DE102012020711B4 - seat pan module - Google Patents

Abstract

Seat pan module of a seat part (12) of a vehicle seat, comprising a spring base structure (15) or a partial seat pan (12A) and a spring base structure (15) which form(s) a load-bearing seat surface, characterized in that the spring base structure (15) is produced as a in a molding process produced elastic plastic part is formed, the specific elasticity properties and damping properties of which are generated by stretching subsequent to at least regional heating of the plastic part, the elastic under-springing structure (15) being formed as a honeycomb-like or a net-like lattice structure and at least one rigid node structure (K1, K2 ) has whose nodes serve as attachment points for at least one piece of peripheral equipment.

Description

The invention relates to a seat pan module of a seat part of a vehicle seat, comprising a partial seat pan and a spring base structure which together form a load-bearing seat surface, the partial seat pan forming a first partial surface of the seat surface and the spring base structure forming a second partial surface of the seat surface. The invention also relates to an associated manufacturing method and a tool for manufacturing the seat pan module.

Wire-like suspension structures for seat parts and backrests of vehicle seats and other seating furniture are known from the prior art. The spring support structures usually consist of a large number of individual wires made of metal or plastic, which are usually pre-bent and connected to one another in various ways. The metal suspension structures and the plastic suspension structures are offered in varying degrees of rigidity. The suspension structures stabilize the upholstery foam of a seat part or a backrest and ensure the desired elasticity and damping of the load-bearing surfaces of the seat part and the backrest. The suspension structures are attached to frame structures of the seat part or the backrest, in particular suspended.

However, it is also known to produce seat pans without spring base structures, on which an upholstery foam is arranged, so that the elasticity of the load-bearing surface of the seat part and the backrest is largely caused by the upholstery foam.

As the state of the art, the publications DE 10 2009 040 901 A1 , DE 199 05 215 A1 , WO 2007/144 703 A1 and U.S.A. 4,183,894 called.

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

1 shows a perspective view obliquely from above of a seat pan 12A of a motor vehicle seat, which is designed as a shaped sheet metal part. The seat pan 12A has a recessed area which is delimited by an edge of the seat pan 12A and opposite by a transverse beam 13B designed as a holding structure 13 and lateral beams 13A also designed as a holding structure 13 opposite one another. Such seat pans 12A having a recessed area are referred to as partial seat pans.

The wires of the spring base structure 15 are fixed in suspensions 14, 14A on the seat pan side, suspensions 14, 14B on the crossbar side and suspensions 14, 14C on the side rail side on the holding structure 14 and the partial seat pan 12A. The holding structure 13 and the partial seat pan 12A and the spring support structure 15 are made of a metallic material.

The elastic comfort properties of the load-bearing surface of the seat part are brought about in the area of the partial seat pan 12A by the foam (upholstery) arranged thereon and in the area of the suspension structure 15 by the elastic properties of the suspension structure 15 and the foam (upholstery) arranged on it. Such a partially sprung seat pan is, for example, in the publication DE 199 438 90 C1 described.

In the known solutions, it is firstly disadvantageous that the partial seat pan has to be connected to the spring base structure. There are high assembly times.

Second, the weight of the assembled component of the bed suspension structure and a partial seat pan formed from a metallic material is still relatively high.

Thirdly, a metallic spring base is almost undamped or dampens a metallic spring base exclusively due to the friction between the foam and the spring base.

In the pamphlet WO 2010 / 104 636 A1 discloses a load-bearing structure having a load-bearing surface formed by load-bearing members. The load-bearing structure includes relatively rigid alignment elements in addition to the load-bearing elements. The properties of the alignment elements are selected in such a way that the alignment elements form a rigid edge for holding the load-bearing elements. The alignment features serve to retain the load-bearing structure in a stretcher and/or to mount the load-bearing structure to a support structure during a stretching process of the load-bearing structure. The load-bearing elements are molded to the more rigid alignment elements in the process, thereby forming a unitary structure in which the load-bearing elements and the alignment elements form one unit. The reference describes the method of making the unitary structure of load bearing members and rigid alignment members and the associated stretching process of the load-bearing elements, whose physical properties are changed by the stretching process.

Proceeding from this state of knowledge, the invention is based on the object of creating an alternative weight-reduced seat structure which can be assembled in particular with less effort and which has the necessary elasticity properties and the desired damping properties for load absorption and is light in weight.

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

It is provided according to the invention that a seat pan module comprises a spring base structure (elastic seat pan module) or a partial seat pan and a spring base structure (partially elastic seat pan module), the spring base structure being an elastic plastic part produced in a shaping process and then stretched to produce specific elasticity properties and damping properties with at least regional heating is formed, wherein the elastic under-springing structure is formed as a honeycomb-like or a net-like lattice structure and has at least one rigid node structure whose nodes serve as attachment points for at least one peripheral piece of equipment.

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

In a preferred embodiment of the invention, the spring base structure forms a load-bearing seat surface.

In another preferred embodiment of the invention, the partial seat pan forms a first partial surface of the seat surface and the sprung structure forms a second partial surface of the seat surface as a common load-bearing seat surface.

This advantageously creates a seat pan module whose spring structure has the specific elasticity properties (springing and damping) desired by the manufacturer, which later offer improved comfort for the person sitting on it.

In addition, the specific weight of the seat pan module and of the foam arranged on the seat pan is reduced in an advantageous manner by the production of the under-springing structure. Insofar as the partial seat pan is also made of a plastic material, a seat pan module with an even further reduced specific weight results in an advantageous manner.

Furthermore, by stretching the spring base structure, the specific elasticity properties and damping properties of the spring base structure consisting of at least one plastic material can be influenced. This type of influencing by stretching, which is preceded by at least some areas of thermal "processing" of the spring base structure, represents a new and innovative way of forming an elastic or partially elastic seat pan module.

The design as a honeycomb or net-like lattice structure is advantageous because this lattice structure has proven to be a stable structure with low material costs and a highly air-permeable partial surface is also advantageously formed in the region of the slatted base structure. Automatic ventilation of the partial area of the seat pan module is advantageously effected, as a result of which the comfort of the seat pan module is increased.

Furthermore, the elastic honeycomb or net-like lattice structure of the under-springing structure has the at least one rigid node structure, which serves as an attachment point for at least one piece of peripheral equipment.

This configuration enables the complex design of a vehicle seat to be simplified. Advantageously, the sprung base structure is already used after its production without further effort for the attachment of items of equipment.

In addition, it is also achieved that the otherwise elastic under-springing structure has, at least in regions (locally) stiff/rigid nodes or node structures that stabilize the under-springing structure.

Furthermore, the elastic honeycomb or net-like lattice structure of the under-springing structure is provided with at least one rigid fastening element. The advantage of this configuration is that the seat pan module already has all the necessary elements after its production in order to be able to fasten the seat pan module in the seat part structure of the vehicle seat.

Provision is advantageously made for the seat pan module to be fastened to a holding structure of a partial seat structure by a rigid, first fastening element and for the under-springing structure to be fastened to the partial seat pan by a stiff, second fastening element.

In a first embodiment, it is provided that the seat pan module is formed in one piece from the partial seat pan and the spring base structure and is formed entirely from at least one plastic material. In this case, the rigid, first fastening element is designed to fasten the seat pan module to the holding structure of the seat part structure. In this case, the seat pan module is made entirely of a plastic material of choice. A one-piece construction is of particular advantage, since there is no need to assemble the partial seat pan and the spring base structure, as is customary in the prior art. In addition, production is simplified and fewer tools are required to produce the seat pan module.

In a second embodiment it is provided that the seat pan module is formed in two parts from the partial seat pan and the spring base structure. In a two-piece design, the seat pan module is either made entirely of a plastic material of choice, or the partial seat pan is made of a metallic material and the slat base structure is made of a plastic material of choice. It becomes clear that to reduce weight and to generate the specific elastic properties of the seat pan module, a large number of different seat pan modules can be formed, with all seat pan modules having in common that the spring structure made of a plastic material is already used for weight reduction and the temperature-influenced stretching/stretching for the specific Elasticity properties of the partially elastic seat pan module ensures.

According to the invention, a method for producing an elastic under-springing structure made of plastic for a seat pan module is proposed.

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

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

These variable boundary conditions allow the manufacturer to influence the manufacturing process in an advantageous manner, which in particular allows him to set the specific elastic properties of the spring base 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 spring base structure and thus of the seat pan module are advantageously influenced. The at least regional heating or the complete heating of the spring structure before stretching influences the design of the associated tools for manufacturing 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 the heating in the second method step, is/are reinforced in the first method step by a small accumulation of material . This means that a change in the at least one node structure and/or the at least one fastening element that may be caused during the temperature-influenced stretching can be advantageously compensated for 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 large accumulation of material. This means that a change in the at least one node structure and/or the at least one fastening element caused by temperature-influenced stretching can advantageously be compensated for by an adapted, strong accumulation of material.

The low or high accumulation of material ensures that the at least one node structure and/or the at least one fastening element retains its rigidity or rigidity, which advantageously supports the stability of the underspring structure and the node structures are suitable for fastening peripheral items of equipment as well the fastening elements provide a sufficiently stiff and rigid hold on the supporting structure of the seat part structure.

In the first step of the method, the manufacturer can advantageously choose from a large number of influencing options, which can be found in the selection of the type of plastic and/or the selection of the geometry and material thickness and/or the regional arrangement of rigid node structures and/or the strength of the material accumulation of the stiff node structures exist.

In the second step of the method, the manufacturer can also advantageously choose from a large number of influencing options, which are the level of the degree of orientation and/or the level of the process temperature during heating and/or the partial heating of the spring base structure, excluding the stiff node structures or by the complete heating of the underspring structure including the rigid nodal structures and/or the degree of material accumulation of the rigid nodal structures.

The possibilities of influencing are explained in more detail in the associated exemplary embodiments.

Finally, a tool is created for producing a seat pan module made of plastic, which has an elastic underspring structure or a partial seat pan and an elastic underspring structure.

The tool comprises a lower tool part and an upper tool part which, in the closed state, form a cavity for forming the partial seat pan and the spring structure, into 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 lower part of the tool and the upper part of the tool is designed as a negative mold of the partial seat pan and the suspension structure, and the lower tool part and/or the upper tool part comprises a slide construction assigned to the suspension structure and a heat-generating device that is also assigned at least in certain areas to the suspension structure. Advantageously, the seat pan module can be subjected to a shaping process in one tool and the suspension structure can be subjected to thermally influenced stretching in the same tool with at least regional heating of the suspension structure with the aid of the slide construction.

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

• Das Werkzeug umfasst ebenfalls ein Werkzeugunterteil und ein Werkzeugoberteil, die im geschlossenen Zustand jedoch nur einen Hohlraum zur Ausbildung der Unterfederungsstruktur bilden, in denen in einem Formgebungsprozess mindestens ein Kunststoffmaterial einführbar ist.

In one embodiment of the invention, there is the possibility of designing the under-springing structure separately from the partial seat pan. In this case, the tool is designed as follows:

• The tool also includes a lower tool part and an upper tool part, which in the closed state, however, only form a cavity for forming the spring support structure, into which at least one plastic material can be introduced in a shaping process.

According to the invention, it is then provided that the cavity between the lower tool part and the upper tool part is designed as a negative mold of the spring base structure and the lower tool part and/or the upper tool part comprises a slide construction assigned to the spring base structure. Furthermore, the heat-generating device assigned at least in certain areas to the spring base structure is arranged in the tool upper part and/or tool lower part. The difference is that the partial seat pan is not taken into account when designing the lower and upper mold parts. The partial seat pan is then produced in a separate tool, which in turn comprises a lower tool part and an upper tool part, with the cavity arranged there being designed as a negative mold of the partial seat pan. In such a separate tool, only the shaping process of the partial seat pan is then carried out accordingly, after which the separately manufactured partial seat pan is connected to the separately manufactured underspring structure.

Further preferred configurations of the invention result from the remaining features mentioned in the dependent claims.

• 1 eine Sitzstruktur, insbesondere eine Sitzteilstruktur nach dem Stand der Technik;
• 2 ein teilelastisches Sitzwannenmodul in einer perspektivischen Ansicht schräg von oben, in einem Werkzeugunterteil liegend, umfassend eine Teilsitzwanne und eine Unterfederungsstruktur aus Kunststoff;
• 3 das teilelastische Sitzwannenmodul während eines Streckprozesses in einer perspektivischen Ansicht schräg von oben, in einem Werkzeugunterteil liegend, umfassend die Teilsitzwanne und die Unterfederungsstruktur aus Kunststoff;
• 4 eine vergrößerte perspektivische Darstellung der Unterfederungsstruktur des Sitzwannenmoduls;
• 5 eine perspektivische Darstellung der Sitzteilstruktur eines zusammengebauten Fahrzeugsitzes mit dem Sitzwannenmodul innerhalb der Haltestruktur des Sitzteiles.

The invention is explained in more detail below in exemplary embodiments with reference to the associated 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 at an angle from above, lying in a lower part of the tool, comprising a partial seat pan and a spring structure made of plastic;
• 3 the partially elastic seat pan module during a stretching process in a perspective view at an angle from above, lying in a lower part of the tool, comprising the partial seat pan and the lower spring structure made of plastic;
• 4 an enlarged perspective view of the 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 are explained below. For the purposes of this description, “+x” (“plus x”) is intended to denote the usual direction of travel of a vehicle, “-x” (“minus x”) the direction opposite to its usual direction of travel, and “y” the direction in the horizontal transverse to the x-direction, and "z" denotes the direction in the vertical transverse to the x-direction. This way of designating the spatial directions in Cartesian coordinates corresponds to the coordinate system generally used in the motor vehicle industry. Within all the figures, the same reference numbers are used below for the same components, with all the components already presented possibly not being explained again using the reference numbers in each figure.

On the 1 has already been discussed in the explanations of the prior art.

The following definitions precede the following explanations. A partial seat pan 12A and a spring base structure 15, which together form the substructure of a seat part 12 on the seat surface side, are referred to below as the seat pan module. The spring base structure 15 has specific elastic properties, which is why it is referred to below as a partially elastic seat pan module.

In principle, two embodiments of the seat pan module are provided, in some cases in a number of the following design variants.

• In einer ersten Ausführungsform wird die Teilsitzwanne 12A und die Unterfederungsstruktur 15 des Sitzwannenmoduls jeweils aus Kunststoff hergestellt. Folgende Ausführungsvarianten der ersten Ausführungsform sind vorgesehen:
  • Einteiliges teilelastisches Sitzwannenmodul aus Kunststoffwerkstoff:
    • Teilsitzwanne 12A und Unterfederungsstruktur 15 können in einer ersten Ausführungsvariante gemeinsam in einem Formgebungsprozess, insbesondere in einem Spritzgussverfahren, in einem einzigen Werkzeug hergestellt werden, wobei für die Bauteile 12A, 15 die gleiche Kunststoffart zum Einsatz kommt oder es können unterschiedliche Kunststoffarten zum Einsatz kommen.

Seat pan module made entirely of plastic:

• In a first embodiment, the partial seat pan 12A and the suspension structure 15 of the seat pan module are each made of plastic. The following design variants of the first embodiment are provided:
  • One-piece, partially elastic seat pan module made of plastic material:
    • In a first embodiment variant, the partial seat pan 12A and the spring support structure 15 can be produced together in one molding process, in particular in an injection molding process, in a single tool, with the same type of plastic being used for the components 12A, 15 or different types of plastic being used.

• Teilsitzwanne 12A und Unterfederungsstruktur 15 können in einer zweiten Ausführungsvariante getrennt voneinander in einem Formgebungsprozess, insbesondere in einem Spritzgussverfahren, in verschiedenen Werkzeugen hergestellt werden. Auch hierbei können für die Bauteile 12A, 15 die gleiche Kunststoffart oder unterschiedliche Kunststoffarten zum Einsatz kommen.

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

• In a second embodiment variant, the partial seat pan 12A and the spring base structure 15 can be produced separately from one another in a shaping process, in particular in an injection molding process, using different tools. Here, too, the same type of plastic or different types of plastic can be used for the components 12A, 15.

• In einer zweiten Ausführungsform wird die Teilsitzwanne 12A aus einem metallischen Werkstoff und die Unterfederungsstruktur 15 aus einem Kunststoffwerkstoff hergestellt.

Seat pan module made of plastic and a metallic material:

• In a second embodiment, the partial seat pan 12A is made of a metallic material and the spring structure 15 is made of a plastic material.

• Die Teilsitzwanne 12A wird als Blechformteil hergestellt und die Unterfederungsstruktur 15 wird in einem Formgebungsprozess, insbesondere in einem Spritzgussverfahren, hergestellt. Die Herstellung erfolgt getrennt voneinander in getrennten Werkzeugen.

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

• The partial seat pan 12A is produced as a shaped sheet metal part and the spring support structure 15 is produced in a shaping process, in particular in an injection molding process. The production takes place separately from each other in separate tools.

It goes without saying that due to the lower specific weight of the plastic material, producing the seat pan module entirely from plastic according to the first embodiment advantageously has the highest savings potential in terms of the desired weight saving compared to the prior art and can be exploited.

It is also understood that with a one-piece seat pan module according to the first variant of the first embodiment, the highest savings potential is also advantageously present and can be exploited compared to the prior art with regard to the assembly of the partial seat pan 12A and the spring base structure 15, which is then no longer necessary. In the case of a one-piece production, assembly times are advantageously saved, in particular during series production.

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

• 2 zeigt ein einteiliges teilelastisches Sitzwannenmodul in einer perspektivischen Ansicht schräg von oben, in einem Werkzeugunterteil W1 liegend, umfassend die Teilsitzwanne 12A und die elastische Unterfederungsstruktur 15.

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

• 2 shows a one-piece, partially elastic seat pan module in a perspective view at an angle from above, lying in a lower tool part W1, comprising the partial seat pan 12A and the elastic underspring structure 15.

The reference number 12A-1 refers to a two-piece, partially elastic seat pan module, in which the partial seat pan 12A is only connected to the spring base structure 15 after it has been manufactured separately. The receiving elements 12A-1 on the partial seat pan 12A and the fastening elements B2, which will be discussed later, are used for the connection.

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 movably arranged within the lower tool part W1 in the x-direction, that is to say in the longitudinal direction of the spring elements of the under-springing structure 15. You are in 2 in a starting position I

3 shows the one-piece, partially elastic seat pan module in a perspective view, also at an angle from above, with the sliders W1-1 in 3 are in a working position II. In working position II, the slides W1-1 are displaced in the −x direction, that is to say in the longitudinal direction of the spring elements of the spring base structure 15.

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 process step, the seat pan module is given its specific shape. In the case of injection molding, either the same type of plastic or different types of plastic can be injected into the mold for the partial seat pan 12A and the underspring structure 15

The partial seat pan 12A and the suspension structure 15 are given their specific shape within the first method step.

In the exemplary embodiment, the structure of the spring base structure 15 is designed as a lattice-like structure. The grid-like structure forms nodes. Locally arranged node structures K with predeterminable geometries are formed within the nodes.

The lattice-like structure of the spring base structure 15 is shown, for example, in 4 shown.

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

Alternatively, a network in the manner of a spider's web with main tension cords and secondary tension cords is proposed as the grid. As a result, the spring base structure 15 is also designed to be very stable.

Other grids are formed as required in pentagonal honeycomb shapes 15-2. It is essential that the lattice structure is formed like a honeycomb in various triangular, quadrilateral, pentagonal, hexagonal, etc. honeycomb shapes, whereby a stable suspension structure 15 is formed, the honeycomb structures of which form the spring elements of the suspension structure 15, which are advantageously easily accessible to a stretching process are. The honeycomb form webs 15-3. In the area of these webs 15-3, rigid structures are advantageously created, which form rigid nodes between the individual honeycombs 15-1, 15-2 and are referred to as node structures K below.

A first node structure with a circular geometry is shown by way of example with the reference symbol K1, in the center of which a circular opening K1-1 is formed.

Another second node structure with a rectangular geometry, which has a rectangular opening K2-1, is also shown by way of example with the reference symbol K2.

In the first step of the method, a first Fastening element B1 formed on, which is used to fasten the lower spring structure 15 of the partial seat pan 12A, in particular to the circular transverse beam 13B of the holding structure 13 (see 1 ), serves.

The first fastening element B1 has a "c"-shaped mouth, the "c" being open in the direction of the lattice-like structure. The assembly of the seat pan module with the support structure 13 of the seat part 12 is later in connection with 5 explained in more detail.

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

Within this second method step, the spring base structure 15 is stretched/stretched, that is to say the spring elements of the spring base structure 15 are pulled apart in the axial direction (x-direction).

Those skilled in the art refer to the process as stretching or stretching or also as stretching.

The suspension structure 15 is converted into what is known as a stretching geometry, in which the spring elements of the suspension structure 15 are stretched/stretched in the x-direction. 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 spring base structure 15.

This shifting of the plastic molecule chains in the axial direction of the spring elements brings about elastic properties and damping properties that can be predetermined 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 slight or strong reorientation of the plastic molecule chains, the elasticity properties and damping properties of the spring elements of the spring base structure 15 change. At the same time, the material's own damping properties of the plastic remain receive.

To carry out the second method step, the spring base structure 15 is connected to the slide W1-1 at its end opposite the partial seat pan 12A, with the slide W1-1 initially being in the starting position I.

The partial seat pan 12A lies in an immovable part of the tool W, so that the partial seat pan 12A is stationary during stretching, as a result of which the spring support structure 15 of the seat pan module produced in one piece is fixed on the seat pan side.

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

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

First procedure:

So that the node structures K1 and K2 and the fastening element B1 are not also stretched/also stretched, in the first procedure there is no heating in the area of the node structures K1 and K2 and in the area of the fastening element B1.

In other words, the spring base structure 15 is brought to the process temperature by heating only outside the node structures K1, K2 and outside the area of the fastening element B1.

In a further preferred embodiment of the invention, the shaping process takes into account that due to heat conduction within the spring elements of the grid-like structure of the spring base structure 15, there is still a small amount of heat input to the local node structures K1, K2 and the fastening element B1.

A slight accumulation of material is made in the area of the local node structures K1 and/or K2 and the fastening element B1, so that with a slight stretching of the local node structures K1, K2 and the fastening element B1, the geometry and the locally desired original elastic properties are retained.

Second approach:

In another procedure of the invention, it is provided that the local node structures K1 and/or K2 and the fastening element B1 are also stretched during the second method step.

In this second procedure, the entire lattice-like structure, consequently the node structures K1 and/or K2 and the area of the fastening element B1, is heated to the process temperature. With this procedure, the tool W can advantageously be made simpler, since no local areas have to be cut out, so that the heat source Q can be made inside the tool W with less technical effort, heating all areas of the slat base structure 15 .

So that the desired geometric and original elastic properties of the node structures K1, K2 and the fastening element B1 are retained, not only is a small accumulation of material provided during the first method step as in the first method, but in this second method a greater accumulation of material is provided, so that the original elastic properties in the node structures K1 and/or K2 and within the fastening element B1 are changed during the stretching process in the second method step, but are compensated for by the accumulation of material.

With this second approach, the desired geometry is achieved and the node structures K1 and/or K2 and the fastening element B1 remain essentially inelastic in terms of their elasticity due to the accumulation of material, which means that the fastening element B1 is also suitable as an essentially rigid fastening element B1 in this second procedure , so that it can serve as a fastening element B1 on the holding structure 13, the transverse bar 13B.

According to the invention, the node structures K1 and/or K2 and the fastening element B1 are therefore essentially rigid or stiff in both procedures in relation to the elastic spring elements of the spring base structure 15 .

In particular, the node structures K1 and/or K2 are therefore advantageously suitable as attachment points for peripheral items of equipment, such as seat occupancy detection mats, fans and other electrical and/or pneumatic connecting lines. The mentioned openings K1-1 or K2-1 advantageously serve to accommodate latching elements by means of which the peripheral items of equipment can be latched into the openings K1-1, K2-1 of the node structures K1 and/or K2 in a reversible manner.

It is made clear once again that the spring elements of the spring base structure 15 stretched during the second method step have a predeterminable length after stretching, which lies between the original length before stretching and the maximum length during stretching. So that the spring support structure 15 of the seat pan module is arranged in the holding structure 13 with pretension, the assembly (connection of the holding structure 13 to the seat pan module 12A, 15) of the seat part 12 is carried out in a special way, which will be discussed later.

• Die Elastizität der Unterfederungsstruktur 15 des teilelastischen Sitzwannenmoduls wird erfindungsgemäß durch die Auswahl der Kunststoffart innerhalb des ersten Verfahrensschrittes beeinflusst.

The description makes it clear which parameters can be used to influence the elasticity of the spring base structure 15:

• According to the invention, the elasticity of the spring support structure 15 of the partially elastic seat pan module is influenced by the selection of the type of plastic within the first method step.

According to the invention, the elasticity of the spring support structure 15 of the partially elastic seat pan module is influenced by the geometry and material thickness produced in the first method step.

According to the invention, the elasticity of the spring support structure 15 of the partially elastic seat pan module is influenced by determining the level of the process temperature within the second method step described.

The elasticity of the spring base structure 15 of the partially elastic seat pan module is influenced according to the invention by additionally forming at least one local node structure K1 and/or K2 within the spring base structure 15 in the first method step.

The elasticity of the spring base structure 15 of the partially elastic seat pan module also depends on whether or not the node structures K1, K2 are subjected to heating together with the spring elements of the spring base structure 15 within the second method step.

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

Finally, the resiliency of the sub-spring structure 15 of the partially resilient seat pan module depends on the degree of orientation of stretching/stretching.

Two-piece, partially elastic seat pan module made entirely of plastic:

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

In this case, the partial seat pan 12A is produced in a separate mold in a shaping process, in particular in an injection molding process. The partial seat pan 12A is not subjected to a stretching process, so that the associated tool does not require a heat source Q for stretching the partial seat pan 12A.

A different tool is used to produce the spring support structure 15 . This tool will, like before, become the 2 and 3 described, designed analogously, with the difference that the tool is designed only for the production of the spring base structure 15.

The method steps already described are carried out during the manufacture of the spring base structure 15 .

• Bei der Herstellung der Teilsitzwanne 12A werden beim Formgebungsprozess innerhalb des ersten Verfahrensschrittes Aufnahmeelemente 12A-1 vorgesehen, die in den 2 und 3 dargestellt sind. Diese Aufnahmeelemente 12A-1 werden, wie bereits erwähnt, nur dann ausgebildet, wenn ein zweiteiliges Sitzwannenmodul ausgebildet wird.

However, the two-piece design results in the following differences, which must be taken into account during production:

• During the production of the partial seat pan 12A, receiving elements 12A-1 are provided during the shaping process within the first process step 2 and 3 are shown. As already mentioned, these receiving elements 12A-1 are only formed if a two-part seat pan module is formed.

Second fastening elements B2 engage in these receiving elements 12A-1 4 are shown and correspond in terms of their shape with the receiving elements 12A-1.

On the 4 has already been discussed in detail.

The spring base structure 15 of a two-part seat pan module includes 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 spring base structure 15 of a one-piece seat pan module includes the lattice-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 the partial seat pan 12A is formed at this point within the manufacturing process.

Finally, it is mentioned that there is an alternative possibility of forming fastening elements both in the (one-piece and in the two-piece) design of the spring base structure 15 and on the side of the lattice-like structure. By means of these fastening elements, which are not shown in more detail, the spring base structure 15 can also be hung in the holding structure 13 laterally (transverse to the longitudinal direction of the spring elements) as seen in the x-direction. As explained, these fastening elements are designed to be stiff, analogously to the node structures K1, K2 or the other fastening elements B1, B2, so that the spring support structure 15 can be attached to the holding structure 13 by essentially elastically rigid fastening elements B1, B2.

• Das hybride Sitzwannenmodul weist gemäß der zweiten Ausführungsform die Teilsitzwanne 12A aus einem Blechformteil auf, welches mit einer Unterfederungsstruktur 15 aus Kunststoff gemäß 4 verbunden ist.

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

• According to the second embodiment, the hybrid seat pan module has the partial seat pan 12A made of a sheet metal part, which is provided with a spring structure 15 made of plastic according to FIG 4 connected is.

For this purpose, the partial seat pan 12A has the receiving elements 12A-1, so that the second fastening elements B2 of the lower spring structure 15 can be hooked into the receiving elements 12A-1.

As mentioned, production takes place in different tools, with the spring support structure 15 being able to be produced in the method steps already explained.

The object of the invention is achieved in that a partial seat pan 12A and the under-springing structure 15 are combined into one component (seat pan module).

Summary:

Because at least the spring base structure 15 is made from a plastic material, the weight of the seat pan module and thus of the entire vehicle seat is reduced. The assembly is either omitted entirely (one-piece design of the seat pan module) or is simplified by the design of positively fitting corresponding receiving elements 12A-1 on the partial seat pan 12A and second fastening elements B2 on the under-springing structure 15.

The attachment to the holding structure 13 of the seat part 12 is simplified by the formation of a first fastening element B1 which corresponds in a form-fitting manner to the transverse bar 13B of the holding structure 13 .

In addition to the weight reduction, the stretching process ensures that the desired elastic properties (spring/damping properties) of the underspringing structure 15 are produced, with the result that the partially elastic seat pan module is obtained.

Local geometric changes are provided within the spring base structure 15, which are designed as node structures K1 and/or K2 and/or fastening elements B1 or B1 and B2, with the node structures K1 and/or K2 being used for attaching peripheral items of equipment and the fastening elements B1, B2 being used for Attachment of the suspension structure 15 are used on the support structure 13 or the partial seat pan 12A.

Assembling the seat pan module:

• 5 zeigt eine perspektivische Darstellung der Sitzteilstruktur eines zusammengebauten Fahrzeugsitzes mit dem Sitzwannenmodul 12A, 15 innerhalb der Haltestruktur 13 des Sitzteiles 12.

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-part or already assembled (connected via 12A-1 and B2) two-part seat pan module is first clipped onto the transverse beam 13B of the holding structure 13 . The first fastening element B1 encloses the transverse tube 13B with its mouth.

The holding structure 13 has latching elements 13C lying opposite one another on the inside of the side rails 13B.

Furthermore, the holding structure 13 has grid elevations 13D on the inside of the side bars 13B.

The partial seat pan 12A has opposing latch openings 12A-2.

Furthermore, the partial seat pan 12A has latching depressions 12A-3 on its outer side, which faces the side rails 13A in the installed position.

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

Depending on the degree of orientation, the length of the spring elements of the underspringing structure 15 after stretching is between the original length before stretching and the maximum length during stretching.

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

After the first fastening element B1 has been clipped onto the crossbar 13B, the latching depressions 12A-3 of the partial seat pan 12A are pushed onto the latching elevations 13D, thereby forming an axis of rotation Y1 in the horizontal direction (y-direction) transverse to the x-axis. During installation, the partial seat pan 12A is initially folded up by a predeterminable angle relative to the x/y plane. In this state, the spring elements of the spring base structure 15 are not yet tensioned. The partial seat pan 12A is then folded down and is essentially in the horizontal x/y plane. The spring elements lengthen as a result of the rotary movement, as a result of which the spring elements of the spring base structure 15 are tensioned. The latching elements 13C finally snap into the latching openings 12A-3 and reversibly fix the partial seat pan 12A to the holding structure 13.

If the spring base structure 15 alternatively has the described lateral fastening elements, these fastening elements are hung in a last method step on the insides of the side rails 13A in elements provided for this purpose, not shown in detail.

Reference List

12

seat part

12A

partial seat pan

12A-1

recording elements

12A-2

detent opening

12A-3

detent recess

13

holding structure

13A

side rails

13B

cross bar

13C

locking element

13D

grid elevation

14

mounts

14A

seat pan-side attachment

14B

suspension on the side of the crossbeam

14C

suspension on the side rail

15

suspension structure

15-1

hexagonal honeycomb

15-2

pentagonal honeycomb

15-3

webs

W

Tool

w1

tool base

W1-1

slider

Q

heat source

K

node structures

K1

first node structure

K1-1

circular opening

K2

second node structure

K2-1

rectangular opening

B1

first fastener

B2

second fastener

I

starting position

II

working position

+x

Direction in the usual direction of travel of a vehicle

-x

Direction opposite to the usual direction of travel +x

y

Direction in the horizontal transverse to the x-direction

e.g

Direction in the vertical transverse to the x-direction

Y1

axis of rotation

Claims (11)

Seat pan module of a seat part (12) of a vehicle seat, comprising a spring base structure (15) or a partial seat pan (12A) and a spring base structure (15) which form(s) a load-bearing seat surface, characterized in that the spring base structure (15) is produced as a in a molding process produced elastic plastic part is formed, the specific elasticity properties and damping properties of which are generated by stretching subsequent to at least regional heating of the plastic part, the elastic under-springing structure (15) being formed as a honeycomb-like or a net-like lattice structure and at least one rigid node structure (K1, K2 ) has whose nodes serve as attachment points for at least one piece of peripheral equipment. seat pan module claim 1 , characterized in that the partial seat pan (12A) forms a first partial surface of the seat and the under-springing structure (15) forms a second partial surface of the seat as a common load-bearing seat. seat pan module claim 1 , characterized in that the elastic honeycomb or net-like lattice structure of the spring base structure (15) has at least one rigid fastening element (B1, B2). seat pan module claim 1 , characterized in that the seat pan module is fastened to a holding structure (13) of a seat part structure by a rigid, first fastening element (B1) and the underspring structure (15) is fastened to the partial seat pan (12A) by a stiff, second fastening element (B2). Seat pan module according to one of the preceding claims, characterized in that the seat pan module is formed in one piece from the partial seat pan (12A) and the spring base structure (15) and is formed entirely from at least one plastic material. Seat pan module according to one of the preceding claims, characterized in that the seat pan module is formed in two parts from the partial seat pan (12A) and the spring base structure (15) and is either made entirely from at least one plastic material or the partial seat pan (12A) from a metallic material and the spring base structure (15 ) is formed from at least one plastic material. Method for producing an elastic underspring structure (15) made of plastic for a seat pan module, comprising - a first method step in which the shape of the underspring structure (15) is produced, and - a second method step in which the underspring structure (15) is stretched and specific elasticity properties and damping properties is/are produced, characterized in that - the spring base structure (15) is produced in the first method step in the form of a lattice, which has at least one rigid node structure (K1, K2) and/or at least one rigid fastening element (B1, B2) and the spring base structure (15) in the second method step before stretching is subjected to heating at least in some areas, with the at least one rigid node structure (K1, K2) and/or the at least one fastening element (B1, B2) being excluded from the heating or together with the slat base structure (15) are subject to heating, the at least one rigid node structure (K1, K2) and/or the at least one fastening element (B1, B2), which/s is/are excluded from heating in the second method step, in the first process step is/are reinforced by a small or large accumulation of material. procedure after claim 7 , characterized in that the elasticity of the spring support structure (15) is influenced in the first method step by - the selection of the type of plastic and/or - the selection of the geometry and material thickness and/or - the at least regional arrangement of rigid node structures (K1, K2) and/or - the strength of the material accumulation of the rigid node structures (K1, K2) arranged at least in certain areas. procedure after claim 8 , characterized in that the elasticity of the spring base structure (15) is influenced in the second method step by - the degree of orientation and/or - the level of the process temperature during heating and/or - the partial heating of the spring base structure (15) excluding the rigid node structures (K1, K2) arranged at least in certain areas or by the complete heating of the spring base structure including the rigid node structures (K1, K2) arranged at least in certain areas and/or - the degree of material accumulation of the rigid node structures (K1, K2) arranged at least in certain areas. Tool (W) in which a seat pan module made of plastic can be produced, which has an elastic underspring structure (15), comprising - a lower tool part (W1) and an upper tool part which, when closed, form a cavity in which, in a shaping process, at least one Plastic material can be filled, characterized in that the cavity between the lower tool part (W1) and the upper tool part is designed as a negative mold of the honeycomb-like or net-like spring structure (15) and the lower tool part (W1) and/or the upper tool part - a slide construction ( W1-1) - as well as a heat-generating device that is also assigned at least in certain areas to the spring base structure (15), whereby the seat pan module (12) is subjected to a shaping process in the tool (W) and the spring base structure (15) is heated at least in certain areas terfederungsstruktur (15) with the aid of the slide construction (W1-1) is subjected to a thermally influenced stretching. Tool (W) in which a plastic seat pan module can be produced, which has a partial seat pan (12A) and an elastic underspring structure (15), comprising - a lower tool part (W1) and an upper tool part, which form a cavity in the closed state, in in which at least one plastic material can be filled in a shaping process, characterized in that the cavity between the lower tool part (W1) and the upper tool part is designed as a negative mold of the partial seat pan (12A) and the honeycomb or net-like spring structure (15), and the lower tool part (W1) and/or or the tool upper part comprises a slide construction (W1-1) associated with the suspension structure (15) and a heat-generating device which is also associated at least in regions with the suspension structure (15), whereby the seat pan module is subjected to a shaping process in the tool (W) and the suspension structure ( 15) can be subjected to thermally influenced stretching with at least regional heating of the spring base structure (15) with the aid of the slide construction (W1-1).

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