Vehicle seat padding element

Abstract

Vehicle Seat Cushioning Element The vehicle seat cushioning element (12) comprises a foam block, said block comprising an outer surface (24) and a groove (26), said groove comprising a bottom (32) and side walls (30) opening onto said outer surface; the cushioning element further comprising an attachment support (22) disposed at the bottom of the groove (26). The attachment support (22) comprises: a contact surface (40) integral with the bottom (32) of the groove; and a rib (42) disposed opposite the contact surface, directed towards the outer surface (24) of the foam block. Figure for abbreviation: Figure 2

Description

Title of the invention: Vehicle seat padding element

[0001] The present invention relates to a padding element for a vehicle seat, comprising a foam block, said block comprising an external surface and a groove, said groove comprising a bottom and side walls opening onto said external surface; the padding element further comprising a hook support, disposed at the bottom of the groove.

[0002] Such a padding element is notably known from document FR2815901 (Dl), in the name of the Applicant.

[0003] In order to secure the seat cover to the padding element, it is known to equip said padding element with attachment supports inserted into the foam and formed, for example, of metal rods, rigid plastic pieces, or hook-and-loop fasteners. Such configurations complicate the recycling of the padding elements.

[0004] The aim of the invention is to provide a padding element combining good strength and a configuration that facilitates recycling.

[0005] To this end, the invention relates to a padding element of the aforementioned type, in which the attachment support comprises: a contact surface, integral with the bottom of the groove; and a rib, arranged opposite the contact surface, in the direction of the external surface of the foam block.

[0006] According to other advantageous aspects of the invention, the padding element comprises one or more of the following characteristics, taken individually or in all technically possible combinations:

[0007] - the mounting support is made of a non-expanded plastic material;

[0008] - each of the foam block and the non-expanded plastic material of the support The adhesive includes polyurethane;

[0009] - the contact surface and the rib of the mounting support extend in such a way continues along the length of the groove in the foam block.

[0010] The invention further relates to a method of manufacturing a padding element as described above, the method comprising: a step of manufacturing the attachment support by molding the non-expanded plastic material; then a step of manufacturing the foam block, by overmolding on said attachment support, so as to secure the contact surface of said attachment support with the bottom of the groove of the foam block.

[0011] According to other advantageous aspects of the invention, the manufacturing process comprises one or more of the following features, taken individually or in all technically possible combinations:

[0012] - the manufacturing step of the hanging support includes: the supply of an element molding comprising a groove of complementary shape to the rib of the hanging support; and the pouring of the plastic material in a fluid state into said groove, so that a top surface of said plastic material forms the contact surface of the hanging support;

[0013] - the molding element comprises flanks arranged on either side of the groove, said flanks having a complementary shape to the lateral walls of the groove of the foam block; and the manufacturing step of the foam block includes an overmolding on said molding element receiving the attachment support, so as to form the groove, the bottom of said groove being integral with the contact surface of said attachment support.

[0014] The invention further relates to a padding element as described above, produced by a manufacturing process as described above.

[0015] The invention further relates to a vehicle seat comprising: a padding element as described above; a soft cover, in contact with the external surface of said padding element; and a plurality of fastening elements, fixed on the one hand to said soft cover and on the other hand to the rib of the fastening support of the padding element.

[0016] Optionally, the vehicle seat is such that the plurality of attachment elements includes at least one metal clip extending between two ends, said ends being inserted into the rib of the attachment support.

[0017] The invention will become clearer upon reading the following description, given solely by way of non-limiting example, and made with reference to the drawings in which:

[0018] [Fig-1] [Fig. 1] is a partial view of a padding element according to an embodiment of the invention;

[0019] [Fig.2] [Fig.2] is a detailed, cross-sectional view of a vehicle seat including the padding element of [Fig.1]; and

[0020] [Fig.3] [Fig.4] Figures 3 and 4 are schematic representations of steps in a manufacturing process for the padding element of [Fig.1].

[0021] Fig. 2 schematically represents a detailed cross-sectional view of a vehicle seat 10 according to an embodiment of the invention.

[0022] The seat 10 includes in particular: a padding element 12; a cover 14; and a plurality of attachment elements 16. Only one attachment element 16 is visible in [Fig.2].

[0023] Figure 1 shows a partial view of the padding element 12, showing the cross-section of Figure 2. In the embodiment shown in Figure 1, the padding element 12 is intended for manufacturing a backrest of the seat 10. According to another embodiment not shown, a padding element is used to manufacture a seat cushion of the seat 10.

[0024] The padding element 12 includes a block 20 and a hook support 22.

[0025] The block 20 is formed from an elastically deformable foam, said foam being composed of a first plastic material. By "foam," it is understood that the block 20 has a flexible, open-cell alveolar structure (cells not shown).

[0026] Preferably, the foam forming the block 20 has a density between 30 kg / m³ and 100 kg / m³. Preferably, the foam forming the block 20 has a pressure-strain characteristic between 3 kPa and 20 kPa according to DIN EN ISO 3386.

[0027] Preferably, the first plastic material comprises polyurethane.

[0028] The block 20 comprises an external surface 24 and a groove 26. As described above Specifically below, the external surface 24 is intended to be covered with the coating 14 for contact with a part of the body of a user of the seat 10.

[0029] Consider an orthonormal basis (X, Y, Z) associated with the padding element 12. In the embodiment shown, the external surface 24 of the block 20 extends substantially in a plane (Y, Z).

[0030] The groove 26 extends over the external surface 24, as seen in [Fig. 1]. More specifically, as seen in [Fig. 2], the groove 26 comprises two lateral walls 30, opening onto said external surface 24. The groove 26 further comprises a bottom 32, disposed opposite the external surface 24 with respect to the lateral walls 30.

[0031] In the embodiment shown, the side walls 30 are substantially parallel to each other. Furthermore, in the embodiment shown, the side walls 30 are substantially parallel to the X direction.

[0032] In an alternative not shown, the side walls of the groove are slightly separated from each other between the bottom 32 of the groove and the external surface 24 of the block 20. For example, the side walls form an angle with each other between 0° and 15°.

[0033] A depth of the groove 26 along the X direction, between the bottom 32 and the external surface 24, is preferably between 5 mm and 3 cm, more preferably between 15 mm and 25 mm.

[0034] Preferably, the groove 26 extends continuously over the external surface 24 and comprises substantially straight portions and / or curved portions. In the embodiment shown, the groove 26 has a substantially U-shaped form, comprising two lateral portions 34 extending substantially along Z and a portion upper portion 36 extending substantially along Y. Each of the lateral portions 34 is continuous with the upper portion.

[0035] In an alternative not shown, the groove 26 is closed upon itself, forming, for example, a rectangle or a square. Such a shape is particularly suitable for a seat (not shown).

[0036] According to another variant not shown, the groove 26 has a shape substantially in H.

[0037] The shape of the groove 26 on the external surface 24 makes it possible to give a certain aesthetic appearance to the padding element 12, to ensure a satisfactory application of the coating 14 on the padding element 12 and to ensure a certain comfort for the passenger.

[0038] The hook support 22 is located at the bottom of the groove 26.

[0039] More specifically, the gripping support 22 comprises a contact surface 40 and a rib 42. The contact surface 40 is integral with the bottom 32 of the groove 26. The rib 42 is arranged opposite the contact surface 40, in the direction of the external surface 24.

[0040] Preferably, the contact surface 40 and the rib 42 of the attachment support extend continuously along the length of the groove 26 of the foam block. Like said groove, the attachment support 22 comprises substantially straight portions and / or curved portions.

[0041] Preferably, the attachment support 22 comprises a base 44 forming the contact surface 40. The rib 42 projects from said base 44, opposite the contact surface 40. More preferably, the base 44 has a width 46 greater than a width 48 of the rib 42, perpendicular to a principal direction of the groove 26.

[0042] Preferably, the attachment support 22 is formed of a second plastic material. More preferably, the second plastic material is non-expanded, that is to say, said second material does not have a cellular structure. In other words, said second material is homogeneous or solid.

[0043] Preferably, the second plastic material has a density between 600 kg / m³ and 900 kg / m³. Preferably, the second plastic material has a Shore A hardness between 60 and 100.

[0044] Preferably, the second plastic material comprises polyurethane.

[0045] The coating 14 of the seat 10 forms a flexible layer. The coating 14 is by example made of a textile material, natural or synthetic, or of natural or synthetic leather.

[0046] The coating 14 comprises: a main zone 50, in contact with the external surface 24 of the foam block 20; and a fixing zone 52, disposed in the groove 26.

[0047] For example, the coating 14 comprises a plurality of layers, including a base layer, a split-foam layer and an appearance layer.

[0048] Each of the plurality of hooking elements 16 is fixed, on the one hand to the rib 42 of the hooking support 22 of the padding element 12, and on the other hand to the fixing zone 52 of the covering 14.

[0049] In the embodiment shown, the hooking element 16 has a curved shape, extending between two ends 54. The hooking element 16 further comprises a central part 56 disposed between said ends 54.

[0050] Each end 54 of the hooking element 16 is inserted into the rib 42 of the hooking support 22. The central part 56 of the hooking element 16 is fixed to the fixing area 52 of the coating 14.

[0051] Preferably, the fastening element 16 is a metal clip, for example a self-piercing, deformable metal clip. Preferably, the plurality of fastening elements 16 are distributed along a length of the groove 26.

[0052] In the embodiment shown, the hooking element 16 is fixed in contact with the fixing zone 52 of the covering 14. According to an alternative embodiment (not shown), the seat 10 further comprises a plurality of return elements, each of said return elements being fixed, on the one hand, to the central part 56 of a hooking element 16, and on the other hand, to the fixing zone 52 of the covering 14.

[0053] A manufacturing process for the above padding element 12 will now be described.

[0054] The manufacturing process comprises: a first step of manufacturing the attachment support 22 by molding the second plastic material; then a second step of manufacturing the foam block 20 by overmolding it onto said attachment support 22. The contact surface 40 of said attachment support 22 is thus bonded to the bottom 32 of the groove 26 of the foam block 20.

[0055] Figures 3 and 4 schematically represent steps in the aforementioned manufacturing process.

[0056] In particular, [Fig.3] schematically represents, in section, a molding element 60 enabling the implementation of the first manufacturing step of the support 22 for hanging.

[0057] The molding element 60 includes a groove 62, the shape of which is complementary to the rib 42 of the attachment support. In the embodiment shown, the molding element 60 includes flanks 64, arranged on either side of the groove 62. The flanks 64 have a shape complementary to the lateral walls 30 of the groove 26 of the foam block 20. The groove 62 is located at one end of the flanks 64.

[0058] In the embodiment shown, the molding element 60 is formed as a single piece with a mold 66 shown in [Fig. 4]. Alternatively, the molding element 60 is a separate piece attached to the mold 66.

[0059] The mold 66 includes a mold bottom 68, of complementary shape to the external surface 24 of the block 20. The sides 64 of the molding element 60 form a projection in relation to the mold bottom 68, the groove 62 being arranged opposite said mold bottom.

[0060] The molding element 60 is arranged on the mold base 68 along a trajectory corresponding to that of the groove 26 on the external surface 24 of the block 20. For example, according to the embodiment shown, the molding element 60 came out of the material with the mold base 68.

[0061] In the embodiment shown in [Fig. 4], the mold 66 further comprises a lid 70, which can be removably assembled with the mold base 68 to define a closed enclosure 72. An internal shape of said enclosure is complementary to an external shape of the padding element 12.

[0062] Preferably, the mold 66 includes vents (not shown) allowing degassing of the enclosure 72.

[0063] According to a preferred embodiment, the first manufacturing step of the attachment support 22 takes place as follows:

[0064] First, the molding element 60 is arranged so that the groove 62 is open upwards.

[0065] Then, a first fluid composition 74 is implemented in a first injection head 76. The first fluid composition 74 is a precursor of the second plastic material forming the adhesion support 22.

[0066] Preferably, the first fluid composition 74 is obtained by mixing a first component, comprising an isocyanate resin, and a second component, comprising a polyol. For example, the second component comprises one or more polyols, as well as additives. The first fluid composition 74 thus makes it possible to obtain a polyurethane.

[0067] More preferably, a water content of the first fluid composition 74 is less than 0.5% by mass relative to the mass of polyols, so as to obtain a dense material.

[0068] Next, the first injection head 76 is positioned above the groove 62 of the molding element 60; then a bead 78 of first fluid composition 74 is poured into said groove 62 while the first injection head 76 is moved along a length of said groove. Preferably, a cross-section of the bead 78 is between 0.2 cm² and 0.6 cm². Preferably, a first flow rate fluid composition 74 is between 3 cm3 and 50 cm3 per second, so as to maintain a substantially laminar flow.

[0069] The groove 62 of the molding element is thus filled with the first fluid composition 74. After hardening, an upper surface 80 of the second plastic material obtained forms the contact surface 40 of the attachment support 22. The material filling the groove 62 forms the rib 42 of said attachment support.

[0070] According to a preferred embodiment, the second manufacturing step of the foam block 20 takes place as follows:

[0071] After the first fluid composition 74 has been poured, with the support 22 still held in the groove 62 of the molding element 60, a second fluid composition 82 ([Fig. 4]) is injected into a second injection head 84. This second fluid composition 82 is the precursor to the foam forming the block 20 of the padding element 12.

[0072] According to a preferred embodiment, the second fluid composition 82 comprises a mixture of the first and second components described above, comprising respectively an isocyanate resin and a polyol. In addition, a foaming agent such as water is added. Preferably, the water content of the second fluid composition 82 is between 0.5% and 6% by mass relative to the mass of polyols. The second fluid composition 82 thus makes it possible to obtain an expanded material such as a polyurethane foam.

[0073] Next, with the mold 66 open, the second injection head 84 is positioned above the mold bottom 68 and the second fluid composition 82 is poured onto said bottom 68. Preferably, a flow rate of the second fluid composition 82 is greater than 150 cm3 per second.

[0074] The mold 66 is then closed by assembling the mold base 68 and the lid 70, materializing the enclosure 72. The second fluid composition 82 expands, filling said enclosure 72 to form the foam block 20.

[0075] During the expansion of the second fluid composition 82, said second composition submerges the molding element 60 carrying the attachment support 22. The contact surface 40 of said support is thus covered by the forming foam.

[0076] The groove 26 of the block 20 is thus formed around the molding element 60. Furthermore, the bottom 32 of said groove is fixed to the contact surface 40 of the attachment support 22.

[0077] According to a first alternative, the pouring of the second fluid composition 82 is carried out while the first fluid composition 64, received in the groove 62, is still hardening. According to a second alternative, the pouring of the second fluid composition 82 is implemented after the end of the hardening of said first fluid composition 74. In both cases, good adhesion is obtained between the contact surface 40 of the support 22 of attachment and the bottom 32 of the groove 26.

[0078] Preferably, the mold 66 is closed while the second fluid composition 82 is already partially expanded. This facilitates the degassing of said mold.

[0079] After hardening of the second fluid composition 82, leading to the formation of the foam block 20, the resulting padding element 12 is demolded.

[0080] According to a preferred embodiment, prior to the first and second steps described above, the manufacturing process includes applying a release agent to the molding element 60 and to the mold base 68. Such a release agent is, for example, in the form of a liquid solution, sprayed onto the surfaces concerned.

[0081] After obtaining the padding element 12, the seat 10 is obtained by stapling each of the hooking elements 16 along the rib 42 of the hooking support 22, said hooking elements 16 being previously assembled to the fixing area 52 of the covering 14.

[0082] According to an alternative not shown, the hooking elements 16 are first stapled along the rib 42 of the hooking support 22, then the coating 14 is assembled to said hooking elements 16 by means of a plurality of anchoring elements (not shown).

[0083] According to another alternative, the hooking elements 16 are each stapled simultaneously on the fixing area 52 of the coating 14 and on the rib 42 of the hooking support 22, for example by a clamp deforming the hooking element 16 to pierce the rib 42 and the area 52 and then form a substantially closed loop of hooking element 16.

[0084] For example, the hooking elements 16 are distributed along the rib 42 so that each hooking element 16 is separated from its neighbors by a substantially regular distance.

[0085] The padding element 12 described above exhibits good mechanical resistance due to the adhesion between the foam block 20 and the support 22 for attachment.

[0086] Furthermore, such a padding element 12 made of plastic material, without a metal insert, facilitates recycling. To this end, the foam block 20 and the attachment support 22 are advantageously made of similar materials, including polyurethane.

Claims

Demands

1. A vehicle seat (10) padding element (12) comprising a foam block (20), said block comprising an external surface (24) and a groove (26), said groove comprising a bottom (32) and side walls (30) opening onto said external surface; the padding element further comprising an attachment support (22) disposed at the bottom of the groove (26); The padding element being characterized in that the attachment support (22) comprises: a contact surface (40), integral with the bottom (32) of the groove; and a rib (42), disposed opposite the contact surface, in the direction of the external surface (24) of the foam block.

2. Padding element according to claim 1, wherein the hook support (22) is formed of a non-expanded plastic material.

3. Padding element according to claim 2, wherein each of the foam block (20) and the non-expanded plastic material of the support (22) of attachment comprises polyurethane.

4. Padding element according to any one of the preceding claims, wherein the contact surface (40) and the rib (42) of the attachment support extend continuously over a length of the groove of the foam block.

5. Method of manufacturing a padding element (12) according to any one of claims 2 to 3, comprising: a step of manufacturing the attachment support (22) by molding the non-expanded plastic material; then a step of manufacturing the foam block (20), by overmolding it onto said attachment support, so as to secure the contact surface (40) of said attachment support with the bottom (32) of the groove (26) of the foam block.

6. A manufacturing method according to claim 5, wherein the manufacturing step of the hanging support comprises: providing a molding element (60) comprising a groove (62) of complementary shape to the rib (42) of the hanging support; and pouring the plastic material in the fluid state into said groove, so that an upper surface (70) of said plastic material forms the contact surface (40) of the hanging support.

7. A manufacturing method according to claim 6, wherein: the molding element (60) comprises flanks (64) arranged on either side of the groove, said flanks having a shape complementary to the lateral walls (30) of the groove in the foam block; and the manufacturing step of the foam block comprises an overmolding on said molding element receiving the attachment support, so as to form the groove (26), the bottom (32) of said groove being integral with the contact surface (40) of said attachment support.

8. Padding element (12) according to any one of claims 1 to 4, produced by a manufacturing process according to any one of claims 5 to 7.

9. Vehicle seat (10), comprising: a padding element (12) according to any one of claims 1 to 4 or according to claim 8; a soft cover (14), in contact with the external surface (24) of said padding element; and a plurality of fastening elements (16), fixed on one side to said soft cover and on the other side to the rib (42) of the fastening support of the padding element.

10. Vehicle seat (10) according to claim 9, wherein the plurality of fastening elements (16) comprises at least one metal clip extending between two ends (54), said ends being inserted into the rib (42) of the fastening support.

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