seat (1) according to claim 1, characterized in that the non-destructively detachable or removable fixation is formed by a clip connection and / or a snap connection between the lower part (8) and the structural frame (6).

3. Vehicle seat (1) according to claim 1 or 2, characterized in that the upper part (7) is permanently and / or non-removably fixed to the structural frame (6) and the upper part (7) preferably has a belt outlet (5).

4. Vehicle seat (1) according to one of the preceding claims, characterized in that the structural frame (6) in a backrest area (A) - an upper cross member (6a) to which the lower part (8) is fixed to the structural frame (6) via the upper fastening part (10a) in a non-destructively detachable or removable manner, and - has a lower cross member (6b) to which the lower part (8) is fixed to the structural frame (6) via the lower fastening part (10a) in a non-destructively detachable or removable manner.

5. Vehicle seat (1) according to claim 4, characterized in that the upper part (7) of the backrest (2) is fastened to the upper cross member (6a) independently of the lower part (8) and / or without common fastening means.

6. Vehicle seat (1) according to claim 4 or 5, characterized in that the upper fastening part (10a) is formed by a nose (18) which is fastened to the supporting structure (11) of the lower part (8), preferably projecting upwards, and which is held on the upper cross member (6a) of the structural frame (6), in particular engages in a holder (21) fastened to the upper cross member (6a).

7. Vehicle seat (1) according to one of claims 4 to 6, characterized in that the lower fastening part (10b) is formed by a hook-shaped section (23) on the supporting structure (11) of the lower part (8), wherein the hook-shaped section (23) is held on the lower cross member (6b) of the structural frame (6), in particular resting on a contact surface (25) of the lower cross member (6b) and / or engaging around it in a hook-shaped manner.

8. Vehicle seat (1) according to claim 7, characterized in that a locking element (23a) is arranged on the hook-shaped section (23), which locks into the lower cross member (6b) in order to fix the lower part (8) to the structural frame (6) in a non-destructively detachable or removable manner.

9. Vehicle seat (1) according to one of claims 4 to 8, characterized in that at least some of the support wires (19) of the lower part (8) are held on the upper cross member (6a) and / or on the lower cross member (6b) of the structural frame (6), wherein preferably ends of the respective support wire (19) engage in receptacles (20) in the upper cross member (6a) and / or in the lower cross member (6b).

10. Vehicle seat (1) according to one of the preceding claims, characterized in that the lower part (8) occupies 65% to 75% of the area of ​​the backrest (2) and the upper part (7) separate from it and not connected thereto occupies between 25% and 35% of the area of ​​the backrest (2).

11. Vehicle seat (1) according to one of the preceding claims, characterized in that the lower cushion body (9) of the lower part (8) and the upper cushion body (15) of the upper part (7) are separated from one another by a dividing line (L) in the assembled state of the vehicle seat (1), preferably by a slot, so that the lower cushion body (9) of the lower part (8) and the upper cushion body (15) of the upper part (7) form a support surface for the occupant which is interrupted by the dividing line (L).

12. Vehicle seat (1) according to one of the preceding claims, characterized in that the lower part (8) is designed as a modular, prefabricated unit with one or more functional components (24), wherein the modular, prefabricated unit has as functional component (24): a lumbar support (24a) and / or an adjustment system (24b) for the side bolsters (17) and / or a massage system (24c) and / or a heater (24d) and / or ventilation (24e).

13. Vehicle seat (1) according to claim 12, characterized in that the respective functional component (24) is fastened to a support mat (22), wherein the support mat (22) is held on the support wires (19).

14. Method for assembling a vehicle seat (1), in particular a vehicle seat (1) according to one of the preceding claims, comprising at least the following steps: - Providing a structural frame (6) with a backrest area (A) and a seat part area (B); - Providing a seat part (3) and fastening the seat part (3) to the seat part area (B); - Providing an upper part (7) with an upper cushion body (15) and a headrest (4) integrated or accommodated therein, wherein the upper cushion body (15) surrounds the headrest (4), and fastening the upper part (7) to the backrest area (A); - Providing a lower part (8) independent of the upper part (7), preferably a modular, prefabricated lower part (8), and fixing the lower part (8) to the backrest region (A), wherein the lower part (8) and the upper part (7) together form the backrest (2) and the lower part (8) is fixed to the backrest region (A) of the structural frame (6) by - the lower part (8) is fixed to the upper side of the structural frame (6) by means of an upper fastening part (10a) by a movement directed in the vertical direction (z), and then - the lower part (8) is fixed to the underside of the structural frame (6) in a non-destructively detachable or non-destructively removable manner by pivoting the lower part (8) around the upper fastening part (10a) by means of a lower fastening part (10b).

15. Method according to claim 14, characterized in that - the upper fastening part (10a) is formed by a nose (18) which is brought into engagement with a holder (21) on an upper cross member (6a) of the structural frame (6) by the movement of the lower part (8) in the vertical direction (z), and / or - the lower fastening part (10b) is formed by a hook-shaped section (23) of the support structure (11) of the lower part (8), which is brought into contact with and / or encompassing a contact surface (25) on a lower cross member (6b) of the structural frame (6) by pivoting the lower part (8) around the upper fastening part (10a), in particular is additionally latched.

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