DE102012020711A1 - Plastic seat pan module of seat structure of vehicle seat, has suspension structure that is manufactured in shaping process to generate elasticity and damping properties under warming areas of stretched elastic-plastic portion - Google Patents

Abstract

The seat pan module has a lower elastic-plastic suspension structure (15), and a seat pan (12A) to form a load bearing seat. The lower suspension structure is manufactured in a shaping process to generate the elasticity and damping properties under the warming areas of the stretched elastic-plastic portion. A portion of the seat pan is provided with a first patch of the seat surface. The second patch of seat surface is formed as a commonly load-bearing seat surface by the suspension structure. Independent claims are included for the following: (1) method for manufacturing elastic-plastic suspension structure for a seat pan module; and (2) tool for manufacturing a plastic seat pan module.

Description

The invention relates to a seat pan module of a seat part of a vehicle seat, comprising a part seat pan and a Unterfederungsstruktur, which together form a load-bearing seat, wherein the part seat pan forms a first partial surface of the seat surface and the Unterfederungsstruktur a second partial surface of the seat. The invention further relates to an associated manufacturing method and a tool for producing the seat pan module.

Wire-like Unterfederungsstrukturen for seat parts and backrests of vehicle seats and other seating furniture are known from the prior art. The Unterfederungsstrukturen consist mostly of a variety of metal or plastic formed individual wires, which are usually pre-bent and connected to each other in various ways. The metal support structures and plastic support structures are offered in varying stiffnesses. The lower suspension structures stabilize the upholstery foam of a seat part or a backrest and provide a desired elasticity and damping of the load-receiving surface of the seat part and the backrest. The Unterfederungsstrukturen be attached to frame structures of the seat part or the backrest, in particular mounted.

However, it is also known to produce seat troughs without suspension structures on which a cushion foam is arranged, so that the elasticity of the load-receiving surface of the seat part and the backrest is largely caused by the upholstery foam.

Furthermore, seat parts are known, which are partially spring-loaded. Such a partially spring-loaded seat pan structure is in 1 shown.

1 shows a perspective view obliquely from above on a seat pan 12A a motor vehicle seat, which is designed as a sheet metal part. The seat pan 12A has a recessed area from one edge of the seat pan 12A and opposite one as a support structure 13 trained crossbar 13B and laterally opposite each other also as a support structure 13 trained side rails 13A is limited. Such seating tubs 12A with a recessed area are referred to as Teilsitzwannen.

The wires of the under suspension structure 15 are in seated side suspensions 14 . 14A , cross-member side suspensions 14 . 14B and side rail side suspensions 14 . 14C at the support structure 14 and the section seat pan 12A fixed. Here is the holding structure 13 and the compartment seat pan 12A and the lower suspension structure 15 made of a metallic material.

The elastic comfort properties of the load-bearing surface of the seat part are in the area of the seat pan 12A through the foam (padding) arranged on it and in the area of the under-suspension structure 15 by the elastic properties of the under suspension structure 15 and the foam (padding) arranged thereon. Such a partially spring-loaded seat pan is for example in the document DE 199 438 90 C1 described.

In the known solutions, it is disadvantageous for the first that the part seating trough must be connected to the lower suspension structure. This results in high assembly times.

Second, the weight of the assembled member of the under-spring structure and a split-seat pan formed of a metallic material is still relatively high.

Thirdly, a metal base suspension is almost undamped or dampens a metal spring only due to the friction between foam and spring suspension.

Based on this knowledge, the invention has the object to provide an alternative weight-reduced seat structure, which in particular can be built together less expensive and which has the necessary elasticity properties for load absorption and the desired damping properties and low weight.

In the publication WO 2010/104636 A1 there is disclosed a load-bearing structure having a load-bearing surface formed by load bearing elements. The load-bearing structure comprises, in addition to the load-bearing elements, relatively rigid alignment elements. The properties of the alignment elements are chosen so that the alignment elements form a rigid edge for holding the load-bearing elements. The alignment members serve during a stretching process of the load-bearing structure to support the load-bearing structure in a drafting apparatus and / or to mount the load-bearing structure to a support structure. The load-bearing elements are molded within the method to the more rigid alignment elements, thereby forming a unitary structure in which the load-bearing elements and the alignment elements form a unit. The document describes this Method for producing the unitary construction of load-bearing elements and rigid alignment elements and the associated stretching process of the load-bearing elements whose physical properties are changed by the stretching process.

Based on this knowledge, the invention has the object to provide an alternative weight-reduced seat structure, which in particular can be built together less expensive and which has the necessary elasticity properties and the desired damping properties for load bearing and low weight.

The starting point for the invention is a seat pan module of a seat part of a vehicle seat, comprising a lower suspension structure, which alone forms a load-bearing seat, or a partial seat pan and a lower suspension structure, which together form a load-bearing seat.

It is inventively provided that a seat pan module a Unterfederungsstruktur (elastic seat pan module) or a Teilsitzwanne and a Unterfederungsstruktur (partially elastic seat pan module), wherein the Unterfederungsstruktur as a produced in a molding process and then to produce specific elastic properties and damping properties under at least regional heating stretched elastic plastic part is trained.

It is thus provided a full suspension or a partial suspension of the load-bearing seat.

In a preferred embodiment of the invention, the Unterfederungsstruktur forms a load-bearing seat.

In another preferred embodiment of the invention, the partial seating trough forms a first partial surface of the seating surface and the lower suspension structure forms a second partial surface of the seating surface as a common load-bearing seating surface.

Advantageously, this creates a seat pan module whose under suspension structure has the manufacturer's desired specific elasticity properties (suspension and damping), which later provide improved comfort for the seated user.

In addition, the specific weight of the seat pan module and the foam disposed on the seat pan is advantageously reduced by the production of the lower suspension structure. Insofar as the part-seat pan is made of a plastic material, there is advantageously an even further reduced seat pan module with regard to the specific weight.

By stretching the lower suspension structure, furthermore, the specific elasticity properties and damping properties of the under-suspension structure consisting of at least one plastic material can be influenced. This type of influence by stretching / stretching, which precedes an at least partially thermal "processing" of the under-suspension structure, represents a new and innovative possibility for forming an elastic or partially elastic seat pan module.

In a preferred embodiment of the invention it is provided that the elastic base structure is formed as a honeycomb-like or net-like lattice structure. The design as a honeycomb-like or net-like lattice structure is advantageous, since this lattice structure has proven to be a stably formable structure with low material costs and, moreover, advantageously a strongly air-permeable partial area is formed in the area of the under-suspension structure. This training promotes the climatic conditions of the seat pan module. It is advantageously effected an automatic ventilation of the partial surface, whereby the comfort of the seat pan module is increased.

Furthermore, advantageously, in a preferred embodiment of the invention, the elastic honeycomb-like or net-like lattice structure of the under-suspension structure has at least one rigid node structure serving as attachment point for at least one peripheral piece of equipment. This embodiment allows the simplification of the complex design of a vehicle seat. Advantageously, the Unterfederungsstruktur serves already after its production without further effort for the attachment of equipment. In addition, it is further achieved that the otherwise elastic lower suspension structure has at least regionally (locally) rigid / rigid node points or node structures stabilizing the lower suspension structure.

In a preferred embodiment of the invention, the elastic honeycomb-like or mesh-like lattice structure of the lower suspension structure is provided with at least one rigid fastening element. The advantage of this embodiment is that the seat pan module already has all the necessary elements after its manufacture in order to secure the seat pan module in the seat part structure of the vehicle seat.

Advantageously, it is provided that a rigid, first fastening element for Attachment of the seat pan module to a support structure of the seat part structure and a rigid, second fastening element for fixing the Unterfederungsstruktur to the part seat pan is used.

In a first embodiment it is provided that the seat pan module is integrally formed from the partial seating pan and the lower suspension structure and is formed entirely from at least one plastic material. In this case, the rigid, first fastening element for fastening the seat pan module to the support structure of the seat part structure is formed. In this case, the seat pan module is made entirely of a plastic material of choice. A one-piece design is of particular advantage, since an assembly of part-seat pan and lower suspension structure, as is customary in the prior art, is eliminated. In addition, the production is simplified and fewer tools for the production of the seat pan module are needed.

In a second embodiment, it is provided that the seat pan module is formed in two parts from the part seat pan and the lower suspension structure. The seat pan module in a two-part embodiment is either entirely made of a plastic material of choice, or the part seat pan is made of a metallic material, and the under-spring structure is made of a plastic material of choice. It can be seen that in order to reduce weight and to produce the specific elastic properties of the seat pan module, a plurality of different seat pan modules can be formed, with all the seat pan modules having in common that the base structure made of a plastic material for weight reduction and temperature-affected stretching / stretching for the specific ones Elastic properties of the partially elastic seat pan module provides.

According to the invention, a method is proposed for producing a plastic underpinned elastic suspension structure for a seat pan module.

The starting point for the invention is a first method step, in which the shape of the lower suspension structure is generated, followed by a second method step, in which the lower suspension structure is stretched to produce specific elasticity properties.

According to the invention, it is provided that the under-suspension structure in the first method step is produced in the form of a grid which has at least one rigid node structure and / or at least one rigid fastening element. In the second method step, prior to stretching, the under-suspension structure is subject to heating at least in regions, the at least one node structure and / or the at least one fastening element being excluded from the heating or subject to heating together with the under-suspension structure. In a preferred embodiment, the thermally influenced stretching is carried out with a special temperature control in a predeterminable temperature range.

These variable boundary conditions advantageously allow the manufacturer to influence the production process, which in particular enables him to set the specific elastic elastic properties of the under-suspension structure as desired.

In a preferred embodiment, there is also the possibility that, depending on whether the node structures are subject to heating, the specific elasticity of the lower suspension structure and thus of the seat pan module are influenced in an advantageous manner. The at least partially heating or the complete heating of the lower suspension structure before stretching / stretching influences the design of the associated tools for producing the seat pan module.

In a preferred embodiment of the invention, it is provided within the method that the at least one node structure and / or the at least one fastening element, which is excluded from heating in the second method step, in the first method step is / are made reinforced by a small accumulation of material , That is to say that any change in the at least one node structure and / or the at least one fastening element that is possibly caused by the temperature-influenced stretching can be advantageously compensated by an adapted, small accumulation of material.

In another preferred embodiment of the invention, it is provided within the method that the at least one node structure and / or the at least one fastening element, which is subject to heating in the second method step, is / are reinforced in the first method step by a strong accumulation of material. That is, a change in the at least one node structure and / or the at least one fastening element caused by the temperature-influenced stretching can be advantageously compensated by an adapted, strong accumulation of material.

It is ensured by the low or strong accumulation of material that the at least one node structure and / or the at least one Retaining element retains its rigidity, which advantageously supports the stability of the spring structure and the node structures are suitable for attachment of peripheral equipment and the fasteners provide a sufficient rigid and rigid grip on the support structure of the seat part structure.

In the first method step, the manufacturer can advantageously be selected from a large number of influencing possibilities, which are the selection of the type of plastic and / or the selection of the geometry and material thickness and / or the arrangement of local structures and / or by the strength of the material accumulation of local structures exist.

In the second method step, the manufacturer can advantageously also summarize from a variety of influencing options, the level of orientation and / or by the height of the process temperature during heating and / or by the partial heating of the lower suspension structure excluding the local structures or by the complete heating of the sub-suspension structure including the local structures and / or the degree of material accumulation of the local structures.

The influencing possibilities are explained in more detail in the accompanying embodiments.

Finally, there is provided a tool for manufacturing a plastic molded seat pan module having a resilient underfill structure or a split seat pan and a resilient underfloor structure.

The tool comprises a tool lower part and an upper tool part, which in the closed state form a cavity for forming the partial seat pan and the lower suspension structure, in which at least one plastic material can be filled in a molding process.

According to the invention, it is now provided that the cavity between the tool lower part and the tool upper part is designed as a negative mold of the partial seat pan and the lower suspension structure and the lower tool part and / or the upper tool part comprises a slide structure associated with the lower suspension structure and a heat-generating device also at least partially associated with the lower suspension structure. Advantageously, the seat pan module is characterized in a tool both a forming process unterziehbar and the lower suspension structure is in the same tool under at least partially heating the Unterfederungsstruktur with the aid of the slide construction a thermally influenced stretching unterziehbar.

It thus advantageously becomes clear that only a single tool is necessary in order to form an underspring structure and a partial seat pan as an elastic plastic part which is produced in a shaping process, in particular injection molding, and subsequently stretched to produce specific elasticity properties and damping properties under thermal influence.

In one embodiment of the invention, it is possible to form the lower suspension structure separately from the partial seating pan. In this case, the tool is formed as follows:
The tool likewise comprises a tool lower part and a tool upper part, which, however, only form a cavity in the closed state for forming the lower suspension structure, in which at least one plastic material can be inserted in a shaping process.

According to the invention, it is then provided that the cavity between the tool lower part and the tool upper part is designed as a negative mold of the lower suspension structure and the lower tool part and / or the upper tool part comprises a slider construction associated with the lower suspension structure. Furthermore, the heat-generating device, which is assigned to the under-suspension structure at least in regions, is arranged in the upper tool part and / or lower tool part. The difference is that the partial seat pan is not taken into account in the design of the lower tool part and the upper part of the tool. The part seat pan is then produced in a separate tool, which in turn comprises a lower tool part and an upper tool part, wherein the cavity arranged there is formed as a negative mold of the part seat pan. In such a separate tool, only the molding process of the part seat pan is then carried out accordingly, after which the separately manufactured part seat pan is connected to the separately produced under suspension structure.

Further preferred embodiments of the invention will become apparent from the remaining, mentioned in the dependent claims characteristics.

The invention will be explained in more detail in embodiments with reference to the accompanying drawings. Show it:

1 a seat structure, in particular a seat part structure according to the prior art;

2 a partially elastic seat pan module in a perspective view obliquely from above, lying in a tool lower part, comprising a part seat pan and a base suspension structure made of plastic;

3 the partially elastic seat pan module during a stretching process in a perspective view obliquely from above, lying in a tool lower part, comprising the partial seat pan and the plastic under suspension structure;

4 an enlarged perspective view of the lower suspension structure of the seat pan module;

5 a perspective view of the seat part structure of an assembled vehicle seat with the seat pan module within the support structure of the seat part.

Possible embodiments of the invention will be explained below. For the purposes of the present description, "+ x" ("plus x") is used to denote the usual direction of travel of a vehicle, with "-x" ("minus x") the direction opposite to its usual direction of travel, with "y" the In the horizontal direction transverse to the x direction, and "z" denotes the direction in the vertical direction transverse to the x direction. This designation of the spatial directions in Cartesian coordinates corresponds to the coordinate system commonly used in the automotive industry. Within all figures, the same reference numerals for the same components are used below, which may not be explained again in each figure again all components already presented by reference numerals.

On the 1 has already been discussed in the notes to the prior art.

The following definitions are preceded by the following definitions. A part seat pan 12A and a lower suspension structure 15 , which together the seat-side substructure of a seat part 12 are hereinafter referred to as a seat pan module. The under suspension structure 15 In this case has specific elastic properties, which is why below is spoken of a partially elastic seat pan module.

Basically, two embodiments of the seat pan module are partially provided in several subsequent embodiments.

Seating module completely made of plastic:

In a first embodiment, the partial seating pan 12A and the lower suspension structure 15 the seat pan module each made of plastic. The following embodiments of the first embodiment are provided:

One-piece partially elastic seat pan module made of plastic material:

Part Shower Curtains 12A and suspension structure 15 can be produced in a single mold in a first embodiment variant together in a molding process, in particular in an injection molding process, wherein for the components 12A . 15 the same type of plastic is used or different types of plastic can be used.

Two-part partially elastic seat pan module made of plastic material:

Part Shower Curtains 12A and suspension structure 15 can be produced separately in a second embodiment in a molding process, in particular in an injection molding process, in various tools. Again this can be for the components 12A . 15 the same type of plastic or different types of plastic are used.

Seat pan module made of plastic and a metallic material:

In a second embodiment, the part seating 12A made of a metallic material and the Unterfederungsstruktur 15 made of a plastic material.

Two-part partially elastic seat pan module (hybrid) made of a metallic material and a plastic material:

The section seat pan 12A is manufactured as sheet metal part and the Unterfederungsstruktur 15 is produced in a molding process, in particular in an injection molding process. The production takes place separately in separate tools.

It is understood that due to the lower specific weight of the plastic material by the manufacture of the seat pan module completely made of plastic according to the first embodiment advantageously with respect to the desired weight saving over the prior art, the highest savings potential exists and can be exhausted.

It is further understood that a one-piece seat part tray module according to the first embodiment of the first embodiment in an advantageous manner with respect to then no longer necessary assembly of the compartment seat 12A and the suspension structure 15 Compared to the state of the art, the highest savings potential is present and can be exploited. It comes in one-piece production advantageously to a saving of assembly times, especially during a series production.

Since the one-piece, partially elastic seat pan module, which is made entirely of plastic material, thus offers the greatest savings potential, the first embodiment variant of the first embodiment will initially be discussed below.

One-piece partially elastic seat pan module made of plastic:

2 shows a one-piece partially elastic seat pan module in a perspective view obliquely from above, lying in a tool base W1, comprising the part seat pan 12A and the elastic base structure 15 ,

The reference number 12A-1 refers to a two-part partially elastic seat pan module, in which the part seat pan 12A with the lower suspension structure 15 only be connected after their separate production. For connection serve the receiving elements 12A-1 at the section seat pan 12 and the fasteners B2, which will be discussed later.

The associated upper tool part of a tool is not shown. In the exemplary embodiment, the lower tool part W1 has a movable slide construction. The slides W1-1 of the slide construction are within the tool lower part W1 in the x-direction, that is to say in the longitudinal direction of the spring elements of the under-suspension structure 15 , movably arranged. You are in 2 in a starting position I.

3 shows the one-piece partially elastic seat pan module in a perspective view also obliquely from above, with the slide W1-1 in 3 in a working position II. In the working position II, the slides W1-1 in the -x direction, that is, in the longitudinal direction of the spring elements of the Unterfederungsstruktur 15 postponed.

Using such a tool W, the seat pan module is manufactured as follows.

In a first method step, the shaping process, in particular injection molding, is carried out. In this first step, the seat pan module receives its specific shape. When injection molding can for the seat pan 12A and the lower suspension structure 15 either the same type of plastic or different types of plastic are injected into the tool.

The seat pan 12 and the lower suspension structure 15 get their specific shape within the first process step.

In the embodiment, the structure of the lower suspension structure 15 designed as a grid-like structure. The grid-like structure forms nodes. Within the nodes locally arranged node structures K are formed with predeterminable geometries.

The lattice-like structure of the lower suspension structure 15 is for example in 4 shown.

Advantageously, the grid is at least partially in a hexagonal geometric honeycomb shape 15-1 formed similar to a honeycomb. Such a shape makes the Unterfederungsstruktur very stable.

Alternatively, as a grid, a network is proposed in the form of a spider web with Hauptzugsträngen and Nebenzugsträngen. This gives us the under suspension structure 15 also very stable.

Other gratings will be in pentagonal honeycomb shapes as needed 15-2 educated. It is essential that the grid structure is honeycomb-shaped in various three-, four-, five-, hexagonal, etc. honeycomb shapes, whereby a stable Unterfederungsstruktur 15 is formed, the honeycomb structures, the spring elements of the Unterfederungsstruktur 15 form, which are advantageously easily accessible to a stretching process. The honeycombs form webs 15-3 , In the area of these footbridges 15-3 In an advantageous manner, rigid structures are created, the rigid nodes between the individual honeycombs 15-1 . 15-2 form and are referred to below as node structures.

By the reference symbol K1 is exemplified a first node structure with a circular geometry, in the center of which a circular opening K1-1 is formed.

By the reference numeral K2 is further exemplified another second node structure shown with a rectangular geometry having a rectangular opening K2-1.

In the first method step is further on the grid-like Unterfederungsstruktur 15 a first fastening element B1 formed, which for fastening the Unterfederungsstruktur 15 of the Part seat pan, in particular on the circular cross member 13B the holding structure 13 (please refer 1 ), serves.

The first fastener has a "c" -shaped mouth with the "c" open in the direction of the grid-like structure. The assembly of the seat pan module with the support structure 13 of the seat part 12 will be in contact later 5 explained in more detail.

After the forming process is completed, a second process step is performed.

Within this second process step, the lower suspension structure 15 stretched / stretched, that is, the spring elements of the lower suspension structure 15 are pulled apart in the axial direction (x-direction).

The person skilled in the art refers to the process as stretching or stretching or stretching.

The under suspension structure 15 is converted into a so-called stretching geometry, in which the spring elements of the lower suspension structure 15 be stretched / stretched in the x-direction in the x-direction in the embodiment. Depending on the plastic used in each case, there is a significant displacement of the plastic molecule chains in the axial direction of the spring elements of the lower suspension structure 15 ,

As a result of this displacement of the plastic molecule chains in the axial direction of the spring elements, predeterminable elasticity properties and damping properties are effected as a function of the degree of stretching. Depending on how high the degree of plastic deformation during stretching is, one speaks of a degree of orientation in the sense of a small or strong reorientation of the plastic molecule chains, the elasticity properties and damping properties of the spring elements of the under suspension structure change 15 , At the same time the material's own damping properties of the plastic are retained.

To carry out the second method step, the lower suspension structure 15 with his the seat pan 12A opposite end connected to the slider W1-1, wherein the slider W1-1 is initially in the initial position I.

The seat pan 12A lies in an immovable part of the tool W, so that the seat pan 12A while stretching is stationary, eliminating the suspension structure 15 of the one-piece seat pan module seat side is fixed.

In the tool W is an in 3 arranged only symbolically represented by the reference numeral Q heat source, which is arranged in the upper tool part and / or in the lower tool part W1.

Within the second process step, the lower suspension structure 15 first heated. Only after the lower suspension structure 15 has been brought to the appropriate process temperature, the slide W1-1 is brought into working position II (movement in the x direction), whereby the desired change in the material properties in the region of the spring elements of the lower suspension structure 15 caused by reorientation of the plastic molecule chains within the spring elements.

First procedure:

So that the node structures K1 and K2 and the fastening element B1 are not stretched / mitgereckt, is waived in the first approach to a heating in the region of the node structures K1 and K2 and in the region of the fastening element B1.

In other words, the suspension structure 15 is brought outside the node structures K1, K2 and outside the area of the fastener B1 by heating to process temperature.

In a further preferred embodiment of the invention is taken into account in the shaping process that by heat conduction within the spring elements of the lattice-like structure of the Unterfederungsstruktur 15 Nevertheless, a small amount of heat is applied to the local node structures K1, K2 and the fastening element B1.

A consideration is given by the fact that in the region of the local node structures K1 and / or K2, as well as the fastening element B1, a slight accumulation of material is made, so that at a low stretch of the local node structures K1, K2 and the fastener B1, the geometry and the original desired locally elastic properties are preserved.

Second approach:

In another approach of the invention, it is provided to entrain the local node structures K1 and / or K2 as well as the fastening element B1 during the second method step.

In this second approach, the entire grid-like structure, thus the node structures K1 and / or K2 and the region of the fastening element B1, on process temperature heated. In this procedure, the tool W can be carried out in an advantageous manner easier because no local areas must be left out, so that the heat source Q with less technical effort within the tool W, all areas of the Unterfederungsstruktur 15 warming, can be performed.

In order nevertheless to maintain almost the desired geometric and original elastic properties of the node structures K1, K2 and the fastening element B1, not only is a slight accumulation of material within the first method step provided during the shaping process, but a second method is used in this second procedure provided greater accumulation of material, so that during the stretching process in the second process step, the original elastic properties in the node structures K1 and / or K2 and within the fastener B1 are indeed changed, but compensated by the accumulation of material.

In this second approach, the desired geometry is achieved and the node structures K1 and / or K2 and the fastening element B1 remain substantially inelastic in terms of their elasticity due to the accumulation of material, whereby the fastening element B1 is also suitable as a substantially unyielding fastening element B1 in this second approach , so that it as a fastener B1 to the support structure 13 , the crossbar 13B , can serve.

The node structures K1 and / or K2 and the fastening element B1 are thus according to the invention in both approaches to the elastic spring elements of the lower suspension structure 15 essentially rigid or stiff.

In particular, the node structures K1 and / or K2 are thereby advantageously used as attachment points for peripheral equipment, such as seat occupancy detection mats, fans and other electrical and / or pneumatic connecting lines. The mentioned openings K1-1 and K2-1 are used advantageously for receiving latching elements, by means of which the peripheral equipment can be reversibly engaged in the openings K1-1, K2-1 of the node structures K1 and / or K2.

It is again made clear that the stretched during the second process step spring elements of the lower suspension structure 15 after stretching, have a predeterminable length which is between the original length before stretching and the maximum length during stretching. Thus the Unterfederungsstruktur 15 the seat pan module in the support structure 13 is arranged on bias, the assembly (connection of the support structure 13 with the seat pan module 12A . 15 ) of the seat part 12 made in a special way, which will be discussed later.

From the description it becomes clear by which parameters the elasticity of the lower suspension structure 15 can be influenced:
The elasticity of the lower suspension structure 15 of the partially elastic seat pan module is influenced according to the invention by the choice of the type of plastic within the first process step.

The elasticity of the lower suspension structure 15 According to the invention, the partially elastic seat pan module is influenced by the geometry and material thickness produced within the first method step.

The elasticity of the lower suspension structure 15 of the partially elastic seat pan module according to the invention is influenced by the determination of the height of the process temperature within the described second method step.

The elasticity of the lower suspension structure 15 the partially elastic seat pan module is influenced according to the invention by already in the first process step within the Unterfederungsstruktur 15 additionally at least one local node structure K1 and / or K2 is formed.

The elasticity of the lower suspension structure 15 The part-elastic seat pan module further depends on whether the node structures K1, K2 within the second method step together with the spring elements of the lower suspension structure 15 to be subjected to heating or not.

Finally, the elasticity of the under suspension structure depends 15 of the partially elastic seat pan module on whether at least one node structure K1 and / or K2 has been formed within the first method step with little or more material accumulation.

Finally, the elasticity of the under suspension structure depends 15 of the partially elastic seat pan module from the degree of orientation of the stretching / stretching.

Two-part partially elastic seat pan module completely made of plastic:

As already mentioned, the seat pan module according to the second embodiment of the first embodiment is produced in two parts.

In this case, the part seating 12A in a molding process, in particular by injection molding, produced in a separate tool. The section seat pan 12A is not subjected to a stretching process, so that the associated tool no heat source Q for stretching the seat pan 12A needed.

For the production of the lower suspension structure 15 another tool is used. This tool will, as just to the 2 and 3 described, designed analogously, with the difference that the tool only for the production of the Unterfederungsstruktur 15 is trained.

In the manufacture of the lower suspension structure 15 the process steps already described are carried out.

Due to the bipartite, however, the following differences arise, which must be taken into account during production:
In the production of the seat pan 12A become in the shaping process within the first process step recording elements 12A-1 provided in the 2 and 3 are shown. These recording elements 12A-1 are, as already mentioned, only formed when a two-part seat pan module is formed.

In these recording elements 12A-1 engage second fasteners B2, which in 4 are shown and in terms of their shape with the receiving elements 12A-1 correspond.

On the 4 has already been discussed in detail.

The under suspension structure 15 a two-part seat pan module comprises the lattice-like structure, optionally at least one node structure K1, K2 and the first fastening element B1 and the second fastening element B2.

The under suspension structure 15 a one-piece seat pan module comprises the grid-like structure, optionally at least one node structure K1, K2 and the first fastening element B1. The second fastening element B2 is then not formed, since at this point within the manufacturing process, the partial seating 12A is formed.

Completely it is mentioned that alternatively exists the possibility, both with the (one-part as well as with the two-part) training of the Unterfederungsstruktur 15 as well as laterally form the grid-like structure fasteners. By means of these fasteners, not shown, the Unterfederungsstruktur 15 in the x-direction (transverse to the longitudinal direction of the spring elements) also seen laterally in the support structure 13 be hung. These fasteners are, as explained, designed to be stiff analogous to the node structures K1, K2 and the other fastening elements B1, B2, so that the Unterfederungsstruktur 15 at the support structure 13 is attachable by substantially elastically unyielding fasteners.

Two-part partially elastic seat pan module made of plastic and a metallic material:

The hybrid seat pan module according to the second embodiment has the part seating pan 12A from a sheet metal part, which with a Unterfederungsstruktur made of plastic according to 4 connected is.

The section seat pan 12A points to the receiving elements 12A-1 on, so that the second fastening elements B2 of the lower suspension structure 15 in the receiving elements 12A-1 can be hung.

The production takes place, as mentioned, in different tools, the Unterfederungsstruktur 15 can be produced in the already explained method steps.

The object of the invention is achieved by a part seat pan 12A and the lower suspension structure 15 to a component (seat pan module) are united.

Summary:

In that at least the lower suspension structure 15 is made of a plastic material, the weight of the seat pan module and thus the entire vehicle seat is reduced. The assembly is either omitted completely (one-piece design of the seat pan module) or is by the formation of positively corresponding receiving elements 12A-1 on the seat pan 12A and second fastening elements B2 on the under-spring structure 15 simplified.

The attachment to the support structure 13 of the seat part 12 is simplified by the formation of a first fastening element B1, which positively with the cross member 13B the holding structure 13 corresponds.

In addition to the weight reduction, the stretching process ensures that the desired elastic properties (spring / damper properties) of the lower suspension structure 15 As a result, the partially elastic seat pan module is obtained.

Within the suspension structure 15 Local geometric changes are provided, which are formed as node structures K1 and / or K2 and / or fastening elements B1 or B1 and B2, wherein the node structures K1 and / or K2 of the attachment of peripheral equipment and the fastening elements B1, B2 of the attachment of the lower suspension structure 15 at the support structure 13 or the seat pan 12A serve.

Assembly of the seat pan module:

The assembly of the seat pan module is carried out according to 5 as follows:
5 shows a perspective view of the seat part structure of an assembled vehicle seat with the seat pan module 12A . 15 within the holding structure 13 of the seat part 12 ,

When assembling the one-piece or already assembled (connected via 12A-1 and B2) two-piece seat pan module first on the cross member 13B the holding structure 13 clipped. The first fastening element B1 engages around the cross tube with its mouth 13B ,

The holding structure 13 points each on the inside of the side rails 13B opposing locking elements 13C on.

Furthermore, the holding structure 13 each on the inside of the side rails 13B Rest surveys 13D on.

The section seat pan 12A has opposite detent openings 12A-2 on.

Furthermore, the compartment seat 12A each on its outside, which in the mounting position to the side rails 13A has, detent recesses 12A-3 on.

In the perspective view of 5 These are the designs 13B . 13C . 12A-2 . 12A-3 only on the upper side rail 13B visible, the inside of which is shown.

The spring elements of the lower suspension structure 15 Depending on the degree of orientation, after stretching they have a length which is between the original length before stretching and the maximum length during stretching.

Taking into account the length which is present after stretching in each case, the spring elements are brought to a desired predefinable preload in their assembly position.

After the first fastener B1 to the cross member 13B been clipped, are the locking recesses 12A-3 the section seat pan 12A on the grid elevations 13D plugged, whereby an axis of rotation Y1 in the horizontal direction (y-direction) forms transverse to the x-axis. When installing the compartment seat 12A initially folded against the x / y plane by a predetermined angle up. In this state, the spring elements of the Unterfederungsstruktur 15 not curious yet. Subsequently, the compartment seat 12A folded down and is located substantially in the horizontal x / y plane. Due to the rotational movement, the spring elements extend, whereby the spring elements of the lower suspension structure 15 be tense. The locking elements 13C finally snap into the detent openings 12A-3 and fix the compartment seat pan 12A reversible to the support structure 13 ,

Insofar the lower suspension structure 15 Alternatively, the described lateral fastening elements, these fasteners are in a final step on the inner sides of the side rails 13A mounted in designated, not shown elements.

LIST OF REFERENCE NUMBERS

12

seat part

12A

Part Shower Curtains

12A-1

receiving elements

12A-2

latching opening

12A-3

latching depression

13

holding structure

13A

side rails

13B

transverse spar

13C

locking element

13D

Rast collection

14

mounts

14A

seat-side hanger

14B

transverse spar-side suspension

14C

side rail side suspension

15

Lower suspension structure

15-1

hexagonal honeycomb

15-2

pentagonal honeycomb

15-3

Stege

W

Tool

W1

Tool part

W1-1

pusher

Q

heat source

K

node structures

K1

first node structure

K1-1

circular opening

K2

second node structure

K2-1

rectangular opening

B1

first fastening element

B2

second fastening element

I

starting position

II

working position

+ x

Direction in the usual direction of travel of a vehicle

-x

Direction opposite to the usual direction + x

y

Direction in the horizontal direction transverse to the x-direction

z

Direction in the vertical direction transverse to the x-direction

Y1

axis of rotation

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 19943890 C1 [0007]
• WO 2010/104636 A1 [0012]

Claims (16)

Seat pan module of a seat part ( 12 ) of a vehicle seat, comprising a lower suspension structure ( 15 ) or a partial seat pan ( 12A ) and a suspension structure ( 15 ) forming a load-bearing seat, characterized in that the under-spring structure ( 15 ) is formed as a produced in a molding process and then stretched to produce specific elastic properties and damping properties under at least regional heating elastic plastic part. Seat pan module according to claim 1, characterized in that the partial seating trough ( 12A ) a first partial surface of the seat surface and the lower suspension structure ( 15 ) forms a second partial surface of the seat as a common load-bearing seat. Seat pan module according to claim 1, characterized in that the elastic base structure ( 15 ) is designed for specific damping properties. Seat pan module according to claim 1, characterized in that the elastic base structure ( 15 ) is formed as a lattice structure, in particular as a honeycomb-like or net-like lattice structure. Seat pan module according to claim 1, characterized in that the elastic honeycomb-like or net-like grid structure of the under suspension structure ( 15 ) has at least one rigid node structure (K1, K2) serving as attachment point for at least one peripheral piece of equipment. Seat pan module according to claim 1, characterized in that the elastic honeycomb-like or net-like grid structure of the under suspension structure ( 15 ) has at least one rigid fastening element (B1, B2). Seat pan module according to claim 6, characterized in that a rigid, first fastening element (B1) for fastening the seat pan module to a support structure (FIG. 13 ) a seat part structure and a rigid, second fastening element (B2) for fastening the under suspension structure ( 15 ) on the compartment seat pan ( 12A ) serves. Seat pan module according to one of the preceding claims, characterized in that the seat pan module in one piece from the part seating pan ( 12A ) and the suspension structure ( 15 ) is formed and is formed entirely of at least one, plastic material. Seat pan module according to one of the preceding claims, characterized in that the seat pan module in two parts from the part seating pan ( 12A ) and the suspension structure ( 15 ) is formed and either completely made of at least one plastic material or the seat pan ( 12A ) of a metallic material and the under suspension structure ( 15 ) is formed of at least one plastic material. Method for producing a plastic elastic suspension structure ( 15 ) for a seat pan module comprising - a first method step in which the shape of the lower suspension structure ( 15 ), and - a second method step, in which the sub-suspension structure ( 15 ) is stretched to produce specific elastic properties and damping properties, characterized in that - the under-suspension structure ( 15 ) is produced in the first method step in the form of a grid which has at least one rigid node structure (K1, K2) and / or at least one rigid fastening element (B1, B2), and - the under-suspension structure ( 15 ) in the second method step prior to stretching at least partially subject to heating, wherein the at least one node structure (K1, K2) and / or the at least one fastening element (B1, B2) are excluded from the heating or together with the Unterfederungsstruktur ( 15 ) are subject to heating. A method according to claim 10, characterized in that the at least one node structure (K1, K2) and / or the at least one fastening element (B1, B2), which is excluded in the second method step from the heating, in the first method step by a small accumulation of material is / are strengthened. A method according to claim 10, characterized in that the at least one node structure (K1, K2) and / or the at least one fastening element (B1, B2), which is subject to the heating in the second step, formed in the first method step reinforced by a strong accumulation of material will be. A method according to claim 10, characterized in that the elasticity of the lower suspension structure ( 15 ) is influenced in the first method step, by - the choice of the type of plastic and / or - the selection of the geometry and material thickness and / or - the arrangement of local structures (K1, K2) and / or The strength of the material accumulation of the local structures K1, K2. A method according to claim 10, characterized in that the elasticity of the lower suspension structure ( 15 ) is influenced in the second method step, by - the level of the degree of orientation and / or - the height of the process temperature during heating and / or - the partial heating of the sub-suspension structure ( 15 ) excluding the local structures (K1, K2) or by the complete heating of the sub-suspension structure including the local structures (K1, K2) and / or the degree of material accumulation of the local structures (K1, K2). Tool (W) for producing a plastic molded seat pan module ( 12 ), which has an elastic base structure ( 15 ), comprising - a tool lower part (W1) and a tool upper part, which form a cavity for forming the Unterfederungsstruktur in the closed state, in which at least one plastic material can be filled in a molding process, characterized in that the cavity between the tool lower part (W1) and upper tool as a negative form of the suspension structure ( 15 ) and the tool lower part (W1) and / or the upper tool part - one of the lower suspension structure ( 15 ) associated slide construction (W1-1) - as well as a likewise the Unterfederungsstruktur ( 15 ) at least partially associated heat-generating device, whereby the seat pan module ( 12 ) in the tool (W) is subjected both to a shaping process and the under-suspension structure ( 15 ) under at least partial heating of the sub-suspension structure ( 15 ) with the aid of the slide construction (W1-1) can be subjected to a thermally influenced stretching. Tool (W) for producing a plastic molded seat pan module ( 12 ), which a Teilsitzwanne ( 12A ) and an elastic under suspension structure ( 15 ), comprising - a tool lower part (W1) and a tool upper part, which in the closed state a cavity for the formation of the part seat pan ( 12A ) and form the Unterfederungsstruktur, in which in a molding process, at least one plastic material can be filled, characterized in that the cavity between the lower tool part (W1) and upper die as a negative mold of the part seat pan ( 12A ) and the suspension structure ( 15 ), and the lower tool part (W1) and / or the upper tool part - one of the lower suspension structure ( 15 ) associated slide construction (W1-1) - as well as a likewise the Unterfederungsstruktur ( 15 ) at least partially associated heat-generating device, whereby the seat pan module ( 12 ) in the tool (W) both subjected to a molding process and the Unterfederungsstruktur ( 15 ) under at least partial heating of the sub-suspension structure ( 15 ) with the aid of the slide construction (W1-1) can be subjected to a thermally influenced stretching.

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