DE102010006668A1 - Cushion, particularly for seat, particularly vehicle seat, has core part, with which flexible outer form of cushion is produced, where core part is formed from plastic material - Google Patents

Abstract

The cushion (10) has a core part (1), with which a flexible outer form of the cushion is produced, where the core part is formed from a plastic material. The core part has a monofilament-structure with a monofilament, where the monofilament is connected with other monofilaments at predetermined cross areas. The monofilament is a plastic fiber finite length. The core part is sectionally surrounded by a supporting part (3). Independent claims are also included for the following: (1) a vehicle seat with a seat surface; and (2) a method for manufacturing a cushion.

Description

The invention relates to a padding in particular for a seat, with at least one core part, with which a resilient outer shape of the padding can be generated, wherein the core part is formed from a plastic material, and a method for producing such a padding.

In contemporary vehicle construction molded seat parts made of polyurethane (PU or PUR foam) are used, which in different degrees of hardness, d. H. different compression hardnesses, are adjustable. Different compression hardnesses are required in seat cushions or seat backs in which, for example, a relatively soft seating surface and harder seat side panels are desired. These degrees of hardness are generated during the manufacture of the padding.

Due to their nature, however, such molded seat parts have a disadvantageous, climate-physiological behavior which results from the use of polyurethane foams. Such foam cells store heat and moisture, forming a so-called skinning between a foam surface and the foam tool during the foaming process. Together with the closed-cell foam structure of the polyurethane foams, the skin prevents any air penetration, so that no air circulation can take place. This leads to a heat / moisture accumulation when a vehicle user, for example, a driver or passenger sits on such a foam pad. This heat accumulation causes the passengers to sweat particularly easily, resulting in loss of comfort. Thus, these foams in terms of heat conduction, air permeability, short-term water vapor absorption, moisture absorption and water vapor resistance, disadvantages.

To avoid this problem, seat structures are proposed in the prior art, in which ventilation by means of fans are used, see. DE 198 28 698 C1 , Alternatively, perforated foam parts are used by air ducts, cf. DE 103 50 146 B4 , However, these systems are extremely cost-intensive and can not be used in the entire seating area due to their complex structure.

Alternatively, constructions of horsehair in a rubber matrix, the so-called rubber hair, or coconut fiber with latex as a binder are known. So-called rubber hairs are expensive, require a lot of space to allow the required softness and thus a certain seating comfort, and are not recoverable due to the common vulcanization process, d. H. not recycle capable.

The invention has for its object to provide a device of the type mentioned above with improved comfort and to provide a method for producing such a device.

The object is solved with the features of the independent claims. Particular embodiments and further developments of the invention are subject of the dependent claims, which are based on the independent claims.

A padding according to the invention, in particular for a seat, can have at least one core part with which a resilient outer shape of the padding can be produced, wherein the core part can be formed from a plastics material. Furthermore, the core part may have a monofilament structure with at least one monofilament, wherein the monofilament may be joined to itself or to other monofilaments at predetermined cross-sections where it intersects itself or other monofilaments, each monofilament being substantially finer than a plastic fiber Length can be. The use of a monofil structure results in a significantly higher air permeability than in upholstery whose core part consists of foams, whereby an active and / or passive seat air conditioning is possible. Another advantage is the fact that no moisture absorption takes place, but the moisture is transported away from the vehicle passenger.

Furthermore, the core part may be at least partially surrounded by a support part. This results in the advantage that in a particularly simple manner different degrees of hardness are adjustable by the support member is formed of an alternative material with a lower and / or higher degree of hardness. Preferably, the support member is also created from a monofilament structure. As a result, different degrees of hardness between the mandrel, d. H. the core part and the contact surface are made to the passenger, at the same time a lower overall space is claimed. The mold core has a higher, harder degree of hardness and the contact surface has a lower, softer degree of hardness. For the purposes of the invention, mold core and core part are used as synonyms.

Furthermore, the core part and / or the support part may at least partially be surrounded by a cover. This results in the advantage that a variety of different surface materials, such as leather, synthetic leather, velor and more Fabric textiles can be stretched on the upholstery.

In addition, the core part can have at least two predetermined areas, each with different degrees of hardness. As a result, zones can be created in a particularly simple manner, which differ in their degrees of hardness, for example, softer degrees of hardness are used in a middle seating area and higher degrees of hardness are used in a side Sitzwulstteil. When cornering, the Sitzwulstteile are particularly good for side guidance.

In addition, two adjacent regions, each having different degrees of hardness, can be separated from one another by at least one separating part. This allows a discrete transition between the two degrees of hardness to be created.

Another aspect of the invention relates to a vehicle seat, which may have a seat surface with a padding described above. For the purposes of the invention, a vehicle seat is to be understood as a seat pad on which a driver or passenger can sit. These are in particular motor vehicle seats, motorcycle seats and / or bicycle saddle to understand. Of course, the padding of the invention may also be provided in a backrest of a vehicle seat. For the purposes of the invention, a seat is generally understood to mean a support surface on which a person can position himself, i. H. a seat with a padding according to the invention can be considered especially as a chair, armchair or sofa. Furthermore, the upholstery according to the invention can also be used for mattresses, mattresses, armrests, headrests, pillows or as underpadding for child seats.

In a further aspect, the invention relates to a method for producing a padding comprising the steps of: producing a monofilament structure by introducing at least one monofilament into a negative mold, wherein during or after the introduction of the at least one monofilament a disordered arrangement of the at least one Monofiles is produced in the negative mold, connecting the at least one monofilament at predetermined cross sections, where it intersects itself or other monofilaments, with itself or with other monofilaments, and solidifying the tangled monofilament structure to a core part.

Furthermore, the outer shape of the at least one monofilament can be produced on exit from an extruder and the at least one monofilament can be converted into the negative mold immediately after it leaves the extruder to produce the monofilament structure.

Furthermore, the method may comprise the steps: removal of the at least one monofilament from a monofilament store, transfer of the at least one monofilament into the negative mold, predetermined and / or confused positioning of the at least one monofilament in the negative mold, connection of the at least one monofilament at predetermined cross areas by applying heat and / or pressure and then solidifying the structure produced.

Furthermore, the method may be characterized in that during or after the introduction of the at least one monofilament, a fluid, in particular air, is introduced into the monofilament structure. By blowing in the air, a confused laying of the monofilament plastic threads can be favored.

Furthermore, the method may be characterized in that the negative mold is tempered before and / or during the production of the monofilament structure. The control of the temperature of the negative mold, d. H. the pre-existing collection container, contributes significantly to the final fixation of the desired shape.

In the apparatus described above and in the described method, the negative mold may be formed as an open or closed mold. In the embodiment in the form of an open mold, the negative mold has at least one opening, wherein the opening is arranged in a region of the negative mold, which is opposite to the effective direction of gravity. This allows the monofilament mass to be introduced through the opening into the negative mold due to the force of gravity acting on it. In the embodiment as a closed mold, the negative mold is substantially formed as a lockable container with a container body and a container lid. At least one opening may be provided in the container lid and / or in the container base body for introducing the monofilaments into the container. In addition or alternatively, at least one opening may be provided in the container lid and / or in the container base body for injecting a fluid into the container.

The invention is explained in more detail below with reference to the figures, in which, schematically, by way of non-limiting example:

1 : A sectional view through a padding according to the invention;

2 a device for producing a padding according to the invention, for illustrating the method according to the invention; and

3 : A device for producing a padding according to the invention, with which an alternative of the method according to the invention is to be described.

1 shows by way of example and not limitation, a section through a first embodiment of a padding according to the invention 10 , which is integrated in a vehicle seat, more precisely in its seat.

The seat has a padding 10 with a resilient core part 1 on, with the core part 1 decisive for the shaping of the outer contour of the upholstery 10 is involved. The upholstery 10 stands with a carrier part 2 in conjunction, the support part 2 a dimensionally stable frame, preferably made of rigid metal and the core part 1 on the support part 2 is arranged. The core part 1 is at least partially from a circulation part 3 surround. On one side of the rest part 3 that the core part 1 is averted, is a reference 4 provided, at least in sections, the support part 3 surrounds. The reference 4 forms the outer skin of the upholstery, which closes towards the outside 10 and may be formed of a leather material, an artificial leather material, a velor fabric or other textile or a combination of these materials.

The core part 1 the in 1 illustrated upholstery 10 is formed from a monofilament structure. The monofilament structure is produced from a thread or a fiber made of plastic material. Optionally, a plurality of plastic fibers, the so-called monofilaments, can be assembled into a monofilament structure. In the monofilament structure, the monofilaments are confused, distributed homogeneously or inhomogeneously in all three spatial directions, and are connected to each other at cross-sections in which they cross and touch themselves or other monofilaments. In other words, when a single monofilament forms a loop, the point at which the two loop end regions lie on top of each other is a cross region in which the loop end regions are firmly joined together, for example, by fusion. Similarly, cross sections also form where two or more different monofilaments are supported. Such cross sections may be punctiform or even linear, if two monofilaments are aligned parallel to one another at least in sections and rest on one another. The density of the monofilament structure depends essentially on the amount of monofilaments incorporated. In other words, by varying the amount of introduced monofilaments 6 can the density and thus the compression hardness of the core part 1 to be controlled. Consequently, the degree of hardness of the molded article, ie, the core part, depends 1 , From three factors, namely the type of material from the monofilament 6 consists of the thickness, ie the titer or the fiber diameter, the monofilament and the density of the molding.

In 1 For example, a coordinate system defines a longitudinal direction X, a depth direction Y, and a height direction Z of the padding 10 , In 1 has the core part 1 different chambers 1a . 1b in the X direction. These chambers represent adjacent areas, each with different degrees of hardness, separated from each other by the partitions 5 partially sealed off. By suitable arrangement of the areas 1a . 1b can have specific functions of upholstery 10 to be generated. As described above, a middle portion of the seat surface may be provided with a soft degree of hardness and outer edge portions of a harder degree of hardness may be provided. When cornering on the one hand, the side guide one on the padding 10 seated person ensured by the more stable side parts in the edge region, while at the same time a sufficiently soft and comfortable seating surface is realized. Of course, such a subdivision in different hardness ranges also in the depth direction, ie in the Y direction.

The edition part 3 forms a spacer knit, which is between the core part 1 and a reference 4 is arranged. This spacer fabric or spacer layer may optionally be constructed of a nonwoven, a braided foam insert, a textile or also of a monofilament structure. By using a monofilament structure in the support part 3 can in the upholstery 10 Thus, layers with different degrees of hardness can also be set in the Z direction if the degree of hardness is the support part 3 the degree of hardness of the core part 1 differs.

In a further, not shown embodiment of the present invention, the reference 4 also directly, ie directly to the core part 1 be applied, so that in this embodiment, the structure of the padding 10 without rest part 3 gets along. It is also conceivable on the separating parts 5 to dispense, so that areas of the monofilament structures with different degrees of hardness directly abut each other. In a further, not shown embodiment of the invention, the separating parts 5 be more pronounced, so that they are different from the carrier part 2 to the reference 4 extend consistently.

The following is intended with reference to the 2 respectively. 3 an inventive manufacturing method for producing the padding of the invention 10 be explained. In a first embodiment of the method, which in 2 is shown, is the starting material from which later the monofilaments 6 are generated in a monofilament memory 9 , At the monofilament storage 9 are extruder 7 arranged to extrude the monofilaments 6 from the store 9 , The monofilaments 6 flow out of the extruders due to the weight G acting on them 7 downwards in the direction of a collecting container or a collecting mold, hereinafter referred to as a negative mold 8th referred to as. Alternatively, the extruders 7 also work with feed while the monofilaments 6 in the negative form 8th press. The injection of the monofilaments by means of feed is particularly suitable when using a closed negative mold in an embodiment of the invention which is not shown. The negative form 8th takes the monofilaments 6 on, where by dropping the monofilaments 6 a confused structure is created. Here are the monofilaments 6 in a heated, substantially flowable state, so that in contact areas of the monofilament strands 6 in which are individual monofilaments 6 cross, the so-called cross areas, the monofilaments 6 automatically merge together. After the solidification of the monofilaments 6 This results in a tightly connected monofilament structure, which then simultaneously forms the core part 1 forms. In this state, the core part attains 1 also its finished form, which corresponds to the outer shape of the later upholstery. As in 2 shown, there are several extruders next to each other 7 , By temporarily switching off the extruder 7 , or by using extruders 7 with smaller extruder outlet diameters, a lower monofil density can be produced in this area than in the areas where the extruders 7 permanently working. This will reduce the number of monofilaments 6 introduced into these areas. Consequently, areas with lower and higher compression hardness can be generated, their arrangement with respect to 1 already explained. By blowing air, for example by means of a nozzle, the in 2 not shown, the laying of monofilaments 6 , ie the thread laying, be more swirled and so a confused installation is reinforced. As a result, the density of the entire monofilament structure decreases further, so that a softer compression hardness is achieved.

In 3 an alternative of the first embodiment of the inventive method is shown, wherein an insert element 11 in the negative form 8th is introduced before the production of the monofilament structure 1 he follows. The insert element 11 At the same time, the support part can also be used 3 be like in 1 shown. The insert element 11 preferably has a lower degree of hardness than the core part 1 ,

Furthermore, the insert element 11 can also be generated by generating a first monofilament structure. In the process, monofilaments are used in a first step 6 in the negative form 8th recorded and arranged swirling in it. After this first monofilament structure is solidified, in a further step, a second monofilament structure can be produced, through which the core part 1 arises. Thus, a padding can be produced in a particularly simple manner with different degrees of hardness in the vertical direction of the padding, the Z direction - as in 1 represented - corresponds.

In a further, not shown embodiment of the invention, the monofilaments 6 are also deducted from an alternative monofilament storage, such as a coil, and in a similar negative form 8th be inserted. In this case, either a single monofilament can be removed from the coil or a variety of different monofilaments are cut individually and in the negative mold 8th be positioned. To the monofilaments 6 At intersection points or intersection areas to connect with each other, they can be subjected to heat and / or pressure to the monofilaments 6 to convert into a semi-liquid state.

In both embodiments of the method according to the invention, the negative mold 8th from the reference 4 - as in 1 shown - be formed. In other words, the reference 4 becomes dimensionally stable in advance to a negative form 8th shaped so that after the insertion of the monofilaments 6 into the mold and solidify it into a monofilament structure in the negative mold 8th the upholstery is completed immediately.

Moreover, in both described embodiments of the method, the negative mold 8th during the insertion of the monofilaments 6 be permanently tempered. By heating the negative mold 8th can the monofilaments 6 be maintained at a predetermined temperature, so that there are particularly good connections between the individual monofilaments in the crossing regions. On the other hand, by cooling the negative mold 8th accelerate the process step of solidifying the monofilaments to the monofilament structure.

Furthermore, it is also provided in all described embodiments of the invention that a variety of types of material can be used which are thermoplastically ausspinnbar, deformable and permanently elastic. By the invention described moldings can be produced, which are particularly good recyclable due to their manufacturing process and due to the fact that is dispensed with binders or adhesives, in contrast to rubber hair or moldings made of latex with coconut fibers, where the fused together materials not are more separately recoverable. Another advantage is the fact that significantly reduced emissions occur in the production of the invention compared to seat moldings made of foams. Ultimately, weight and cost savings can be achieved with the aid of this invention.

The aforementioned features and embodiments of the present invention may be combined as desired.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19828698 C1 [0004]
• DE 10350146 B4 [0004]

Claims (11)

Upholstery, in particular for a seat, comprising: - at least one core part ( 1 ), with which a resilient outer shape of the padding can be generated, wherein the core part ( 1 ) is formed from a plastic material, characterized in that the core part ( 1 ) a monofilament structure with at least one monofilament ( 6 ), wherein the monofilament ( 6 ) at predetermined cross sections where it is itself or other monofilaments ( 6 ), with itself or with other monofilaments ( 6 ), each monofilament ( 6 ) is essentially a plastic fiber of finite length. Device according to claim 1, characterized in that the core part ( 1 ) at least in sections of a support part ( 3 ) is surrounded. Device according to one of the preceding claims, characterized in that the core part ( 1 ) and / or the support part ( 3 ) at least in sections of a reference ( 4 ) is surrounded. Device according to one of the preceding claims, characterized in that the core part ( 1 ) at least two predetermined areas ( 1a . 1b ) each having different degrees of hardness. Apparatus according to claim 4, characterized in that two adjacent areas ( 1a . 1b ) each having different degrees of hardness from each other by at least one separating part ( 5 ) are sealed off. Vehicle seat, characterized in that the seat surface has a padding according to one of the preceding claims. Process for producing a padding according to one of claims 1 to 5, comprising the steps of: - producing a monofilament structure by introducing at least one monofilament ( 6 ) in a negative form ( 8th ), wherein during or after the introduction of the at least one monofilament ( 6 ) a confused arrangement of the at least one monofilament ( 6 ) in the negative form ( 8th ), - connecting the at least one monofilament ( 6 ) at predetermined cross sections where it is itself or other monofilaments ( 6 ) crosses, with itself or with other monofilaments, and - solidification of the confused monofilament structure into a core part ( 1 ). Method according to claim 7, characterized in that the outer shape of the at least one monofilament ( 6 ) when exiting an extruder ( 7 ) is generated and the at least one monofilament ( 6 ) immediately after exiting the extruder ( 7 ) in the negative form ( 8th ) is converted to produce the monofilament structure. Method according to claim 7 or 8, comprising the steps of: - removing the at least one monofilament ( 6 ) from a monofilament memory ( 9 ), - transfer of the at least one monofilament ( 6 ) in the negative form ( 8th ), - predetermined or confused positioning of the at least one monofilament ( 6 ) in the negative form ( 8th ), - connection of the at least one monofilament ( 6 ) at predetermined cross-sections by application of heat and / or pressure, and - subsequent solidification of the structure produced. Method according to one of claims 7 to 9, characterized in that during the introduction of the at least one monofilament ( 6 ) or after the introduction of the at least one monofilament ( 6 ) a fluid, in particular air, is introduced into the monofit structure. Method according to one of claims 8 to 10, characterized in that the negative mold ( 8th ) is tempered during the production of the monofilament structure.

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