Vehicle seat trim element and associated manufacturing process

Abstract

Vehicle Seat Upholstery Element and Associated Manufacturing Method. The present invention relates to an automotive seat upholstery element (10), comprising: a foam block (12); a reinforcement layer (16); and a cover layer (18); the reinforcement layer (16) being disposed between the foam block (12) and the cover layer (18) and integral with each of said foam block and cover layer. Each of the foam block (12) and the reinforcement layer (16) is formed of at least 75% by mass of polyurethane, preferably at least 85% by mass of polyurethane. Figure for the abstract: Figure 2

Description

Title of the invention: Upholstery element for vehicle seat and associated manufacturing method

[0001] The present invention relates to a vehicle seat trim element, comprising: a foam block; a reinforcement layer; and a covering layer; the reinforcement layer being disposed between the foam block and the covering layer and integral with each of said foam block and covering layer.

[0002] A similar trim element is notably known from document FR3092042 in the name of the Applicant.

[0003] It is advantageous to offer a lining element requiring a minimum number of steps for assembling solid layers together. Furthermore, the presence of different layers of varying chemical compositions complicates the recycling of such a lining element.

[0004] In order to solve these problems, the invention relates to a trim element as described above, in which each of the foam block and the reinforcement layer is formed of at least 75% by mass of polyurethane, preferably of at least 85% by mass of polyurethane.

[0005] According to other advantageous aspects of the invention, the trim element comprises one or more of the following characteristics, taken individually or in all technically possible combinations:

[0006] - the coating layer is formed of at least 75% by mass of polyurethane, preferably of at least 85% by mass polyurethane.

[0007] - one face of the reinforcing layer comprises a first zone, in contact with the block of foam, and a second area, away from said block of foam;

[0008] - the foam block has a density between 25 Kg / m3 and 80 Kg / m3;

[0009] - the reinforcing layer has a density between 200 kg / m³ and 1,000 kg / m³

[0010] - the reinforcing layer has a thickness between 200 µm and 2 mm;

[0011] - the coating layer has a thickness between 10 pm and 100 pm.

[0012] The invention further relates to a method for manufacturing an element of a lining according to any one of the preceding claims, comprising the following steps: supplying a mold comprising a mold base and a lid, capable of being removably assembled to form an enclosure; with the mold base and lid separated, deposition, on a wall of the mold base, of a first fluid composition, precursor of the coating layer, and then of a second fluid composition, precursor of the reinforcing layer, so as to bond the layer reinforcement to the coating layer; then deposition in the bottom of the mold of a third fluid composition, precursor of the foam block, said third fluid composition comprising an expanding agent; assembly of the bottom of the mold and the lid; and expansion of the third fluid composition, so as to bond the foam block to the reinforcement layer.

[0013] According to other advantageous aspects of the invention, the method comprises one or more of the following features, taken individually or in all technically possible combinations:

[0014] - during the expansion step of the third fluid composition, a portion of the the mold lid is in contact with the second zone of the reinforcement layer;

[0015] - the second fluid composition comprises an amount of water less than 1% in mass relative to a total mass of the second fluid composition;

[0016] - the deposition of at least one of the first and second fluid compositions is carried out by spraying;

[0017] - the deposit of the third fluid composition is carried out by pouring it into the bottom of mold.

[0018] 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:

[0019] [Fig-1] [Fig.1] is a cross-sectional view of a trim element according to a mode of realization of the invention; and

[0020] [Fig.2] Fig.2 is a detailed, cross-sectional view of the trim element of the [Fig.l].

[0021] Figures 1 and 2 show a trim element 10 according to an embodiment of the invention. The trim element 10 is particularly intended to equip the seat or backrest of a vehicle seat (not shown). Such a seat is particularly intended to be mounted in a land, air, or sea vehicle, for example, in a car, bus, truck, train, airplane, motorcycle, boat, or agricultural vehicle.

[0022] The trim element 10 comprises a block 12 and a cover 14.

[0023] The block 12 is formed from an elastically deformable foam, said foam being composed of a first polymer material. By "foam," it is understood that the block 12 has a flexible alveolar structure.

[0024] Preferably, the foam forming the block 12 has a density between 25 kg / m³ and 80 kg / m³. Preferably, the foam forming the block 12 has a pressure-strain characteristic between 3 kPa and 30 kPa according to DIN EN ISO 3386.

[0025] The first polymer material comprises at least 75% by mass of polyurethane relative to the total mass of said first polymer material. Preferably, the first polymer material comprises at least 85% by mass of polyurethane relative to the total mass of said first polymer material, more preferably 100% by mass of polyurethane.

[0026] For example, when the first polymer material comprises less than 100% by mass of polyurethane, the first polymer material comprises polyurethane as well as a bio-based or recycled material and / or a material derived from tires and / or polyethylene terephthalate and / or an inorganic filler.

[0027] Preferably, the thickness of the foam block 12 is between 5 mm and 200 mm.

[0028] The cover 14 forms a flexible sheet. As seen in [Fig.2], the cover 14 comprises a reinforcement layer 16 and a coating layer 18. As described below, the reinforcement layer 16 is arranged between the foam block 12 and the coating layer 18 and is integral with each of said foam block and coating layer.

[0029] The reinforcing layer 16 is formed of a second polymer material. More preferably, the second polymer material is non-expanded, that is to say, said second material does not have closed cells.

[0030] The second polymer material comprises at least 75% by mass of polyurethane relative to the total mass of said second polymer material. Preferably, the second polymer material comprises at least 85% by mass of polyurethane relative to the total mass of said second polymer material, more preferably 100% by mass of polyurethane.

[0031] According to a specific example, the second polymer material comprises polyurethane as well as a bio-based or recycled material and / or a material derived from tires and / or polyethylene terephthalate and / or an inorganic filler.

[0032] Preferably, the second polymer material has a density between 200 Kg / m3 and 1000 Kg / m3.

[0033] The reinforcing layer 16 comprises a first 20 and a second 22 opposite faces. A thickness 24 of the reinforcing layer 16 is preferably between 200 µm and 2 mm, more preferably between 0.5 mm and 1.5 mm.

[0034] The coating layer 18 is integral with the first face 20 of the reinforcement layer 16. Opposite said reinforcement layer, the coating layer 18 has an external face 26.

[0035] The coating layer 18 is formed of a third polymer material. More preferably, the third polymer material is non-expanded, that is to say, said third material does not have closed cells.

[0036] The third polymer material is a so-called mold base paint, intended to give the final product its external appearance.

[0037] Preferably, said third polymer material comprises at least 75% by mass of polyurethane relative to the total mass of said third polymer material. More preferably, the third polymer material comprises at least 85% by mass of polyurethane relative to the total mass of said third polymer material.

[0038] Preferably, the third polymer material is a two-component material. Such a material gives good performance to the final product.

[0039] Preferably, a dry mass extract of the bottom of mold paint is between 20% and 40% of the deposited liquid mass.

[0040] A thickness 28 of the coating layer 18 is between 10 pm and 100 pm, more preferably between 15 pm and 50 pm.

[0041] Preferably, as described below, the outer face 26 of the coating layer 18 has a textured or non-smooth appearance, for example with slight asperities.

[0042] Thus, the cover 14 has an external face, formed by the external face 26 of the coating layer 18, and an internal face, formed by the second face 22 of the reinforcement layer 16.

[0043] According to one embodiment, the second face 22 of the reinforcing layer 16 comprises: a first zone 30, in contact with the foam block 12; and a second zone 32, away from said foam block. Preferably, the second zone 32 is adjacent to an edge 33 of the cover 14. More preferably, the second zone 32 is located at a periphery of the first zone 30.

[0044] Fig. 1 shows an installation 40 for manufacturing the trim element 10 described above.

[0045] The installation 40 includes a mold 42 and at least one application device 44, 46, 48.

[0046] The mold 42 comprises: a mold base 50, having a first surface 52; and a lid 54, having a second surface 56.

[0047] The first surface 52 of the bottom 50 of the mold has in particular a shape complementary to the external face 26 of the coating layer 18. In particular, the first surface 52 of the bottom 50 of the mold preferably has slight asperities intended to form the texture of said external face 26.

[0048] The second surface 56 of the lid has a shape complementary to the foam block 12. In the embodiment shown, the lid 54 comprises several parts 58, 59 that are removable from one another. Such a configuration allows in particular to adapt to a particular shape of the 12 foam block, especially to an undercut shape.

[0049] The mold base 50 and the lid 54 are able to be assembled in a removable manner, to form an enclosure 60 defined by the first 52 and second 56 surfaces.

[0050] Preferably, the mold 42 further includes vents (not shown) allowing degassing of the enclosure 60.

[0051] In the embodiment shown, the installation 40 comprises a first 44, a second 46 and a third 48 application devices.

[0052] The first application device 44 is suitable for depositing a first fluid composition 64 on the bottom 50 of the mold, in contact with the first surface 52. The first fluid composition 64 is a precursor of the third polymer material forming the coating layer 18.

[0053] Preferably, the first application device 44 is adapted for spraying the first fluid composition 64 onto the bottom 50 of the mold.

[0054] The second application device 46 is suitable for depositing a second fluid composition 66 onto the mold base 50. The second fluid composition 66 is a precursor of the second polymer material forming the reinforcing layer 18.

[0055] Preferably, the second fluid composition 66 comprises an amount of water less than 1% by mass relative to a total mass of the second fluid composition.

[0056] Preferably, the second application device 46 is adapted for spraying the second fluid composition 66 onto the bottom 50 of the mold.

[0057] The third application device 48 is suitable for depositing a third fluid composition 68 into the bottom 50 of the mold.

[0058] The third fluid composition 68 is a precursor of the first polymer material forming the foam block 12. Said third fluid composition 68 includes, in particular, a blowing agent.

[0059] According to one embodiment, the third application device 48 is adapted for depositing the third fluid composition 68 onto the mold bottom 50 by pouring. According to another variant, the third application device 48 is adapted for depositing the third fluid composition 68 by injection into the mold 42.

[0060] A method for manufacturing the above-mentioned trim element 10, using the installation 40 described above, will now be described.

[0061] Optionally, a release agent is first applied to the first 52 and second 56 surfaces of the mold 42. Such a release agent is, for example, in the form of a liquid solution, sprayed onto the surfaces concerned. For example, the release agent includes an incorporated noise-reducing compound. Alternatively, a noise-reducing compound is sprayed over the release agent on the second surface 56, after the release agent has been sprayed.

[0062] Next, the first fluid composition 64 is sprayed onto the first surface 52 of the mold base 50, using the first application device 44. Then the second fluid composition 66 is sprayed onto the layer of the first composition thus obtained, using the second application device 66. A precursor of the coating 14 is thus obtained.

[0063] Next, by means of the third application device 48, the third fluid composition 68 is poured into the bottom 50 of the mold, onto said precursor of the cover 14. In particular, the pouring is carried out on a first part of said precursor corresponding to the first zone 30 of the second surface 22 of the reinforcement layer 16, as described above.

[0064] Next, the mold 42 is closed by assembling the mold base 50 and the lid 54. According to one embodiment, at least a portion 59 of the lid 54 is in contact with a second portion of the precursor of the cover 14, corresponding to the second zone 32 of the second surface 22 of the reinforcing layer 16, as described above. Preferably, the closing of the mold 42 is therefore carried out while the first 64 and second 66 fluid compositions are at least partially hardened.

[0065] The enclosure 60 is thus materialized. The third fluid composition 68 expands, filling said enclosure 60 to form the foam block 12.

[0066] After hardening of the third fluid composition 68, leading to the formation of the foam of block 12, the filling element 10 of [Fig. 1] is obtained. It is then demolded.

[0067] As an alternative to the process described above, the mold 42 is closed before the application of the third fluid composition 68, the latter then being injected into the enclosure 60.

[0068] Such a manufacturing process makes it possible to obtain a complete trim element by simply applying different fluid compositions, without a subsequent step of assembling solid materials together.

[0069] The element 10 is then assembled to a frame (not shown) to form a vehicle seat. Where the second surface 22 of the reinforcement layer 16 has a second zone 32 not attached to the foam block 12, said second zone 32 is preferably used as an attachment zone for the element 10 to said frame. The second zone 32 is, for example, wrapped around attachment ridges (not shown) present on said frame, or attached to clips (not shown) that hook onto said frame.

[0070] Each of the foam block 12, the reinforcement layer 16 and the coating layer 18 having a high polyurethane content, recycling of the trim element 10 is facilitated compared to a block 12 and a cover 14 formed of separate materials.

Claims

Demands

1. Automotive seat trim element (10), comprising: a foam block (12); a reinforcement layer (16); and a cover layer (18); the reinforcement layer (16) being disposed between the foam block (12) and the cover layer (18) and integral with each of said foam block and cover layer; the trim element being characterized in that each of the foam block (12) and the reinforcement layer (16) is formed of at least 75% by mass of polyurethane, preferably of at least 85% by mass of polyurethane.

2. Trim element according to claim 1, wherein the coating layer (18) is formed of at least 75% by mass of polyurethane, preferably of at least 85% by mass of polyurethane.

3. A trim element according to claim 1 or 2, wherein one face (22) of the reinforcement layer (16) has a first zone (30), in contact with the foam block (12), and a second zone (32), away from said foam block.

4. A filling element according to any one of the preceding claims, wherein the foam block (12) has a density between 25 Kg / m3 and 80 Kg / m3.

5. A trim element according to any one of the preceding claims, wherein the reinforcing layer (16) has a density between 200 Kg / m3 and 1000 Kg / m3.

6. A trim element according to any one of the preceding claims, wherein the reinforcing layer (16) has a thickness (24) between 200 pm and 2 mm.

7. Trim element according to any one of the preceding claims, wherein the coating layer (18) has a thickness (28) of between 10 pm and 100 pm.

8. A method for manufacturing a trim element according to any one of the preceding claims, comprising the following steps: - providing a mold (42) comprising a mold base (50) and a lid (54), capable of being removably assembled to form an enclosure (60); - with the mold base and lid separated, a first fluid composition (64) is deposited on a wall of the mold base, precursor of the coating layer (18), then of a second fluid composition (66), precursor of the reinforcement layer (16), so as to bond the reinforcement layer (16) to the coating layer (18); then - deposition in the bottom (40) of the mold of a third fluid composition (68), precursor of the foam block (12), said third fluid composition comprising an expanding agent; assembly of the bottom of the mold and the lid; and expansion of the third fluid composition, so as to bond the foam block (12) to the reinforcement layer (16).

9. A manufacturing method according to claim 8 taken in combination with claim 3, wherein, during the expansion step of the third fluid composition (68), a part (59) of the mold cover (54) is in contact with the second zone (32) of the reinforcement layer (16).

10. A manufacturing process according to claim 8 or 9, wherein the second fluid composition (66) comprises an amount of water less than 1% by mass relative to a total mass of the second fluid composition.

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