Method for producing a cushion and cushion for a vehicle

Abstract

A method for producing a cushion is proposed. The method comprises the following steps: • (S1) providing a substrate (20) comprising a vertical nonwoven fabric, wherein the substrate (20) is substantially non-expandable, • (S2) placing the substrate (20) into a temperature-controllable mold (10), • (S3) deforming the substrate (20) with the temperature-controllable mold (10), and • (S4) feeding a flow of hot gas and / or cool gas through the temperature-controllable mold (10). By feeding the gas flow through the temperature-controllable mold (10), the substrate (20) is brought into contact with the hot gas and / or the cool gas.

Description

[0001] 24-2319 PIF

[0002] 1

[0003] Methods for manufacturing a cushion and cushions for a vehicle

[0004] The invention relates generally to the field of upholstery components. Specifically, the invention relates to a method for manufacturing upholstery and to such upholstery for a vehicle.

[0005] In the field of upholstery, there is a growing search for alternatives to polyurethane foam. Non-woven fabric is a well-known material that can be used in many applications instead of PU foam. However, processing such a material in upholstery presents a challenge. In particular, it can prove difficult to produce upholstery with non-woven fabric that exhibits similar static, haptic, and / or dynamic properties to PU foam.

[0006] Conventional processing methods for nonwovens often reach their limits when manufacturing upholstery components. Shaping the nonwoven requires new approaches to achieve the desired upholstery properties.

[0007] The object of the present invention is to address the aforementioned challenges and to at least partially overcome the disadvantages of the prior art. In particular, the invention aims to provide an improved method for manufacturing upholstery and an improved upholstered door for a vehicle.

[0008] The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description.

[0009] A first aspect of the present disclosure relates to a method for manufacturing a cushion. The method comprises the following steps:

[0010] • Providing a substrate comprising a vertical nonwoven fabric, wherein the substrate is essentially non-expandable,

[0011] • Placing the substrate in a temperature-controlled mold,

[0012] • Deforming the substrate with the temperature-controlled forming tool, and

[0013] • Flowing a hot gas and / or a cool gas through the temperature-controlled mold. 24-2319 PIF

[0014] 2

[0015] By flowing through the temperature-controlled mold, the substrate is exposed to the hot gas and / or the cool gas.

[0016] A method for manufacturing a cushion is proposed, wherein the cushion can be designed for use in a motor vehicle. The method provides, in a first step, a substrate comprising a vertical nonwoven fabric and being essentially non-expandable. The substrate can comprise one or more layers of vertical nonwoven fabric. In the context of this disclosure, a nonwoven fabric can be understood as a textile fabric produced by felting, needling, or bonding fibers. A vertical nonwoven fabric can be defined as a nonwoven fabric in which the fibers are predominantly oriented perpendicular to the substrate surface or the main surface of the substrate. A vertical nonwoven fabric can also be called a V-nonwoven or V-lap nonwoven.The term "non-expandable" can be understood to mean that the substrate cannot expand, or can only expand minimally, with temperature changes. Therefore, the substrate preferably does not expand during the manufacturing process. In a second process step, which is preferably carried out after the first, the substrate can be placed in a mold. The mold can have a cavity that serves to shape the substrate. The substrate can be placed in this cavity. The mold is temperature-controlled, i.e., it can be heated and cooled, and can give the substrate its final shape. The temperature-controlled mold can selectively change its temperature during the process or during deformation. Such a mold can be called a variothermal mold. For example, efficient energy consumption can be achieved with such a mold.In the context of this disclosure, a temperature-controlled mold can refer to a mold that can be heated and / or cooled by means of gas, liquid, or other elements and / or components. The mold can have heating and / or cooling elements and, alternatively or additionally, a heating and / or cooling mechanism. In a third process step, which is preferably carried out after the second process step, the substrate is preferably formed and deformed into the desired shape by the mold. This can be done under pressure. That is, the mold can exert pressure on the substrate.

[0017] Finally, in a fourth process step, which is preferably carried out simultaneously with the third process step, the forming tool can be permeated with either a hot gas or a cool gas during deformation. In the context of the present disclosure, a gas can be described as hot if it is 24-2319 PIF

[0018] 3

[0019] a temperature of at least 40°C. In the context of this disclosure, a gas can be described as cool if its temperature is 20°C or lower. By passing such a gas through the mold, the temperature of the mold and, in particular, of the substrate can be selectively influenced during forming. A gas flow can therefore be generated which is oriented and / or designed in such a way that it can flow within the mold, in particular into the cavity formed by the mold. This means that the substrate within the mold can be actively exposed to or brought into contact with the hot or cool gas. The gas flows through the mold and can thus interact with the substrate to be formed. This allows the substrate to be heated and / or cooled, in particular, across its entire thickness or depth.This can support and optimize the deformation process.

[0020] The choice of gas can depend on various factors, such as the availability and cost of the gas, the temperature range achievable with the gas, the chemical compatibility of the gas with the substrate material, as well as the energy efficiency and environmental impact of the gas. For example, hot air and cold air can be used. The gas used to heat the mold can differ from the gas used to cool it.

[0021] The substrate preferably consists predominantly of a thermoplastic. In particular, the substrate comprises polyethylene terephthalate (PET) or polybutylene (PBT). Alternatively or additionally, the substrate may comprise polyethylene (PE) and / or polypropylene (PP). The substrate preferably consists of a material that is advantageous for recycling.

[0022] Such a process can improve, and in particular more control, the production of a cushion from a vertical nonwoven fabric. Temperature control during the deformation of the substrate can be improved. A recyclable cushion can advantageously be produced using such a process.

[0023] Furthermore, the invention is based on the understanding that by selectively directing hot and / or cool gases through the forming tool, certain properties of the deformed substrate can be achieved, making it particularly suitable for use in a seat, such as a vehicle seat. 24-2319 PIF

[0024] 4

[0025] It should be noted that the mold can also be heated by other means. For example, the mold temperature can be regulated using heating cartridges, integrated thermocouples, or similar devices. The mold can also be preheated before the substrate is placed inside. This can be achieved using heating cartridges located within the mold.

[0026] According to one embodiment, the temperature-controlled mold is permeated with hot gas and subsequently with cool gas. The hot gas can assist in the deformation of the substrate. Once the substrate has assumed the desired shape, it can be cooled using the cool gas. The cool gas is preferably different from the hot gas. Furthermore, the hot and cool gases can flow into the mold at different velocities. For example, to ensure rapid and efficient cooling of the deformed substrate, the cool gas can flow into the mold at a higher velocity than the previously flowing hot gas. Since the deformed substrate does not need to be removed from the mold for cooling, the production of the cushion can therefore be a single-stage process (a so-called one-step process).

[0027] According to one embodiment, the temperature-controlled mold is heated at least partially to the melting temperature of the vertical nonwoven fabric, in particular to a temperature between 110°C and 180°C, by means of the flowing hot gas. The nonwoven fabric can, in particular, have two melting temperature ranges: a low-melting range and a high-melting range. The temperature-controlled mold is preferably heated to the low-melting range. This allows a smooth substrate surface to be achieved without having to heat the substrate to the high-melting range. The method can provide that the temperature-controlled mold, in which the substrate is placed, is heated at least partially to a specific temperature by means of a flowing hot gas.The main advantage of heating the forming tool to the melting temperature of the vertical nonwoven fabric is that it allows for the formation of a smooth surface on the formed substrate. By heating the substrate to its melting temperature in a controlled manner, the fibers of the nonwoven fabric soften and conform evenly to one another during the forming process, particularly at the substrate surface. This allows for targeted control of the fiber bonds. This enables the formation of a cushion 24-2319 PIF.

[0028] 5

[0029] It is manufactured with a smooth and homogeneous surface that has a pleasant feel. The cushion may have a smooth, skin-like texture.

[0030] It should be noted that the heating of the mold can be supported by an additional heating mechanism, such as heating cartridges.

[0031] According to one embodiment, the hot gas and / or cool gas is a gas mixture. A mixture of air and nitrogen is a possible gas mixture. Such a mixture can exhibit increased thermal conductivity. The cool gas can, for example, be argon. Since argon is a noble gas, it does not react with the materials of the mold or the substrate.

[0032] According to one embodiment, the hot gas and / or the cool gas has a water vapor content of less than or equal to 30 g / kg. This means that each kilogram of gas preferably contains a maximum of 30 grams of water vapor. In an advantageous embodiment, a dry gas or a dry gas mixture flows through the mold. The invention is based on the finding that by selectively flowing such a hot and / or cool gas through the mold, certain properties of the formed substrate can be achieved, making it particularly suitable for use in a seat, such as a vehicle seat.

[0033] According to one embodiment, the deformed substrate is cooled by means of the flowing cool gas in the temperature-controlled mold. Such a cooling process can serve to stabilize the substrate in its final, deformed shape. The controlled cooling in the mold prevents the substrate from reverting to its original shape. Instead, it can harden in the desired shape and retain it permanently.

[0034] According to one embodiment, the deformed substrate is removed from the mold after passing through the temperature-controlled mold with the hot gas and / or cool gas.

[0035] According to one embodiment, at least one functional element is formed by deforming the substrate. This means that by selectively shaping and deforming the nonwoven substrate in the temperature-controlled mold, not only is a general cushion shape created, but specific functional elements can also be integrated. These functional elements can, for example, be recesses, 24-2319 PIF

[0036] 6

[0037] These could be raised areas, depressions, or other geometric structures that can give the finished cushion additional functionality. Such functional elements can serve purposes such as support, guidance, or positioning. The ability to mold such functional elements directly into the cushion can significantly increase the complexity and functionality of the final product.

[0038] A second aspect of the present disclosure relates to a cushion for a vehicle, which is manufactured according to a method as described above and / or below.

[0039] The invention is based on the finding that such a cushion has increased durability while simultaneously improving seating comfort.

[0040] All benefits, revelations and / or explanations described above and / or below in relation to one aspect of the present revelation apply equally to all other aspects of the present revelation.

[0041] Exemplary embodiments of the invention are described below with reference to the figures. The figures show:

[0042] Fig. 1 schematically shows a process step of a process according to an exemplary embodiment, and

[0043] Fig. 2 shows a flowchart of a process according to an exemplary embodiment.

[0044] Similar, similar-looking, identical, or equivalent elements are marked with similar or identical reference symbols in the figures. The figures are merely schematic and not to scale.

[0045] Fig. 1 schematically shows a process step of a method according to an exemplary embodiment. In particular, Fig. 1 schematically shows the execution of a process step of the method for producing a cushion. For this purpose, a temperature-controlled mold 10 is preferably used. The temperature-controlled mold 10 can have an upper mold part 11 and a lower mold part 12. A substrate 20, which preferably has a vertical nonwoven fabric, can be placed between the upper mold part 11 and the lower mold part 12 in order to be deformed in the mold 10. The upper mold part 11 and the lower mold part 12 together can form a 24-2319 PIF

[0046] 7

[0047] Form a cavity that can serve to shape the substrate 20. The mold 10 is temperature-controlled, i.e., it can be heated and cooled. The mold 10 can be temperature-controlled by means of heating and / or cooling elements. Optionally, the mold 10 can also be temperature-controlled by means of a gas flow 13.

[0048] The mold 10 can be supplied with a hot gas and / or a cool gas. The gas flow 13 is preferably oriented or designed such that it can also flow through the substrate 20. For this purpose, the mold 10 preferably has flow channels which are open towards the cavity of the mold 10. In addition, the gas flow 13 can remain within the mold, in particular to heat or cool the upper mold part 11 and / or the upper mold part 12. The mold 10 preferably has the corresponding channels for this purpose. A gas supply unit and / or a gas pump can be provided to generate the gas flow 13, or gas flows 13.

[0049] The gas flow 13 can be configured such that sections of the substrate 20 are exposed to more of the hot gas and / or the cool gas than other sections. Preferably, however, a homogeneous exposure of the substrate 20 to the gas is desired.

[0050] Fig. 2 shows a flowchart of a process according to an exemplary embodiment. In a first process step S1, a substrate 20 is provided, which consists primarily of a vertical nonwoven fabric. The substrate 20 is essentially non-expandable. This can mean that the substrate 20 cannot expand, or can only expand slightly, under the influence of heat. The substrate 20 may also contain a binder. In a second process step S2, the substrate 20 is placed in a temperature-controlled mold 10. The mold 10 can form a cavity provided for this purpose. In a third process step S3, the substrate 20 is formed with the temperature-controlled mold 10. For this purpose, the mold 10 can be closed. The forming of the substrate 20 can be carried out under pressure. During the forming of the substrate 20 with the mold 10, i.e.,Preferably during process step S3, the mold 10 is preferably supplied with a hot gas and / or a cool gas in an optional fourth process step S4. This is preferably done in such a way that the substrate 20 is thereby exposed to the hot gas and / or the cool gas. The process is preferably carried out such that the temperature-controlled mold 10 – and thus the substrate 20 – is heated to a temperature of 24-2319 PIF.

[0051] 8

[0052] - is first subjected to a flow of hot gas and then to a flow of cool gas.

[0053] The vertical nonwoven fabric can contain PET and, in particular, fibers with a melting point between 110°C and 180°C. It can therefore be advantageous to allow the hot gas to flow through the mold 10 in such a way that at least the inner surfaces of the mold 10, i.e., the surface of the cavity of the mold 10, can be heated to a temperature between 110°C and 180°C. This allows the substrate 20 to melt, at least partially, especially at its surface. This can lead to the formation of a smooth surface on the substrate 20. A cushion produced in this way can therefore have an improved feel.

[0054] It should be noted that, in the context of this disclosure, "gas" may refer to a mixture of different gases. Preferably, however, a dry gas is used. In the context of this disclosure, a dry gas may refer to a gas having a water vapor content of less than or equal to 30 g / kg.

[0055] Such a process can be used to manufacture a cushion for a vehicle.

[0056] In particular, a cushion can be manufactured for a vehicle seat, a vehicle backrest or similar.

[0057] It should be further noted that the terms "comprising" and "comprising" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features and steps described with reference to one of the above embodiments may also be used in combination with other features and steps of other embodiments described above. Reference numerals in the claims are not to be considered as limitations. 24-2319 PIF

[0058] 9

[0059] Reference symbol list

[0060] 10 forming tools

[0061] 11 Tool top

[0062] 12 Tool base

[0063] 13 Gas flow

[0064] 20 substrate

[0065] S1 first process step 52 second process step 53 third process step 54 fourth process step

Claims

-2319 PIF 10 Claims 1. A method for manufacturing a cushion, comprising the following steps: • (S1) Providing a substrate (20) comprising a vertical nonwoven fabric, wherein the substrate (20) is essentially non-expandable, • (S2) Placing the substrate (20) into a temperature-controlled molding tool (10), • (S3) Molding the substrate (20) with the temperature-controlled molding tool (10), and • (S4) Flowing a hot gas and / or a cool gas through the temperature-controlled mold (10), wherein the substrate (20) is exposed to the hot gas and / or the cool gas by the flow through the temperature-controlled forming tool (10).

2. Method according to claim 1, wherein the temperature-controlled molding tool (10) is supplied with the hot gas and subsequently with the cool gas.

3. Method according to any of the preceding claims, wherein the temperature-controlled forming tool (10) is heated at least partially to the melting temperature of the vertical nonwoven fabric, in particular to a temperature between 110°C and 180°C, by means of the hot gas flowing through it.

4. Method according to any of the preceding claims, where the hot gas and / or cool gas is a gas mixture.

5. Method according to any of the preceding claims, where the hot gas and / or the cool gas has a water vapor content of less than or equal to 30 g / kg.

6. Method according to any of the preceding claims, wherein the deformed substrate (20) is cooled by means of the flowing cool gas in the temperature-controlled forming tool (10).

7. Method according to any of the preceding claims, -2319 PIF 11 wherein the deformed substrate (20) is removed from the molding tool (10) after passing through it with the hot gas and / or cool gas.

8. Method according to any of the preceding claims, wherein at least one functional element is formed by deforming the substrate (20).

9. Upholstery for a vehicle manufactured according to a method according to one of the preceding claims.

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