DE102010062707A1 - Method for producing upholstered parts, in particular for vehicle seats, upholstery part and tool - Google Patents

Abstract

The invention relates to a method for producing upholstery parts for a vehicle seat. According to the invention, at least one pad segment (4) is placed on a first sheet (2) made of a nonwoven material, which is covered by a second sheet (3) made of nonwoven material, so that the pad segment (4) between the first and the second sheet (2, 3) is arranged, the first and second flat structures (2, 3) then being pressed together with the cushion segments (4) under the supply and / or action of thermal energy to form a composite cushion (1). The invention further relates to a composite cushion (1), a vehicle seat and a tool for carrying out the method.

Description

The invention relates to a method for producing upholstered parts for a vehicle seat according to the preamble of claim 1. Furthermore, the invention relates to a composite cushion according to the preamble of claim 5. Furthermore, the invention relates to a vehicle seat according to the preamble of claim 8. Furthermore, the invention relates to a Tool according to the preamble of claim 9.

In the prior art padding elements for a vehicle seat are made of a plurality of materials.

Object of the present invention is to provide a comparison with the prior art improved and in particular cost-effective method for producing upholstery parts for a vehicle seat, an improved composite cushion, a vehicle seat produced with at least one composite cushion and a tool for performing the method.

With regard to the method for producing upholstered parts for a vehicle seat, the object is achieved by the features specified in claim 1. With regard to the composite cushion, the object is achieved by the features specified in claim 5. With regard to the vehicle seat, the object is achieved by the features specified in claim 8. With regard to the tool for carrying out the method according to the invention, the object is achieved by the features specified in claim 9.

Advantageous developments of the invention are the subject of the dependent claims.

In the method for producing upholstered parts for a vehicle seat, according to the invention, at least one upholstery segment is laid onto a first sheet of nonwoven material which is covered by a second sheet of nonwoven material so that the upholstered segment is placed between the first and second sheets, with the following subsequently first and second fabric with the cushion segments under the supply and / or action of thermal energy to be pressed materially bonded to a composite cushion. Such a composite cushion is produced in a single step and thus cost and can advantageously be used immediately after removal from the production tool. Thus, the method is particularly advantageous or applicable in a large-scale production.

In an advantageous embodiment, the first and the second fabric are formed from a nonwoven material with a composite. Thus, no separate and / or separately applied to the nonwoven composite material is necessary, whereby the production time of the composite cushion is reduced.

In a particularly advantageous embodiment, the composite is introduced on and / or between the individual fibers of the nonwoven material and / or act as a composite fiber directly into the nonwoven material. By this integration of the composite in the nonwoven material a particularly simple handling of nonwoven material and composite is possible.

In a further advantageous embodiment, a hotmelt adhesive or a reactive adhesive which is activated during pressing is used as the composite. By means of these conventional and process-reliable composite means a fast and resilient connection of the fabrics and the upholstery elements is made possible.

The composite cushion preferably has a contoured three-dimensional surface with stampings between the individual pad segments. The stampings advantageously a pattern or a surface structure in the composite cushion can be introduced.

In an advantageous embodiment, the first sheet in the region of the stampings is directly bonded to the second fabric cohesively.

In a further advantageous embodiment, the stampings of the composite pad are designed as predetermined bending points. As a result, the composite cushion of a curved or kinked surface of a seat and / or back shell of the vehicle seat can be adjusted.

In a vehicle seat receives a composite cushion according to the invention by applying to a seat and / or backrest shell a final, three-dimensional curved shape. Thus, a vehicle seat, in particular a padding of a vehicle seat, can be produced in a simple and efficient manner.

The tool for carrying out the method according to the invention comprises a flat, uncontoured, multi-part, horizontal, outer frame, in which an inner frame can be inserted as a template for einzulegende cushion segments, wherein the inner frame after insertion and placement of the cushion segments can be removed, and wherein by means of a Press frame a pressing pressure on the outer frame can be applied, wherein the pressing frame and / or the outer Frame of thermal energy can be fed. This makes an easy-to-use, process-reliable tool for the cost-effective production of composite cushions possible.

Particularly advantageously, the process parameters of the pressing process, the pressing pressure, a pressing temperature and / or the pressing time are variably adjustable. Thus, these process parameters can be adjusted to the materials of a composite cushion to be produced.

Reference to the accompanying schematic figures, the invention is explained in detail.

Showing:

1 schematically a top view and a sectional view of a composite seat cushion according to the invention for a vehicle seat,

2 1 is a schematic sectional side view through a three-dimensionally formed composite seat cushion for a vehicle seat back,

3 1 is a schematic sectional view through a three-dimensionally shaped composite cushion for a vehicle seat surface;

4 FIG. 2 is a schematic plan view of the fabrics and the cushion segments before a material connection; FIG.

5 schematically a sectional view of the fabric and the cushion segments according to 4 .

6 FIG. 2 is a schematic plan view of the fabrics and a padded segment disposed therebetween, prior to a bonded connection; FIG.

7 schematically a sectional view of the fabric and the pad segment according to 6 .

8th schematically a sectional view of an alternative embodiment of the fabric and the pad segment according to 6 and

9 schematically a sectional view of the fabric and the cushion segments according to 4 after a cohesive connection process.

Corresponding parts are provided in all figures with the same reference numerals.

In 1 is a schematic plan view and a sectional view of a composite cushion according to the invention 1 represented for a vehicle seat. The composite cushion 1 comprises a first sheet 2 and a second sheet 3 where between the fabrics 2 and 3 at least one cushion segment 4 is arranged. Here is the number and position of the cushion segments 4 variable, so that, for example, different patterns on a surface of the composite cushion 1 can be applied.

The fabrics 2 and 3 are preferably made of a conventional textile nonwoven material. A preferred nonwoven material is, for example, a polyester fiber produced from synthetic polymers. Such a polyester fiber is advantageously very tear and abrasion resistant and absorbs little moisture.

The cushion segments 4 For example, consist of a foamed material, in particular of a polyurethane foam.

In a further advantageous embodiment, the cushion segments 4 consist of vegetable and / or animal, preferably rubberized natural fibers.

In 2 is a schematic sectional side view through a three-dimensional molded composite cushion 1 represented for a vehicle seat back. It is at the upper end of the composite cushion 1 in one piece a headrest upholstery 5 formed. Such a composite cushion 1 is advantageously integrally applied to a vehicle seat back.

In 3 is a schematic sectional view through a three-dimensional molded composite cushion 1 represented for a vehicle seat. It is laterally on the composite cushion 1 in one piece a seat side bolster 6 formed. Such a composite cushion 1 is advantageously integrally applied to a vehicle seat surface.

In 4 is a schematic plan view of the fabrics 2 and 3 and the cushion segments 4 shown before a cohesive connection.

In 5 is a schematic sectional view of the fabric 2 and 3 and the cushion segments 4 according to 4 shown.

In 6 is a schematic plan view of the fabrics 2 and 3 and a padded segment disposed therebetween 4 shown before a cohesive connection.

In 7 is a schematic sectional view of the fabric 2 and 3 and the padding segment 4 according to 6 shown.

In 8th is a schematic sectional view of an alternative embodiment of the fabric 2 and 3 and the padding segment 4 according to 6 shown.

In 9 is a schematic sectional view of the fabric 2 and 3 and the cushion segments 4 according to 4 shown after a cohesive connection process.

In the process of producing the composite cushion 1 becomes in a first process step, the first sheet 2 placed in a flat, uncontoured, multi-part, horizontal, outer frame of a tool, not shown. In a second method step, an inner frame is used as a template for the cushion segments to be inserted 4 on the first sheet 2 inserted in the outer frame. In a third process step, the cushion segments 4 inserted as inserts in individual segments of the inner frame.

In one embodiment, a plurality of cushion segments 4 forming a defined pattern on the first sheet 2 be arranged as in 4 shown. In the process, the individual cushion segments become 4 spaced apart on the first sheet 2 arranged. In this case, the individual cushion segments 4 have different dimensions and thicknesses and consist of different materials and thus have different densities and compression hardness. As a result, a damping effect of the composite cushion 1 advantageously vary in sections.

In an alternative embodiment, a composite cushion 1 by means of a single pad segment 4 formed as in 6 shown.

In a fourth method step, the inner frame, which serves as a template for the alignment of the cushion segments 4 serves, removed from the outer frame. This results between the adjacent arranged cushion segments 4 a gap 7 , as in 5 shown. A division of the inner frame into individual frame segments, for example, by lattice-like strips used. In a fifth method step, the second sheet is formed 3 on the cushion segments 4 hung up. In a sixth method step, a pressing pressure is applied to the outer frame by means of a pressing frame, which pressure is applied to the fabrics arranged between the outer frame and the pressing frame 2 and 3 and the cushion segments 4 acts.

During this pressing process, a cohesive connection between the fabrics takes place 2 and 3 and the cushion segments arranged between them 4 ,

In this case, the composite material necessary for the cohesive connection, for example an adhesive, can be applied in advance to the cushion segments 4 and / or the fabrics 2 and 3 applied or in the course of the juxtaposition of fabrics 2 and 3 and upholstery segments 4 be applied flat.

In an advantageous embodiment, the composite may be applied to and / or between the individual fibers of the nonwoven material of the fabrics 2 and 3 be introduced.

In a particularly advantageous embodiment, the composite can be used as composite fiber directly in the nonwoven material of the fabric 2 and 3 be acted.

The composite may be formed as a conventional hot melt adhesive, wherein the pressing frame and / or the outer frame of the tool thermal energy can be fed, which activates the hot melt adhesive. The thermal energy for activating the hot-melt adhesive can be generated, for example, directly in the tool by means of a conventional high-frequency welding process.

In an alternative embodiment, the composite may be formed as a reactive adhesive, which is activated during pressing by the action of the pressing pressure.

Particularly advantageously, the process parameters of the pressing process, for example the pressing pressure, a pressing temperature and / or the pressing time, are variably adjustable. Thus, these process parameters are advantageously to the materials of a composite cushion to be produced 1 adapted adjustable.

During the pressing, furthermore, a final three-dimensional shaping of the composite cushion takes place 1 which may differ from the shape of the layered, yet unpressed components. The areas between the cushion segments 4 , hereinafter as stamps 8th referred to as predetermined kinks when later applying the composite cushion 1 on a curved seat structure, such as a seat back or a seat, serve.

In the area of these stampings 8th can the fabrics 2 and 3 lie directly on each other and thus be directly materially connected to each other. But it is also possible that in the course of compression, a relatively thin layer of material from the cushion segments 4 between the sheets 2 and 3 pushes as in 9 shown.

In an advantageous embodiment, before pressing under the first sheet 2 and / or over the second sheet 3 each a further sheet 9 be introduced into the stratification. This is the other fabric 9 is formed as a conventional cover fabric of a cushion part and is also cohesively to the other components of the composite cushion during pressing 1 tethered. Thus, through the fabric 9 a seat cover for the composite cushion 1 trains and integrates into this. This can be a subsequent covering the composite cushion 1 with a fabric and then trimming necessary omitted. Also these other fabrics 9 preferably consist of a conventional textile nonwoven material. A preferred nonwoven material is, for example, a polyester fiber produced from synthetic polymers. Such a construction of a composite cushion 1 with another sheet 9 is in the sectional views 5 and 7 shown.

In an alternative embodiment, instead of the second sheet 3 another sheet 9 as upholstery fabric directly on the upholstery segments 4 be applied. This variant is in 8th shown.

LIST OF REFERENCE NUMBERS

1

composite cushion

2

first sheet

3

second sheet

4

padded segment

5

Headrest upholstery

6

Seat side cheek

7

gap

8th

Verprägung

9

further sheet

Claims (10)

Method for producing upholstered parts for a vehicle seat, characterized in that a first fabric ( 2 ) of a nonwoven material at least one cushion segment ( 4 ), which by means of a second sheet ( 3 ) is covered from non-woven material, so that the cushion segment ( 4 ) between the first and second sheets ( 2 . 3 ), wherein subsequently the first and second sheets ( 2 . 3 ) with the cushion segments ( 4 ) under the supply and / or action of thermal energy to form a composite cushion ( 1 ) are pressed. Method according to claim 1, characterized in that the first and second sheets ( 2 . 3 ) are formed from a nonwoven material with a composite. A method according to claim 2, characterized in that the composite is introduced on and / or between the individual fibers of the nonwoven material and / or is acted as composite fiber directly into the nonwoven material. A method according to claim 2 or 3, characterized in that as a bonding agent, a hot melt adhesive or a reactive adhesive, which is activated during pressing, is used. Composite cushion ( 1 ) for a vehicle seat, produced according to a method according to one of the preceding claims, with at least one between a first and a second fabric ( 2 . 3 ) arranged pad segment ( 4 ), characterized in that the composite cushion ( 1 ) a contoured three-dimensional surface with stampings ( 8th ) between the individual cushion segments ( 4 ) having. Composite cushion ( 1 ) according to claim 5, characterized in that in the region of the stampings ( 8th ) the first sheet ( 2 ) directly with the second sheet ( 3 ) is integrally connected. Composite cushion ( 1 ) according to claim 5 or 6, characterized in that the stampings ( 8th ) are formed as predetermined kinks. Vehicle seat comprising at least one composite cushion ( 1 ) according to one of claims 5 to 7, characterized in that a composite cushion ( 1 ) receives a final, three-dimensional curved shape by applying to a seat and / or backrest shell. Tool for carrying out the method according to one of claims 1 to 4, comprising a flat, uncontoured, multi-part, horizontal, outer frame, in which an inner frame as a template for einzulende cushion segments ( 4 ) can be introduced, wherein the inner frame after the introduction and arrangement of the cushion segments ( 4 ) Can be removed, and wherein by means of a pressing frame, a pressing pressure on the outer frame can be applied, wherein the pressing frame and / or the outer frame thermal energy can be supplied. Tool according to claim 9, characterized in that the process parameters of the pressing process, the pressing pressure, a pressing temperature and / or the pressing time are variably adjustable.

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