Quilting system and manufacturing process for such a system

Abstract

Padding system (1) comprising: a pad (2) including a groove (4) on a surface (5) of the pad intended to receive an occupant, a hole (7) extending along an axis (A) and passing through the pad (2) from a bottom wall (6) of the groove, a fastening device (3) integral with the pad (2), configured to secure a headrest (40) to said pad (2), the fastening device (3) comprising: a fastening portion (10) including a portion (11) configured to allow the attachment of the headrest (40), said fastening portion (10) being held protruding in the groove (4), a base portion (15) extending below the fastening portion (10) in the hole (7), at least one attachment portion (20) connected to the base portion (15), including a rod (21) passing through the pad (2) at a distance from the hole (7) and a stop collar (22) projecting from the bottom wall (6) of the groove,The stop collar (22) is obtained by a material melting operation on a free end (23) of the rod (21). Figure 3 (abstract):

Description

Title of the invention: Quilting system and method for manufacturing such a system. Technical field

[0001] This disclosure relates to the field of fastening devices configured to secure a cover to padding, particularly for seats, preferably vehicle seats. This disclosure relates to a padding system comprising padding and a fastening device attached to the padding configured to secure a cover to the padding, as well as to a method for manufacturing such a padding system. Previous technique

[0002] Seat cushions are typically made substantially of urethane (or polyurethane, PU) polymer foam, in particular polyurethane foam obtained from polyether / polyol (or PUR) type polyols. Such foams can be shaped in molds relatively easily to form different cushion shapes for various vehicle seat components, such as the seat cushion and backrest, for example.

[0003] It is also known to incorporate overmolded fasteners into the mold. These fasteners allow, in particular, a headgear to be attached to the padding by clipping onto the insert fasteners.

[0004] Polyurethane foam padding is satisfactory, but can retain moisture, particularly in humid conditions. This can cause discomfort for an occupant of a vehicle seat containing such padding.

[0005] Furthermore, polyurethane foam is conventionally produced by mixing, among other things, polyols with isocyanates. The chemical reaction carried out emits CO2 to form a foam, and the emitted CO2 contributes to global warming.

[0006] Furthermore, polyurethane foam is not recyclable. Therefore, at the end of their life, the seats are dismantled and sorted to separate the recyclable components from the non-recyclable ones. The recyclable components are then ground up to form a new raw material, while the non-recyclable components are typically landfilled or, if possible, incinerated to generate energy.

[0007] However, prior art, in particular application FR 3 139 025, is known of a padding formed from a 3D entanglement of continuous fibers, arranged Irregularly forming loops welded together, this material is breathable and less CO2-intensive to manufacture. The fasteners typically used as inserts in polyurethane foam mattresses are not compatible with this 3D entanglement of continuous fibers.

[0008] Application FR 3 139 025 teaches how to densify and stiffen local areas of the 3D entanglement to allow the attachment of a cap to the padding, and according to various techniques.

[0009] According to the findings, there is a need for other fastening systems suitable for attaching a headgear to padding, and in particular to padding formed from a 3D entanglement of continuous fibers. Summary

[0010] This disclosure improves the situation.

[0011] A padding system is proposed comprising: • a padding comprising a groove on a surface of the padding intended to receive an occupant, a hole extending along an axis and passing through the padding from a bottom wall of the groove, • - a fastening device attached to the padding, configured for to secure a head covering to said padding, the fastening device comprising: • a fastening part, in particular a clipping part, comprising a portion, in particular elastically deformable, configured to allow the fastening of the cap, said fastening part being held protruding in the groove, • a base extending below the fixing part in the hole, • at least one attachment part connected to the base part, comprising a rod passing through the padding at a distance from the hole and a stop collar projecting from the bottom wall of the groove, the stop collar being obtained by melting material from a free end of the rod.

[0012] The fastening device is thus inserted into the padding before the fusion operation is carried out in such a way that the padding system includes a fastening device attached to the padding, by means of the stop formed by the collar of the attachment part.

[0013] The features described in the following paragraphs may optionally be implemented independently of each other or in combination with each other:

[0014] The stop collar can be welded to the mattress. In this case, the melting operation included a welding operation. The stop collar is thus obtained by melting material from a free end of the rod, causing the stop collar to weld to the bottom wall of the groove in the mattress.

[0015] Alternatively, the stop collar is not welded to the padding, the fusion operation having been carried out solely to produce the stop collar that bears against the bottom wall of the groove. In this case, the stop collar forms only a retaining element per stop.

[0016] The stop collar is, for example, obtained by ultrasonic melting. In this case, the melting operation consisted of using at least one sonotrode and a counter-tool to melt the end of the rod in order to obtain the stop collar, while keeping the fixing device in place in the padding.

[0017] The stem preferably extends substantially perpendicularly to the bottom wall of the groove. It passes through all or part of the thickness of the padding.

[0018] In some examples, the rod has a cylindrical shape. The cylindrical rod is preferably hollow at least at the free end of the rod.

[0019] In other examples, the stem has a blade shape. In this case, the padding preferably has a through slot, the blade extending into said slot.

[0020] The blade can extend transversely to an axis of the throat, in particular perpendicularly to it.

[0021] Alternatively, the blade can extend along the axis of the groove.

[0022] Regardless of its shape, the stem can play a stabilizing role for the fastening device in a position that allows for easy fastening, particularly clipping, of the cap. In particular, when there are several fastening devices, they are preferably aligned along the longitudinal axis of the groove, so as to facilitate the fastening of the cap.

[0023] The fastening device may include two attachment parts extending on either side of the hole, preferably symmetrically between them, with in particular an alignment between the rods and the hole along the axis of the groove.

[0024] The hole may include a first passage section, on a first upper portion of the hole, and at least a second passage section, extending along the axis of the hole, on a second lower portion of the hole. This at least second passage section may be wider than the first passage section, forming at least one shoulder between the first lower portion and the second upper portion of said hole. In this case, the fastening device may extend essentially at the level of the first upper portion of the hole.

[0025] The fastening device may include at least one connecting portion configured to connect the base portion and said at least one attachment portion. In the case where the hole has a first and a second passage section, then the connecting portion may extend into said second passage section, in particular at the shoulder.

[0026] The padding may comprise a 3D entanglement of continuous thermoplastic fibers arranged irregularly, forming loops welded together. In this case, the groove and the hole may be formed within the 3D fiber entanglement. If the stem forms a blade, then the slot in the padding is preferably formed within the 3D fiber entanglement.

[0027] The padding is then made of a material other than polyurethane foam. This padding material is advantageously a recyclable plastic, and its production generates less CO2 emissions than the production of polyurethane foam, thus reducing the environmental impact of the seat element incorporating this padding. In addition to the environmental benefits, the padding can be significantly lighter than a similar polyurethane foam padding. Furthermore, the padding material can be more breathable, allowing better air and moisture to pass through the padding.

[0028] The padding material and the fastening device material may be the same material, or two different materials with similar physicochemical properties, in particular the same chemical composition. This may allow the padding and fastening device to be recycled simultaneously without separating them. Alternatively, the padding material and the fastening device material may be incompatible materials. In this latter case, solutions may be implemented to separate the incompatible materials for recycling.

[0029] In examples, the padding material and the material of said fastening device may be a thermoplastic polymer whose main chain repeating pattern includes the ester function and optionally the ether function, in particular a thermoplastic elastomer whose main chain repeating pattern includes the ester function and optionally the ether function.

[0030] According to another aspect, in combination with all or part of the above, a vehicle seat assembly is proposed comprising a padding system as defined above, and a cover covering all or part of the padding, and fixed to the padding by a fixing element, in particular a clip, fitting into, in particular elastic, the fixing part of the fixing device.

[0031] According to another aspect, in combination with all or part of the above, a method for manufacturing a padding system as defined above is proposed, comprising: / A / Supply of a mattress comprising a groove on a surface of the mattress intended to receive an occupant, a hole extending along an axis (A) and passing through the mattress from a bottom wall of the groove, / B / Supply of a fastening device comprising: a fastening part, in particular a clipping part, comprising a portion, in particular elastically deformable, configured to allow the fastening of the cap, a base part extending below the fixing part, at least one attachment part connected to the base part, comprising a rod extending at a distance from the base part, / C / Insertion of the fastening device into the hole so that the fastening part is positioned in the groove, protruding from the bottom wall of the groove with the base part extending into the hole, the rod passing through the padding at a distance from the hole, the free end of the rod protruding from the bottom wall of the groove, / D / melting of material from a free end of the rod so as to make the stop collar, protruding from the bottom wall of the groove.

[0032] The supply of the padding may include obtaining the padding by extruding a 3D tangle of continuous thermoplastic fibers arranged irregularly forming loops welded together, and shaping the 3D tangle by thermoforming in order to obtain the groove and the hole.

[0033] According to another aspect, in combination with all or part of the foregoing, a method for recycling a vehicle seat assembly according to claim 12 is proposed, wherein the material of the padding and said fastening device is a thermoplastic polymer having a chain repeat pattern The main function includes the ester function and possibly the ether function, comprising: Optionally, separation of the cover from the padding system, grinding of the padding and the fastening device attached to the padding, for the production of granules, the use of granules for the manufacture of a plastic product based on a thermoplastic polymer whose main chain repeating pattern includes the ester function and possibly the ether function, in particular by molding or extrusion. Brief description of the drawings

[0034] Other features, details and advantages will become apparent upon reading the detailed description below, and upon analysis of the accompanying drawings, on which:

[0035] [Fig-1] is a schematic and perspective top view of an example system safe mattress.

[0036] [Fig.2] is a schematic and perspective bottom view of an example of quilting system.

[0037] [Fig.3] is an enlarged, schematic, top-view perspective view of the device fixing an example of a padding system.

[0038] [Fig.4] is an isolated, side, schematic and perspective view of the device fixing an example of a padding system.

[0039] [Fig.5] is a cross-sectional view along a plane including the axis of the throat of an example of quilting system.

[0040] [Fig.6] is a cross-sectional view similar to the view in [Fig.5] illustrating the installation work of a part of the process according to an example.

[0041] [Fig.7] is a view similar to [Fig.3] of another example of a fastening device.

[0042] [Fig.8] is a view similar to [Fig.3] of another example of a fastening device.

[0043] [Fig.9] schematically shows, in side view perspective, an example of a seating element.

[0044] [Fig. 10] schematically and in perspective shows an example of an installation for the implementation of at least part of an example of a process. Description of the implementation methods

[0045] In the various figures, the same reference numerals designate identical or similar elements. For the sake of brevity, only the elements that are useful for understanding the described embodiment are shown in the figures and are described in detail below.

[0046] In the following description, when reference is made to absolute position qualifiers, such as the terms "front", "rear", "top", "bottom", "left", "right", etc., or relative position qualifiers, such as the terms "above", "below", "superior", "lower", etc., or to orientation qualifiers, such as "horizontal", "vertical", etc., reference is made, unless otherwise specified, to the orientation of the figures or of a vehicle seat element or of a vehicle seat in its normal position of use.

[0047] Reference is now made to [Fig. 1], which represents a padding system 1 comprising padding 2 and a fastening device 3, integral with the padding, configured to allow the attachment of a cover over the padding 2, preferably under tension on the padding. Only one fastening device 3 is shown in the figure, but the padding system 1 may include several.

[0048] The padding may comprise a 3D entanglement of continuous thermoplastic fibers arranged irregularly, forming loops welded together, to which the fastening device 3 is attached. Generally, the fibers of the 3D entanglement, typically polyester-based, may be hollow and / or solid fibers. The fibers may have a diameter between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm. The term "continuous" in "continuous fibers" means that the fibers are much longer than their diameter, and due to the manufacturing process, which is described below, typically by a ratio of at least 100, or even 500, or even 1000.

[0049] The 3D entanglement of continuous fibers can have an apparent density between 20kg / m3 and 70 kg / m3, in particular between 45 kg / m3 and 60 kg / m3, preferably between 35 and 70kg / m3.

[0050] Often, and especially as can be understood from the extrusion manufacturing process which will be described below, the fibers typically extend from a first end on a first edge of the 3D entanglement and to a second end on a second edge of the 3D entanglement, opposite to the first edge.

[0051] The fibers of the padding may comprise a thermoplastic polymer, the fiber composition preferably comprising at least 95% by weight of polyester. For example, the fiber composition, or even the padding itself, may comprise 95% to 99% by weight of a first polymer from the polyester family, such as PBT (polybutylene terephthalate), and 1% to 5% by weight of a second polymer from the polyester family, such as PTT (trimethylene terephthalate) or another polymer from the polyester family. The sum of PBT and PTT (or the other polymer) may amount to 100% by weight of the fibers, or even the padding.

[0052] Preferably, the voids between the fibers of the 3D interlocking of quilting fibers are left free. This results in a highly breathable quilt, due to the numerous inter-spaces between the fibers which promote air circulation, and in contrast to a molded polyurethane body, which is closer to an air-impermeable body, comparatively.

[0053] The padding may be, but not limited to, seat padding, in particular seat padding, or backrest padding, armrest padding, or any other seat padding.

[0054] The padding 2 includes a groove 4, in depth, extending in this example along a longitudinal axis X, over a surface 5 of the padding intended to receive an occupant.

[0055] The padding 3 further includes a hole 7, more clearly visible in [Fig. 2] and [Fig. 5], extending along an axis A and passing through the padding 3 from of a bottom wall 6 of the groove 4. The hole 7 is in this example passing through from an opening opening onto the bottom wall 6 of the groove, and to an opening, on the side 8 of the padding opposite the groove 4. The hole 7 comprises a first passage section SI, on a first portion 71 of the hole 7 along the axis A, upper, and at least a second passage section S2, in extension along the axis A, on a second portion 72 of the hole, lower.

[0056] The length of the first portion 71 of the hole 7 along the axis A may be less than or equal to the length of the second portion 72 of the hole 7 along the axis A.

[0057] In the illustrated example, the second passage section S2 is wider than the first passage section SI, forming at least one shoulder 73 between the first portion 71 and the second portion 72 of the hole 7. The passage section of the hole is understood to be the section viewed along a plane perpendicular to the axis A. Said shoulder 73 is formed due to the difference in section between the first section SI and the second section S2.

[0058] In this example, the padding 3 has a surface 5 which is partially flat on one side of the groove 4, and curved in a raised relief on the other side of the groove, as seen in [Fig. 1]. The relief of the surface 5 may be different without departing from the scope of this disclosure.

[0059] The fastening device 3 comprises, as more clearly seen in Figures 3 and 4, a fastening portion 10, in this example a clipping portion, including a portion 11, in this example elastically deformable, configured to allow the attachment of the headband. The fastening portion 10 is held protruding in the groove 4. The portion 11, elastically deformable in this example, has two elastic tabs, each having a curved portion extending above the bottom wall 6 of the groove, so as to form together a portion of a circle, and then, at the free end of the fastening portion 10, two elongated plates along the longitudinal axis of the groove 4, inclined towards the inside of the circle. Other shapes of the fastening portion 10 can be envisaged, its role being to allow the headband to be attached to the frame of a seat.

[0060] The fastening device 3 further comprises a base portion 15 extending under the fastening portion 10 in the hole 7. In the illustrated example, the base portion 15 forms a support base supporting the fastening portion 10. In this example, the base portion 15 forms a hollow parallelepiped with a hollow base, extending essentially into the first portion 71 of the hole 7 and having a lower end 150 extending into the second portion 72 of the hole 7.

[0061] The fastening device 3 further comprises at least one attachment part 20 connected to the base part 15, in the illustrated example two attachment parts 20 on either side of the base part 15, in this example along the longitudinal axis X. Each The attachment part 20 includes a rod 21 passing through the padding 2 at a distance from the hole 7 and a stop collar 22 projecting from the bottom wall 6 of the groove 4. By "at a distance from the hole", we mean a non-zero distance, the rod or rods 21 not extending into the hole 7. In this example, the rods 21 are arranged at an equidistant distance from the attachment part 10, symmetrically on either side of it, on the longitudinal axis X.

[0062] Each stop collar 22 is obtained by melting material from a free end 23 of the rod 21. The stop collar 22 has a diameter greater than that of the rod 21, specifically the melted end 23 of the rod 21. The melted stop collar 22 forms an extended fixing surface and ensures the alignment of the fixing device 3, i.e., its non-rotation. Figure 4 illustrates the fixing device 3 before insertion into the padding and the melting operation. Figure 3 illustrates the fixing device 3 in place on the padding 2 after the melting operation to form the, in this example, the stop collars 22.

[0063] The two attachment parts 20 extend on either side of the hole 7, in this example symmetrically between them, with in particular an alignment between the rods 21 and the hole 7 along the longitudinal axis X of the groove 4.

[0064] The fastening device 3 in this example comprises at least one connecting portion 16 configured to connect the base portion 15 and each attachment portion 20 and extending along the second portion 72 of the hole 7. In this example, and as shown in [Fig. 5], the connecting portion 16 bears against the shoulder 73, extending, together with the base portion 15, over the entire extent of the second passage section S2 at the shoulder 73. It should be noted that each rod 21 extends above the second portion 72 of the hole and alongside the first portion 71 of the hole, in this example parallel to the axis A of the hole 7. In the illustrated example, the connecting portion 16 extends perpendicularly to the axis A of the hole, around the base portion 15.

[0065] In an example not shown, the hole 7 has a unique passage section from the surface 5 to the opposite side 8. In this case, the connecting portion 16 can bear against the side 8.

[0066] The fixing device 3 is held against the stop collar 22 which is supported or welded to the side of the surface 5 of the padding 2, and against the connecting part 16 which is supported against the shoulder 73, or, in the absence of a shoulder 73, against the opposite side 8 of the padding 2. For example, a pull-out strength of 7 daN is sought.

[0067] In the illustrated example, the stop collar 22 is welded to the padding 2. In this case, the stop collar 22 is welded, therefore fixed, to the bottom wall 6 of the groove. In other examples, it is not welded, forming only a buttress surface extending over the bottom wall 6 of the groove but not fixed to this wall 6.

[0068] The stop collar 22 can be obtained by ultrasonic melting. In such a case, as illustrated in [Fig. 6], the tool may include one or more sonotrodes SO and a counter-tool CO for holding the fastening device 3 while performing the melting operation, which may be a welding operation of the stop collar 22 to the padding 2 at the bottom wall 6 of the groove. In the illustrated example, the two sonotrodes SO are inserted onto the ends of the rods 21 from the groove 4, while the counter-tool CO is inserted into the second passage section S2, extending in this example into the entire second portion 72 of the hole 7. In the case of welding, the materials of the padding and the fastening device are compatible for welding. They may be made of the same thermoplastic polymer material. Alternatively, they may both be made of polyester.Alternatively, they incorporate weldable plastic materials, with the fastening device including, for example, ABS (polyacrylonitil / butadiene / styrene) or PC (polycarbonate).

[0069] The melting operation which is carried out consists of melting solid material, in this case made up of the free end 23 of the rod in order to bind, in the case of welding, to the padding and not the other way around.

[0070] Thus, as illustrated in [Fig. 6], in particular, the method used to manufacture the padding system comprises providing a padding 2 having a groove 4 on a surface 5 of the padding 2 intended to receive an occupant, a hole 7 extending along an axis A and passing through the padding 2 from a bottom wall 6 of the groove. The fastening device 3 is also provided and inserted into the hole 7 so that the fastening portion 10 is positioned in the groove 4, projecting from the bottom wall 6 of the groove, the free end 23 of the rod 21 projecting from the bottom wall 6 of the groove. Then, the material is melted from the free end 23 of the rod 21 to create the stop collar 22, projecting from the bottom wall 6 of the groove.

[0071] The rod 21, in the example of Figures 1 to 6, has a cylindrical shape. This cylindrical shape is hollow at least at the free end 23 of the rod 21, in this example along the entire height of the rod 21 as shown in Figures 5 and 6. The hollow shape allows for faster melting during the melting operation to produce the stop collar 22.

[0072] In the illustrated example where the padding 2 comprises a 3D entanglement of continuous thermoplastic fibers arranged irregularly forming loops welded together, the groove 4 and the hole 7 are formed in said 3D entanglement of fibers.

[0073] The material of the padding 2 and the material of the fastening device 3 may be the same material, or two different materials having similar physicochemical properties, in particular the same chemical composition. In this case, the melting operation may result in the welding of the stop collar 2 and the bottom wall 6 of the groove with which it is in contact. This may allow the padding and the fastening device to be recycled simultaneously without separating them. In an alternative embodiment, the material of the padding and the material of the fastening device may be incompatible materials. In this case, the stop collar 22 may not be welded but may simply bear against the bottom wall 6 of the groove.

[0074] In examples, the padding material 2 and the fastening device material 3 may be a thermoplastic polymer whose main chain repeating pattern includes the ester function and optionally the ether function, in particular a thermoplastic elastomer whose main chain repeating pattern includes the ester function and optionally the ether function.

[0075] In the example illustrated in Figures 1 to 6, the rod 21, in this case each rod 21, forms a cylindrical rod. In this example, no opening is pre-formed, for example by thermoforming, in the padding 2 so as to create a recess to accommodate the rod 21. Thus, the rod 21 enters the padding 2, separating, for example, the fibers from the 3D fiber entanglement.

[0076] In the examples illustrated in Figures 7 and 8, the rod 21 has a blade-like shape, as can be seen, that is to say, a rod 21 having, in a cross-section, a width less than its length, the cross-sectional shape being rectangular in this example. In this case, the padding 2 may include a through slot 30, formed for example in the 3D entanglement of fibers, the blade extending into said slot.

[0077] In the example of [Fig. 7], the blade extends transversely to the X-axis of the groove. This means that the cross-sectional length L of the blade extends along an axis perpendicular to the X-axis of the groove 4. The slot 30 is then also transverse to the X-axis of the groove 4. The shape of the stop collar 22 is substantially rectangular in this example. Also in the example of [Fig. 7], as in that of [Fig. 8], the fastening device 3 comprises a single attachment device 20, which, given its shape, allows the aligned positioning of the fastening device 3 in the padding 2 desired for securing the cap.

[0078] The example in [Fig.8] differs from that in [Fig.7] in that the blade forming the rod 21 extends along the X axis of the groove 4.

[0079] The creation of the slot does not require the removal of material.

[0080] Figure 9 shows an example of a vehicle seat assembly 100 comprising a padding system 1, and a cover 40 intended to cover all or part of the padding 2, when it is attached to the padding 2 by a fastening element, in particular a clip element, which in this elastic example is fitted in a manner known per se with the fastening part 10 of the fastening device 3. Several fastening devices 3 are preferably provided on the padding 2 to cooperate, in particular by clipping, with several fastening elements, in particular clips, of the cover 40.

[0081] The vehicle seat assembly 100 comprises a seat and a backrest forming a vehicle seat element 50 comprising a frame 51, or structure, in particular metallic, and the padding 2.

[0082] In [Fig. 9], an XYZ coordinate system is shown, with the X direction oriented along the sliding direction of the slide G between the seat frame 51 and a vehicle floor, the Y direction oriented along a transverse direction of the seat, and the Z direction along the vertical. The frame 51 comprises a seat frame and a backrest frame, articulated about a transverse axis of rotation, for example by means of continuous type joints.

[0083] The supply of the padding may include, as illustrated in [Fig. 10], obtaining the padding by extruding a 3D tangle of continuous thermoplastic fibers arranged irregularly forming loops welded together, as well as shaping the 3D tangle by thermoforming in order to obtain the groove and the hole.

[0084] The process comprises extruding a thermoplastic polymer, in particular a thermoplastic polymer as defined above, through an FE extrusion die of the installation. The FE extrusion die may, in particular, be fed with thermoplastic polymer granules, in particular a thermoplastic polymer as defined above, for example, from a recycling process.

[0085] The extrusion die FE comprises extrusion nozzles distributed along a lengthwise and a widthwise direction of the extrusion die. Starting with the thermoplastic polymer, the extrusion die generates a curtain RD of continuous molten fibers, which fall by gravity. The curtain of continuous molten RD fibers then passes between two counter-rotating calendering elements RC1, RC2, for example in the form of rollers, generating a 3D entanglement of fibers with an irregular or random distribution, with loop fusion between the continuous fibers and a layer of total thickness determined by the center distance between said two calendering elements RC1, RC2.

[0086] The two calendering elements RC1, RC2 are driven in rotation at a speed typically lower than the fiber fall speed, ensuring an accumulation fibers that form loops which heat-weld each other, generating irregular, random, three-dimensional entanglement.

[0087] Finally, the 3D fiber entanglement is solidified by immersion in a coolant to form a mat, which, after a possible cutting operation, allows for the 3D entanglement of continuous fibers. Solidification is achieved immediately afterward, as the two guide elements can be half-immersed in the coolant for this purpose.

[0088] The continuously moving 3D fiber tangle layer is then guided out of the coolant reservoir to be dried, typically by shaking / vibrating. The moving layer is then cut by cross-sections, allowing the production of different first CH layers of padding 2, as seen in [Fig. 10].

[0089] It is understood that the padding system may include a fastening device, or preferably several fastening devices, and in particular several fastening devices as previously described, received in several holes, distributed in parallel along the length of the same groove.

[0090] When the padding is a seat padding or a backrest padding, the padding, in particular the 3D entanglement of continuous fibers, may include a central part (typically called a medallion for the person skilled in the art), intended to receive the buttocks and / or thighs of the seat occupant in the case of a seat padding, and at least one lateral part PL, in particular a right lateral part and a left lateral part, typically in the form of a lateral roll, projecting from the central part PC, said lateral part configured to ensure the lateral support of the occupant, raised from the central part.

[0091] The groove 4 can extend along the length of the padding, in excess of the central part PC, along the lateral part, said groove juxtaposed to the lateral part, and in order to stretch the cap over the central part, but also against the surface of the central part of the padding.

[0092] When the material of the padding 2 and the fastening device 3 is a thermoplastic polymer whose main chain repeating pattern includes the ester function and optionally the ether function, a recycling process can be implemented at the end of the life cycle comprising:

[0093] - optionally, a separation of the headgear from the padding system 1,

[0094] - a grinding of the padding 2 and the fastening device 3 attached to the padding 2, for the production of pellets,

[0095] - a use of the granules for the manufacture of a plastic product based on a thermoplastic polymer whose main chain repeating pattern includes the ester function and possibly the ether function, particularly by molding or extrusion.

Claims

Demands

1. A safe mattress system (1) comprising: • a safe mattress (2) including a groove (4) on a surface (5) of the mattress intended to receive an occupant, a hole (7) extending along an axis (A) and through the mattress (2) from a bottom wall (6) of the groove, • a fastening device (3) integral with the mattress (2), configured to secure a headrest (40) to said mattress (2), the fastening device (3) comprising: • a fastening portion (10) including a portion (11) configured to allow the attachment of the headrest (40), said fastening portion (10) being held protruding in the groove (4), • a base portion (15) extending under the fastening portion (10) in the hole (7), • at least one attachment portion (20) connected to the base portion (15),comprising a rod (21) passing through the padding (2) at a distance from the hole (7) and a stop collar (22) projecting from the bottom wall (6) of the groove, the stop collar (22) being obtained by a material melting operation on a free end (23) of the rod (21).

2. Padding system (1) according to claim 1, wherein the stop collar (22) is welded to the padding (2).

3. Padding system (1) according to claim 2, wherein the stop collar (22) is obtained by ultrasonic fusion.

4. Padding system (1) according to any one of the preceding claims, wherein the rod (21) has a cylindrical shape, which is hollow at least at said free end (23) of the rod (21).

5. Padding system (1) according to any one of claims 1 to 3, wherein the stem (21) has a blade shape, the padding (2) having a through slot (30), the blade extending in said slot (30), the blade extending transversely to an axis (X) of the groove (4).

6. Padding system (1) according to any one of claims 1 to 3, wherein the stem (21) has a blade shape, the padding (2) having a through slot (30), the blade extending in said slot (30), the blade extending along the axis (X) of the groove.

7. Padding system (1) according to any one of the preceding claims, wherein the fastening device (3) comprises two fastening parts (20) extending on either side of the hole (7), preferably symmetrically between them, with in particular an alignment between the rods (21) and the hole (7) along the axis (X) of the groove.

8. Padding system (1) according to any one of the preceding claims, wherein the padding (2) comprises a 3D entanglement of irregularly arranged continuous thermoplastic fibers forming loops welded together, said groove (4) and hole (7) being formed in said 3D entanglement of fibers.

9. Vehicle seat assembly (100) comprising a padding system (1) according to any one of claims 1 to 8, and a cover (40) covering all or part of the padding (2), and fixed to the padding (2) by a fastening element that fits into, in particular, an elastic element, with the fastening part (10) of the fastening device (3).

10. A method for manufacturing a padding system (1) according to any one of the preceding claims, comprising: • / A / Providing a padding (2) comprising a groove (4) on a surface (5) of the padding (2) intended to receive an occupant, a hole (7) extending along an axis (A) and passing through the padding (2) from a bottom wall (6) of the groove, • / B / Providing a fastening device (3) comprising: • a fastening portion (10) comprising a portion (11) configured to allow the fastening of the headgear (40), • a base portion (15) extending under the fastening portion (10), • at least one attachment part (20) connected to the base part (15), comprising a rod (21) extending away from the base part (15), • / C / Insertion of the fastening device (3) into the hole (7) so that the fastening part (10) is in position in the groove (4), projecting from the bottom wall (6) of the groove with the base part (15) extending into the hole (7), the rod (21) passing through the padding (2) away from the hole (7), the free end (23) of the rod (21) being projecting from the bottom wall (6) of the groove, • / D / melting of material from a free end (23) of the rod (21) so as to make the stop collar (22), projecting from the bottom wall (6) of the groove.

11. Method according to claim 10, the supply of the padding (2) comprising obtaining the padding by extrusion of a 3D entanglement of continuous thermoplastic fibers arranged irregularly forming loops welded together, and shaping the 3D entanglement by thermoforming in order to obtain the groove (4) and the hole (7).

12. A method for recycling a vehicle seat assembly according to claim 9, wherein the material of the padding (2) and said fastening device (3) is a thermoplastic polymer whose main chain repetition pattern includes the ester function and optionally the ether function, comprising: • optionally, separating the cover from the padding system, • grinding the padding and the fastening device attached to the padding, for the production of granules, • using the granules for the manufacture of a plastic product based on a thermoplastic polymer whose main chain repetition pattern includes the ester function and optionally the ether function, in particular by molding or extrusion.