CN111976230A

CN111976230A - Leather layer system, upholstered element and method for producing the same

Info

Publication number: CN111976230A
Application number: CN202010433839.XA
Authority: CN
Inventors: M·佩达克
Original assignee: Freya Car Seat Co ltd
Current assignee: Freya Car Seat Co ltd
Priority date: 2019-05-24
Filing date: 2020-05-21
Publication date: 2020-11-24
Also published as: FR3096302A1; DE102020112688A1

Abstract

The invention relates to a leather layer system for use as a covering for a foam body, having a leather layer, a foam layer and an adhesive layer between the leather layer and the foam layer for the planar connection of the foam layer to the leather layer, the foam layer facing the inside of the leather layer system and the leather layer facing the outside of the leather layer system, and the foam body being formed by an in situ foaming process inside a chamber defined by the inside of the leather layer system, and to a method for producing such an upholstered element. According to the invention, the foam layer is made of ethylene propylene diene monomer and has a semi-closed structure.

Description

Leather layer system, upholstered element and method for producing the same

Technical Field

The invention relates to a leather layer system as a component of a covering for a foam body, in particular as an interior lining element in a vehicle, to an upholstered element and to a method for producing the upholstered element.

Background

In the field of vehicle interiors, a series of upholstered elements are known which comprise a body of foam material, in particular, which is covered with a leather layer. In the context of leather layers, it is common to use laminated leather layers in order to make the leather layer stiffer and thus to optimize the subsequent processing of the leather layer and its durability. The covering is thus formed by a leather layer system.

The foam body is shaped, for example, in the shape of a corresponding upholstered element, for example, in the shape of a seat or backrest or headrest or armrest of a vehicle seat, and the leather layer system is adapted to the outer shape of the foam body. For this purpose, for example, the so-called foam-in-place process (FIP process) can be used, in which the leather layer system is inserted into a foam-in-place mold, wherein the foam-in-place mold imitates the contour of the upholstered element to be produced, for example a seat or backrest or headrest or armrest. After the leather layer system has been placed flat on the foam-in-place mould, it defines a chamber with its inner side. In the context of the FIP process, the foam flows into the chamber and then solidifies, so that a solid foam body is formed in the chamber. The foam body is completely surrounded by the leather layer system, so that the leather layer system acts as a covering.

In the FIP process carried out in this way, it is disadvantageous that the leather layer system produced from conventional laminated leather layers can be damaged by the injected foam material, since the injected foam material reacts directly with the leather layer and thus destroys it, and/or that, instead, forces are exerted on the leather layer during curing and thus compresses it, so that the leather layer can be adversely affected in the FIP process. In addition, in the case of laminated leather layers, wrinkling of the leather layer cannot always be prevented, since the laminated leather layer can move relative to the substrate, i.e. the foam body, in particular during deformation. Furthermore, it can happen in conventional lamination processes that the leather layer becomes very stiff, thereby reducing comfort when used as a wrap in upholstered elements.

In order to avoid the reactive destruction of the leather layer by the injected foam in the FIP process, protective layers are known which, however, on account of their rigidity do not prevent the leather from wrinkling. Furthermore, the protective layer cannot be elastically bent, so that the ability to adapt to the underlying foam body is reduced.

A leather layer system with an inwardly facing foam layer of PU foam is known from CA 2597280 a1, which comprises open-cell or closed-cell foam. However, the leather layer system, on account of its structure, does not contribute to a sufficient protection of the leather layer system when applied in the FIP process and furthermore avoids wrinkle formation when deformed.

Other leather layer systems with additional foam layers are known, for example, from CN 202213244U, CN 103029402A, US 20170259126A 1 and JP 2018108685 a. These leather layer systems also do not help to eliminate the above-mentioned drawbacks.

Disclosure of Invention

It is therefore an object of the present invention to provide a leather layer system for use as a covering for a foam body, with which the disadvantageous effects on the leather quality due to the formation of the foam body and the formation of wrinkles can be avoided. The object of the invention is also to specify an upholstered element and a method for producing the upholstered element.

This object is achieved by a leather layer system according to claim 1 and by an upholstered element and a method according to the other independent claims. Preferred further developments are given in the dependent claims.

According to the invention, the foam layer of the leather layer system is therefore made of Ethylene Propylene Diene Monomer (EPDM) and has a semi-closed structure. Semi-closed cell construction is understood to mean that the EPDM foam layer is formed from a mixture of open cell EPDM foam and closed cell EPDM foam. The leather layer system is used as a covering for a foam body, for example as a component of an upholstered element, in particular in a vehicle.

By configuring the foam layer as a semi-closed EPDM structure, the properties of open-cell EPDM foam and closed-cell EPDM foam are advantageously combined, so that according to the invention a particularly elastic foam layer is formed which is at the same time both air-permeable and water-impermeable. Here, in the foam layer, a cavity is formed based on a part of the open-cell type foam. These cavities can be compressed and thus at least partially closed during or after the formation of the foam body, which takes place in a foam-in-place process (FIP process). The foam layer can thus be used as a barrier layer in the FIP process, which barrier layer bends when the foam body is formed and thus supports the forces acting in the FIP process. The leather layer can thus advantageously be protected and thus compression avoided. Furthermore, the foam layer can be used as a barrier or protective layer for PU foam injected in the FIP process without damaging the leather layer from the inside.

The FIP process for forming the foam body is carried out according to the invention in that the leather layer system is inserted into the foam-in-place mould in such a way that the outer side of the leather layer system rests flat on the foam-in-place mould and a chamber is delimited by the inner side of the leather layer system. Next, a foam material, preferably PU foam, is injected into the chamber. The foam material is then cured in order to form a foam body formed in the chamber by an in situ foaming process, so that the cured foam body lies flat against the inner side of the leather layer system and thus forms a cushioned element.

It is thus advantageously achieved that the inwardly directed foam layer can serve as a barrier or protective layer for the FIP process in order to protect the leather layer accordingly.

Furthermore, the layer structure with the semi-closed EPDM foam layer has the advantage that the leather layer system is less stiff and therefore offers a higher comfort. Furthermore, the formation of folds (loose-face defects) can be prevented when the foam layer or the entire leather layer system is deformed. This results in the EPDM foam layer not significantly reducing its thickness upon deformation, for example between 1 mm and 5 mm depending on the application, due to its semi-closed cell structure. The leather layer, which is connected to the foam layer in a flat manner via the adhesive layer, is therefore not shrunk or compressed (getaucht) during deformation, in the FIP process or during use, so that wrinkle formation can be avoided.

Preferably, the adhesive layer is formed by a hot-melt adhesive. The leather layer can thus be reliably connected to the foam layer, for example during the lamination process, so that the leather layer system can be reliably held together when loaded during use.

Preferably, it is further provided that the leather layer system completely surrounds the foam body in order to form a complete covering. This forms an upholstered element which is completely surrounded by the leather layer to the outside and has the advantages of the leather layer system according to the invention. It can also be provided that only a significant part of the upholstered element is enclosed by the leather layer system according to the invention. For example, in a headrest, only the region of the passenger's head covering is enclosed by the leather layer system according to the invention in order to provide increased comfort. Instead, a common leather layer system can be used on the back side of the headrest. This applies correspondingly to other vehicle components.

According to a preferred further development, it is provided that the foam layer has a thickness of between 1 mm and 5 mm. The blocking and protective action according to the invention can thereby be achieved very effectively, without the leather layer system becoming too thick.

Preferably, it is further provided that the foam layer is different from the encapsulated foam body, wherein the foam layer is at least partially connected or connectable to the foam body. It is thus provided that the foam body formed in the in-situ foaming process can be formed from any desired foam material, for example from open-cell PU foam, and that the foam layer can be used as described as an additional foam layer between the foam body and the leather layer as a barrier and protective layer. By connecting the foam layers to the leather layer, they can be positioned in a simple manner in the foam-in-place mould in the foam-in-place process by a corresponding arrangement and can advantageously also be connected to the foam body. It is thus possible to avoid the leather layer system being lifted from the foam body, thereby increasing the comfort or preventing the formation of wrinkles.

Furthermore, it is preferably provided that an additional foam padding is arranged at least in places on the foam layer made of ethylene propylene diene monomer, wherein the foam padding is likewise made of ethylene propylene diene monomer. The foam padding can be pre-cured and then glued to the inner side of the leather layer system according to the invention, so that two superimposed layers of epdm are formed.

The comfort-enhancing advantage of the particularly high elasticity of the cushioning-based element according to the invention in the region of the two superimposed layers made of epdm can thus be further extended. If additional foam cushions are provided on the headrest, for example in the head support region, the comfort for the passenger is increased. At the same time, the foam pad also acts as a barrier layer that is both breathable and impermeable to water.

The dimensions of the additional foam padding can be selected specifically for the application. In addition to use in the head support region of a headrest, foam cushions may also be used in other upholstered vehicle components in order to increase comfort for the passenger, for example in seats, armrests or backrests.

In order to achieve this effect, it can also be provided that the foam padding of the leather layer system according to the invention is produced locally thicker, with the same effect as the foam padding is additionally applied.

According to the invention, an upholstered element is furthermore provided, which has a foam body and a leather layer system as a covering of the foam body, wherein the leather layer system has a leather layer, a foam layer and an adhesive layer between the leather layer and the foam layer for the planar connection of the foam layer to the leather layer, wherein the foam layer faces the inner side of the leather layer system and the leather layer faces the outer side of the leather layer system, and the foam body is formed by an in situ foaming process within a chamber delimited by the inner side of the leather layer system, wherein the foam layer is made of ethylene propylene diene monomer and has a semi-closed cell structure. Preferably, the upholstered element is here a vehicle component, in particular a seat or backrest or a headrest or armrest of a vehicle seat, or any other upholstered cover of a vehicle interior, for example a cover in the ceiling or on an instrument panel or the like. In this case, the upholstered element can, for example, also be provided with an additional foam padding in the manner described above.

Drawings

The invention is illustrated in more detail below with the aid of examples. Wherein:

FIG. 1 shows a schematic view of a vehicle seat;

fig. 2a, 2b show a detail of a leather layer system which is used as a covering for the foam body for the vehicle seat according to fig. 1;

FIG. 2c shows another embodiment of a leather layer system with an attached foam cushion;

FIG. 3 shows a flow chart of a method according to the invention; and

fig. 4 shows a schematic view of a foam-in-place mold.

Detailed Description

Fig. 1 shows a vehicle seat 1 with a seat part 2, a backrest 3 and a headrest 15. The seat 2, the backrest 3 and the headrest 15 are each designed as an upholstered element 50 in the sense of the present invention and for this purpose each have a correspondingly shaped

foam body

2a, 3a, 15 a. The

foam bodies

2a, 3a, 15a here define the shape of the seat 3 and the backrest 3 or headrest 15. The

foam bodies

2a, 3a, 15a are each completely surrounded by a

covering

2b, 3b, which matches the shape of the

underlying foam body

2a, 3a, 15 a. The

coverings

2b, 3b each consist of a leather layer system 4 according to the invention, which is shown in detail in fig. 2a and 2b in a sectional view.

In this connection, the leather layer system 4 has a leather layer 5, an adhesive layer 6, preferably made of a hot-melt adhesive, and a foam layer 7. The adhesive layer 6 serves here to connect the two

outer layers

5 and 7. The leather layer system 4 rests with its inner side 4a flat against the

respective foam body

2a, 3a, 15a and is connected to it in any desired manner. The outer side 4b of the leather layer system 4 in the vehicle seat 1 according to fig. 1 is in contact with the passenger or faces the vehicle interior in the corresponding region.

According to the invention, the foam layer 7 is formed from a semi-closed cell foam, wherein ethylene-propylene-diene monomer (EPDM) is used as foam. A semi-closed cell foam is understood here to be a foam formed from a mixture comprising an open cell foam and a closed cell foam.

This foam combines the properties of two cell structures (open-cell and closed-cell), thus constituting a particularly elastic foam layer 7 which is at the same time both breathable and impermeable to water. In the foam layer 7, cavities 8 are formed on the basis of a part of the open-cell foam, which cavities are compressed and thus at least partially closed during or after the injection of the foam, in particular PU foam, into the

covering

2b, 3b, 15b in a so-called foam-in-place process (FIP process) to form the

foam body

2a, 3a, 15 a. The foam layer 7 can thus serve as a barrier layer in the FIP process, which barrier layer bends during the formation of the

foam bodies

2a, 3a, 15a and thus supports the forces in the FIP process. Thus, the leather layer 5 can be protected. Furthermore, foam layer 7 acts as a barrier or protective layer to the advantage that PU foam injected in the FIP process does not damage leather layer 5 from the inside.

The FIP process for forming the

respective foam body

2a, 3a, 15a is carried out according to fig. 3 in that, in a first step St1, the outer side 4b of the leather layer system 4 is placed flat against the foaming mold 10, which is schematically illustrated in fig. 4, and is fixed thereto in a suitable manner, so that the leather layer system 4 is completely laid within the foaming mold 10. The foam-in-place mould 10 here mimics the shape of the upholstered element 50, here the seat 2 or the backrest 3 or the headrest 15, so that the leather layer system 4 inserted into the mould follows the desired contour of the respective upholstered element 50(2, 3, 15). The upholstered element 50 can also be a headrest or an armrest or another upholstered element in the vehicle interior. The foam layer 7 of the leather layer system 4 faces the interior of the foam-in-place mould 10 and delimits a chamber 11 therein.

Next, in a second step St2, a foam material, for example PU foam, is completely filled into the cavity 11 and cured, preferably under the action of heat, in a third step St 3. In the chamber 11, a

solid foam body

2a, 3a, 15a is thus formed, which lies flat on the inner side 4a of the leather layer system 4 on the foam layer 7 and essentially has the contour of the foam-in-place mold 10 and thus the contour of the corresponding upholstered element 50(2, 3, 15).

The upholstered element 50(2, 3, 15) thus produced has the corresponding desired shape and has the leather layer system 4 directly as a

covering

2b, 3b, 15b surrounding the cured

foam body

2a, 3a, 15 a. The foam layer 7 can also be connected to the solidified

foam body

2a, 3a, 15a at least in regions during the FIP process.

Based on the described elasticity of the foam layer 7, which is ensured by the semi-closed cell structure and the use of EPDM, the foam layer 7 can be used as a barrier or protective layer in this FIP process, as described above. At the same time, the leather layer system 4 acts less rigidly as a

covering

2b, 3b, 15b for the

foam body

2a, 3a, 15a and prevents the formation of folds (loose-face defects) when the foam layer 7 or the entire leather layer system 4 is deformed. This is caused by the fact that the foam layer 7, on account of its semi-closed cell structure, does not significantly reduce its thickness D (see fig. 2b) upon deformation, which thickness is, for example, between 1 mm and 5 mm depending on the application. The leather layer 5, which is connected to the foam layer 7 in a flat manner via the adhesive layer 6, therefore does not shrink or compress during deformation, either in the FIP process or during use, so that wrinkle formation can be avoided.

In addition, it can be provided according to fig. 2c that a foam padding 20 is provided in the upholstered element 50, for example in the headrest 15, on the inner side 4a of the covering 15b, which is at least partially designed as a leather layer system 4. The foam insert 20 rests flat on the foam layer 7 made of ethylene propylene diene monomer and is likewise made of ethylene propylene diene monomer. The foam padding 20 can be correspondingly prefabricated and glued to the inner side 4a of the leather layer system 4 according to the invention, so that two superimposed layers of epdm are formed.

Thus, the cushioning-based element 50 according to the present invention; the comfort-enhancing advantage of the particularly high elasticity of 15 in the region of the two

superimposed layers

7, 20 made of epdm can be further extended. If an additional foam pad 20 is provided on the headrest 15 in the head support region 15c as shown, the comfort for the occupant is increased. In a corresponding manner, this can also provide selected regions for other vehicle components, for example the seat 2 and/or the backrest 3 and/or the armrest or the like.

For the production process, the leather layer system 4 with the additional partial foam padding 20 is placed in the foam-in-place mold 10 in a planar manner at the corresponding location, so that the cavity 11 is correspondingly provided at this location with a projection in the form of the foam padding 20. The foam material injected into the hollow space 11 then rests on this foam padding 20 and also on the foam layer 7 of the leather layer system 4, so that the foam padding 20 also acts as a barrier.

List of reference numerals

1 vehicle seat

2 seat part

2a foam body of seat part 2

2b cover of seat 2

3 back support

3a foam body of a backrest 3

3b cover of backrest 3

4 leather layer system

4a inner side of the leather layer system 4

4b outer side of the leather layer system 4

5 leather layer

6 adhesive layer

7 semi-closed cell foam layer

8 cavity

10 foaming mould in situ

11 chamber

15 head rest

15a headrest 15

15b cover for headrest 15

20 foam cushion

50 cushioned element

Thickness of foam layer

St1, St2, St3 Steps of the method according to the invention

Claims

1. A leather layer system (4) as a covering (2b, 3b, 15b) for a foam body (2a, 3a, 15a), having a leather layer (5), a foam layer (7) and an adhesive layer (6) between the leather layer and the foam layer for the planar connection of the foam layer (7) to the leather layer (5), wherein the foam layer (7) is oriented toward the inner side (4a) of the leather layer system (4) and the leather layer (5) is oriented toward the outer side (4b) of the leather layer system (4), and the foam body (2a, 3a, 15a) is formed by a foam-in-place process inside a chamber (11) which is delimited by the inner side (4a) of the leather layer system (4), characterized in that the foam layer (7) is made of ethylene propylene diene monomer and has a semi-closed structure.

2. Leather layer system (4) according to claim 1, characterized in that the adhesive layer (6) is formed by a hot-melt adhesive.

3. The leather layer system (4) according to claim 1 or 2, characterized in that the leather layer system (4) surrounds the foam body (2a, 3a, 15a) almost completely in order to form a full covering (2b, 3b, 15b) or at least partially.

4. Leather layer system (4) according to any of the preceding claims, wherein the foam layer (7) has a thickness (D) between 1 mm and 5 mm.

5. Leather layer system (4) according to one of the preceding claims, wherein the foam layer (7) is different from the encapsulated foam body (2a, 3a, 15a), wherein the foam layer (7) is at least partially connected or connectable to the foam body (2a, 3a, 15 a).

6. Leather layer system (4) according to any of the preceding claims, wherein the foam body (2a, 3a, 15a) is manufactured from an open-cell foam material, preferably from PU foam, by a foam-in-place process.

7. Leather layer system (4) according to one of the preceding claims, characterized in that an additional foam padding (20) is applied, preferably glued, at least locally on the foam layer (7), wherein the foam padding (20) is made of ethylene propylene diene rubber and has a semi-closed cell structure.

8. An upholstered element (50; 2, 3, 15) having a foam body (2a, 3a, 15a) and having a leather layer system (4) as a covering (2b, 3b, 15b) for the foam body (2a, 3a, 15a), in particular according to one of the preceding claims, wherein the leather layer system (4) has a leather layer (5), a foam layer (7) and an adhesive layer (6) between the leather layer and the foam layer for the planar connection of the foam layer (7) to the leather layer (5), wherein the foam layer (7) faces an inner side (4a) of the leather layer system (4) and the leather layer (5) faces an outer side (4b) of the leather layer system (4), and the foam body (2a, 3a, 15a) is formed by a foam-in-place process inside a chamber (11) defined by the inner side (4a) of the leather layer system (4), characterized in that the foam layer (7) is made of ethylene propylene diene monomer and has a semi-closed cell structure.

9. The upholstered element (50; 2, 3, 15) according to the preceding claim, characterized in that the upholstered element (50) is a vehicle component, in particular a seat (2) or a backrest (3) or a headrest (15) or an armrest of a vehicle seat (1), or any other upholstered cover of a vehicle interior, for example in a ceiling or on a dashboard.

10. Method for manufacturing an upholstered element (50; 2, 3, 15) according to one of the claims 8 or 9, having at least the following steps:

-providing a foam-in-place mould (10) and a leather layer system (4) according to any of claims 1 to 7;

-placing the leather layer system (4) in the foam-in-place mould (10) in such a way that the leather layer system (4) lies flat with its outer side (4b) on the foam-in-place mould (10) and a chamber (11) is delimited by the inner side (4a) of the leather layer system (4) (St 1);

-injecting (St2) a foam material into the constituted chamber (11); and

-solidifying the injected foam material in order to form a foam body (2a, 3a, 15a) in the chamber (11) by means of a foam-in-place process, such that the solidified foam body (2a, 3a, 15a) lies flat against the inner side (4a) of the leather layer system (4) (St 3).