DE102016105014A1 - Method for producing a component, component - Google Patents

Abstract

A method of manufacturing a component using a tool having a first mold having a base and a soft foam lid, and a second mold having the base and a cover, comprising the steps of: a) inserting and drawing a blank of an envelope b) introducing and distributing a flexible foam component mixture into the lower part, c) closing the first mold, d) reacting the flexible foam component mixture into a flexible foam material, which forms a second section of the component e) opening and removing the soft foam cover, f) placing a third section of the component on the second surface section of the second section, g) Sch h) introducing a coating material mixture into the closed second tool mold; i) curing the coating material mixture to form a coating material which forms a watertight fourth section of the component, wherein the fourth section is arranged such that it forms the third surface section of the second section fully covering, j) opening and removing the cover, k) removing the component.

Description

The invention relates to a method for producing a component according to the preamble of patent claim 1 and to a component according to the preamble of patent claim 8.

Components made of foamed materials are usually produced when a low weight is to be achieved with a simple manufacturing process. During foaming, for example, a propellant can be added to a plastic granulate. By supplying heat, a volatile constituent of the blowing agent separates, which leads to foaming of the melt. This can take place, for example, in a suitable tool mold.

In the conventional production of foam components made of PUR (polyurethane foam), for example, polyols are mixed with isocyanates and a blowing agent (usually water). The polyols react with the isocyanates in a polyaddition to form PUR and the propellant forms gas inclusions, which are responsible for the cellular structure of the foam. However, components made of polyurethane can also be foamed without the addition of blowing agent and thus in a compact form.

For example, find plastic components, especially polyurethane, in foamed and unfoamed form as part of vehicle seats use. It has been shown in practice that especially in commercial vehicles such as wood loading lanes, which are used in spite of the open cab outside and are therefore often exposed to moist environmental conditions, an optimized moisture and splash protection for the foam components of the vehicle seats used here is beneficial. In particular, it should be noted that water vapor can diffuse into the cells of the foam, which adversely increases the thermal conductivity of the foam. Furthermore, there is a risk that the life of the seat and possibly associated electrical devices is drastically reduced by the moisture and any mold growth.

The object of the invention is therefore to optimize a method for producing a component for the vehicle seat described so far that a splash and moisture protection of the foam components is integrated with the component. It is also an object to provide a component with foam components that is best possible against splashing water and moisture.

This problem is solved according to the features of patent claim 1 and claim 9.

• a) Einlegen und Einziehen eines Zuschnittes eines wasser- und gasdichten Hüllwerkstoffs in das Unterteil mittels Anlegen eines Unterdrucks, wobei ein hüllförmiger erster Abschnitt des Bauteils gebildet wird,
• b) Eintragen und Verteilen einer Weichschaumkomponentenmischung in das Unterteil,
• c) Schließen der ersten Werkzeugform,
• d) Ausreagieren der Weichschaumkomponentenmischung zu einem Weichschaumwerkstoff, welcher einen mit dem ersten Abschnitt mittels eines ersten Oberflächenabschnitts verbundenen zweiten Abschnitt des Bauteils bildet, wobei der zweite Abschnitt ferner einen zweiten und einen dritten abdeckungsfreien Oberflächenabschnitt aufweist,
• e) Öffnen und Entfernen des Weichschaumdeckels,
• f) Auflegen eines dritten Abschnitts des Bauteils, bevorzugt in Form einer Folie, auf den zweiten Oberflächenabschnitt des zweiten Abschnitts,
• g) Schließen der zweiten Werkzeugform,
• h) Eintragen einer Coatingmaterialmischung in die geschlossene zweite Werkzeugform,
• i) Aushärten der Coatingmaterialmischung zu einem Coatingmaterial, welches einen wasserdichten vierten Abschnitt des Bauteils ausgestaltet, wobei der vierte Abschnitt so angeordnet wird, dass er den dritten Oberflächenabschnitt des zweiten Abschnitts vollständig abdeckt,
• j) Öffnen und Entfernen des Coatingdeckels,
• k) Entnehmen des Bauteils.

An essential point of the invention is that a method is carried out for producing a component, which preferably embodies a cushion part of a vehicle seat, using a tool with a first tool mold, which has a lower part and a soft foam cover, and a second mold, which the Has lower part and a Coating,
the following process steps include:

• a) inserting and drawing a blank of a water-tight and gas-tight enveloping material into the lower part by applying a negative pressure, wherein a shell-shaped first portion of the component is formed,
• b) introducing and distributing a flexible foam component mixture into the lower part,
• c) closing the first mold,
• d) reacting the flexible foam component mixture into a flexible foam material which forms a second portion of the component connected to the first portion by means of a first surface portion, the second portion further comprising a second and a third cover-free surface portion,
• e) opening and removing the soft foam lid,
• f) placing a third section of the component, preferably in the form of a foil, on the second surface section of the second section,
• g) closing the second mold,
• h) introducing a coating material mixture into the closed second tool mold,
• i) curing the coating material mixture to form a coating material which forms a watertight fourth section of the component, wherein the fourth section is arranged such that it completely covers the third surface section of the second section,
• j) opening and removing the coating lid,
• k) removing the component.

In this case, both the second and the fourth section of the component preferably consist of the same material and more preferably of polyurethane. For example, the second section in the form of the soft foam material by means of its cushioning properties as a cushion part ensures increased seating comfort. The second section preferably has only the first, the second and the third surface section.

The third section is preferably designed in the form of a film. This can be waterproof; However, it has proven to be advantageous in practice if this film is breathable. Thus, it is particularly preferable for water vapor to be released from the soft foam material to the environment, but for water to not penetrate into the soft foam material from the outside.

The fourth section preferably represents a compact plastic part which is not foamed and, for example, has a high strength and is therefore suitable for arranging mounting elements for mounting the component on a body part or on a supporting frame of the seat. For example, the fourth section is formed by means of a compact polyurethane layer, which assumes the function of a carrier part or a fastening element. The introduction of the coating material mixture by means of another reaction casting machine with the same production cycle.

Preferably, the negative pressure applied in step a) has a value between -0.6 and -1.2 bar, more preferably -0.8 bar. Furthermore, it has proven to be advantageous if the lower mold is heated to 45 ° C. before step a).

Closing of the soft foam cover and / or the coating lid is preferably carried out by applying a closing pressure with a value between 3 and 5 bar, more preferably with a value of 4 bar.

Suitable process parameters from practice provide that step b) is completed after about 3 seconds. Subsequently, it takes about 6 to 7 seconds (corresponds to the so-called start time) to the foaming phase of the flexible foam component mixture, which in turn takes place within the so-called rise time and is completed after about 50 seconds. The step c) takes place after shooting, but before the climbing time.

In step d), it has proven useful in practice if a temperature of 100 to 120 ° C., preferably of 110 ° C., arises in the interior of the soft foam material. Furthermore, it has proven useful if, during step i), a temperature of 150 to 170 ° C., preferably 160 ° C., arises in the interior of the coating material. This ensures in each case for a lower viscosity and thus for a uniform distribution of the flexible foam component mixture and / or the Coatingmaterialmischung.

For example, the curing time of the coating material mixture to the coating material is 50 s to 70 s, preferably 1 minute.

Furthermore, it has proven useful if, 3 minutes after closing the soft foam cover, step e) takes place, that is, the soft foam lid is opened.

After removal of the component, it may be necessary to trim the blank or its projection on the component; This is preferably done manually. Subsequently, the waste is removed.

The method thus ensures that all surface sections of the second section are optimally covered. In particular, arranging the third section on the second section and arranging the fourth section on the third section ensure that the penetration of spray water into the cushion part is virtually eliminated.

In addition, complex cushion contours can be represented by means of the method according to the invention, which would not be possible by means of conventional cushioning technology. The cover is also glued to the foam with the right contour.

The preferred method variant according to which the fourth section is arranged in step i) in such a way that it at least partially covers adjacent surface sections of the first and / or third section of the component to the third surface section of the second section. Thus, an optimal overlap of all sections and thus for a further improved splash water protection is ensured.

Particularly preferably, the fourth section covers the surface sections of the first section such that the fourth and the first section terminate in a direction of depth of the component. However, it is also possible that the fourth section is arranged to extend further in the depth direction of the component than the first section.

Depending on the desire and structure of the mold, the coating material can thus be applied over the entire surface or only partially on the back of the pad, ie the back of the second section. The coating material thus connects the first section, preferably the cover, to the second section, which preferably represents the cushioning element. If integrated bolting points are arranged in the fourth section, these enable the attachment of the entire component to the sheet metal part or to the body of the vehicle. When the back side of the component is closed, ie when the coating material is applied over the entire surface, this also serves as an improved spray water protection.

The method may be configured such that the fourth portion of the component is arranged such that at least the third portion is completely covered by the fourth portion toward an underside of the component. In other words, the first and fourth sections completely take over the moisture-sealing of the component. However, this makes the component comparatively difficult. In practice, it has therefore been found to be particularly advantageous if the fourth section is the third Section only partially covers. In particular, it is advantageous if the fourth section covers the edge section of the third section; Particularly preferably, the fourth section covers all edge sections of the third section.

In order to further increase the comfort for a seat occupant, it is advantageous if, after step a), a heating device, preferably in the form of an electric heating grid, is mounted on the flexible foam cover. This heater is preferably an electric heater. More preferably, the heater on connections and / or cables, which are arranged led out of the tool.

In order to mount the heater can be arranged on the soft foam lid corresponding storage facilities advantageous. For example, in the form of pins, bolts, grooves and / or correspondingly shaped surfaces, which are arranged on a first boundary surface of the flexible foam cover, which forms the boundary for a later surface of the component facing the seat occupant (also referred to below as the support surface) ,

Particularly advantageously, the heating device is detachably connected to the storage facilities. This makes sense, since the heater should not remain on this, but in the soft foam material with removal of the flexible foam lid. For example, at least one, preferably four, of the bearing devices are configured in the form of first pins, which are arranged with their lower end against the first boundary surface of the flexible foam cover and have a circumferential groove at a predefined distance from the first boundary surface of the flexible foam cover at its upper end. Above the groove, the first pin is designed, for example, in the form of a ball element.

Preferably, a first pin is arranged at each of the four corners of the soft foam lid. In between, preferably, second, cylindrically shaped pins are arranged with their lower end on the first boundary surface of the flexible foam cover, which preferably have a chamfer at its upper end.

In contrast to the second pins so the first pins offer the ability to fix the heater by means of positive engagement in a direction parallel to the longitudinal axis of the pin. The number, arrangement and precise design of the first pins is therefore crucial for the force that is necessary to remove the soft foam cover while maintaining the heater in the soft foam material. The second pins, however, provide positive locking only in a plane perpendicular to its longitudinal axis. Upon removal of the soft foam lid, the pins are pulled out of the soft foam material in a direction parallel to their longitudinal axis.

According to a preferred embodiment, the heating device is arranged at a closed first tool mold spaced from the first portion of the component and is wrapped in step b) of the flexible foam component mixture. Accordingly, the heating device is arranged in the finished component to the first portion of the component spaced. This offers the advantage that on the one hand, the heating device is not visible on the surface of the finished component. In addition, such an overheating or uneven heating of the support surface of the component can be successfully avoided by a uniform temperature distribution is achieved by the lower heater. In particular, in the case of a surface-configured, but also with other heating device, it is ensured that temperature gradients of the component are thus minimized at least on the support surface.

In order to further increase the seating comfort for the occupant, it has proven to be advantageous if the support surface is designed such that at least portions thereof are not in contact with the seat occupant, but are arranged at a distance therefrom. These spaced sections are configured for example in the form of air conditioning ducts and provide for optimized ventilation of the body surface of the seat occupant and the removal of sweat.

Therefore, it is advantageous if, prior to step a), at least one three-dimensional mold element is inserted into the lower part, which forms at least one air-conditioning duct which is superficially arranged in the finished component and designed to be open. The three-dimensional shape element can be configured, for example, in the form of a curved cylindrical element. This may have a closed or a hollow cross-section.

For example, the bent cylinder element is designed in the form of a rigid tube or a flexible tube. The three-dimensional shape elements are preferably in the form of aluminum tubes. It is understood that in the exact configuration of the form elements individual customer requirements and boundary conditions such as component dimensions can be very well taken into account.

The three-dimensional shape element can either be inserted only in the lower part or arranged fixed thereto. For example, the three-dimensional molded part recesses in the form of through holes and the lower part Recesses in the form of holes and / or internal threaded holes, so that pins or screws can be inserted through the three-dimensional molding and inserted or screwed into the base.

In practice, it has also been found to be advantageous if, after step a), the flexible foam cover and / or the coating cover are sprayed with a release agent.

This ensures that the component can be reliably removed from the mold without the sheath breaking off from the soft foam material and remaining in the tool. This danger exists when there is better adhesion between the shell and the tool than between the shell and the soft foam material. Another advantage of using a release agent is that the cleaning of the tool halves is easier.

For example, release agents based on silicone, based on PTFE, with or without wax, oil-containing or oil-free are known from the prior art. Furthermore, there are release agents based on different solvents. In practice, among other things, the use of the release agent with the trade name "ACMOSIL 36-4536" from the company ACMOS has proven successful.

Preferably, the flexible foam lid is first heated to 45 ° C and / or the coating lid to 80 ° C. The surfaces of the lower part, the soft foam cover and / or the Coatingdeckels can be heated, for example, by arranging a surface heating and / or a volume heating. For example, the release agent is applied by means of a release agent gun manually or by machine, whose nozzle has a diameter of 0.3 mm.

For example, tool steels are used for the lower part, the soft foam cover and / or the Coating cover, which contain, in addition to carbon, for example, chromium, tungsten, silicon, nickel, molybdenum, manganese, vanadium or cobalt as alloying elements and withstand the operating temperatures above 200 ° C.

The drawing of the Hüllwerkstoffs in the lower part is further facilitated if prior to step a) the blank of Hüllwerkstoffs by cutting the sheet-like Hüllwerkstoffs, which preferably consists of PVC or a PVC synthetic leather, is formed and then heated. The cutting is preferably carried out at room temperature and / or by machine or manually. The heating takes place, however, at 70 ° C in a convection oven, which is preferably used for PVC materials.

All advantages mentioned in connection with the method according to the invention also apply in particular to the component according to the invention described below.

The object of the invention is in fact likewise achieved by a component which is preferably designed and preferably produced by a cushion part of a vehicle seat according to a method according to one of claims 1-7, and which has at least on a top side and edge sides a first shell-shaped section and one with the first section having a first surface portion connected second portion of the component in the form of a soft foam material, wherein the second portion further comprises a first portion facing away from the second and third surface portion, wherein a third portion of the component in the form of a film on the second surface portion of the second Section is arranged, wherein a fourth portion of the component in the form of a coating material, the third surface portion of the second portion is arranged completely covering.

Due to the fact that the soft foam material is arranged completely covered, thus an optimum moisture protection of the component is ensured.

For example, a product with the trade name "Platilon ^® U" is used as a film having the type designation 2102 A, which is a film based on polyurethane. More preferably, the material of the film used is one selected from the group consisting of high density polyethylene (HDPE) or low density polyethylene (LDPE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), a polyester and polycarbonate (PC).

Furthermore, it has proven to be advantageous if the fourth portion of the component surface sections of the first and / or the second portion of the component is arranged at least partially covering. This ensures an optimized connection between all sections of the component by means of the fourth section.

Moreover, it is advantageous if such a component has a heating device, preferably in the form of a heating grid, which is arranged spaced apart within the second portion and the first portion of the component.

Advantageous embodiments will be apparent from the dependent claims.

Advantages and expediencies can be found in the following description in conjunction with the drawing.

Show it:

1a in a perspective view, the lower part used for the inventive method with a blank shown schematically;

1b in a further perspective view of the lower part according to 1 with inserted form elements;

2 in a perspective view of the soft foam cover with heater used for the inventive method;

3 in a perspective view of the coating lid used for the inventive method;

4a in a plan view, a first inventive component for use as a backrest cushion part;

4b in a plan view, a second inventive component for use as a seat cushion part;

5 a cross-sectional view of the first component according to the invention according to 4a ,

In 1a is a perspective view of the inventive method for producing a component 1 , in this case a seat and a backrest cushion part for a Holzaufladelaster, used lower part 7 shown. This base forms together with the according to 2 shown soft foam cover a first tool shape of the tool used and together with the according to 3 Coating cover shown 9 a second tool shape of the tool used.

A first share 1a of the later component 1 (please refer 4a and 4b ) is formed by cutting 10 made of gas-tight PVC artificial leather 4 in the lower part shown 7 is inserted and retracted by applying a negative pressure, so that it is in contact with a first boundary surface 23a and a second boundary surface 23b of the lower part 7 is arranged. In particular, the first boundary surface 23a has several planar and curved portions, which although not described in detail herein, but the complexity of the shape of the later component 1 illustrate. Not shown here are the production of the blank 10 by cutting the flat enveloping material and then heating.

On the first boundary surface 23a are more elements 25a as mounting elements in the form of holes, tapped holes etc. available.

According to the present 1b is shown that before inserting the blank in the lower part 7 in the present case three three-dimensional shape elements 14a . 14b . 14c inserted and at the first boundary surface 23a can be attached, which in the finished component 1 superficially arranged and openly designed air conditioning ducts 15a . 15b . 15c train (see 4a & 4b ).

For the lead out of cables is also an implementation 26 within the lower part 7 arranged.

After inserting and pulling in the blank 10 can in the lower part shown 7 a soft foam component mixture, not shown, are introduced and distributed.

The soft foam lid 8th according to 2 has bearing elements 26a . 26b in the form of on a boundary surface 23c the soft foam lid 8th arranged pins. The distribution of bearing elements 26a . 26b is essentially similar to a rectangular shape. It should be noted that at each corner of this rectangular shape, a first bearing element 26a is arranged with circumferential groove. Apart from the four corners are only second bearing elements 26b (only one marked) arranged.

Matching the rectangular shape of the distribution is the shape of a heater 20 formed, which is attached to the pins (not shown).

Also visible in 2 and 3 is a device 30 in the form of a spray can, by means of the soft foam lid 8th and / or the coating lid 9 with a release agent 11 can be sprayed.

The first tool mold is then closed by the soft foam lid 8th according to 2 on the lower part 7 according to the 1a and 1b is placed. Subsequently, the flexible foam component mixture can react to form a flexible foam material. It forms with the first section 1a connected second section 1b of the component 1 , Subsequently, the opening and removal of the soft foam lid takes place 8th ,

According to 3 is a breathable film 3 shown the third section 1c of the component 1 forms and after removing the soft foam lid 8th on the second section 1b of the component not shown 1 is placed.

Furthermore, the cover is Coating 9 to see which after attaching the film 3 on the lower part 7 according to the 1a and 1b is laid and forms the second tool shape. The coated cover shown 9 is for a partial attachment of a coating material, not shown, as a fourth section 1d of the component 1 trained and has for this purpose a plurality of boundary surfaces, one of which with 23d and another with 23e is marked. In particular, the design of the boundary surfaces 23d . 23e making sure that the coating material is frame-like on the remaining sections 1a . 1b . 1c of the component 1 is arranged.

As described, after closing the second tool mold, a coating material mixture, not shown, is introduced into the closed second mold, which subsequently hardens to form a coating material. This forms a watertight fourth section 1d of the component 1 out. After the subsequent opening and removal of the cover 9 can the component 1 be removed.

By means of the shown tool halves in the form of the lower part 7 and the two lids 8th . 9 is thus the production of according to 4a shown component 1 in the form of a backrest cushion part 2a possible. To see is the seat occupant facing support surface 26a and by means of the arrangement of the three-dimensional form elements 14a . 14b . 14c formed climate channels 15a . 15b . 15c which the support surface 26a and thus partially interrupt the contact with the body surface of a seat occupant and thus ensure the removal of sweat. Also visible is a component height direction 1z , a component width direction 1y and a component depth direction 1x ,

Dashed is in the 4a a course of the fourth section 1d indicated in the component depth direction 1x considered under the first section 1a located. You can see that the fourth section 1d only partially on the back of the component 1 is arranged. The fourth section forms here 1d essentially a circumferential element in the form of a closed ring element.

Another component 1' is according to 4b 1 in the form of a seat cushion part 2a shown and has analogous to the component 1 according to 4a in this case via a coherent climate channel 15d and the thus interrupted support surface 27b ,

According to the present 5 is a cross section of the component 1 along the line AA (see 4a to see). As part of the outer shell of the component 1 , which is preferably produced by a method according to any one of claims 1-7, is at an upper side 21 and border sides 22a . 22b of the component, a first envelope-shaped portion 1a in the form of PVC artificial leather 4 arranged. At the same time forms the first section 1a the support surface 27a for a seat occupant, not shown. You can also see two cross sections of the middle climate channel 15b , A bottom 19 of the component 1 is by means of a second section 1b and two parts of the fourth section 1d educated.

Also visible is the foamed heater 20 which is spaced from the first section 1a of the component 1 is arranged and from the second section 1b wrapped is arranged. It is by removing the soft foam lid 8th and the consequent pulling out of the pins 26a . 26b still demoulding channels 28a . 28b to see. In the detail view according to 5a , which a section of the 5 shows, it can be seen that the means of soft foam material 5a formed second section 1b of the component 1 with the first section 1a by means of a first surface section 13a is arranged connected. Further, the second section 1b another one 13b and a third surface portion 13c on. Beginning and optionally end of the surface sections 13a . 13b . 13c are in the 5a each marked with arrows. However, it should be noted that the respective end of the surface sections 13a and 13b which is the surface section 13c turned away, is not visible within this detail view, but rather the surface sections 13a and 13b to continue.

You can see that a third section 1c of the component 1 in the form of a foil 3 on the second surface section 13b of the second section 1b is arranged. It should be noted that in the 5 for the sake of clarity, the sections 1b ; 1c . 1c ; 1d . 1b ; 1d Although they are shown in pairs complained of, but in reality (as well as in 5a illustrated) are connected to each other contacting. Next, it is important to note that the film 3 according to 5a For the sake of clarity, it is illustrated with an extension in the component depth direction, which is only present to a very limited extent in reality due to the fact that the thickness of a film is negligibly small compared to its length and width.

Furthermore, it can be seen that the coating material 5b a watertight fourth section 1d of the component 1 designed, the fourth section 1d is arranged so that it has the third surface section 13c of the second section 1b completely covers.

The fourth section 1d is also arranged so that it the third surface section 13c of the second section 1b adjacent surface sections 16 respectively. 18 of the first 1a or the third section 1c of the component 1 completely covered in this case. Here is the surface section 16 essentially in component depth direction 1x and the surface portion 18 essentially in the component width direction 1y arranged extending.

The fourth section covers here 1d the surface section 16 of the first section 1a so off that the fourth 1d and the first section 1a in component depth direction 1x considered complete with each other.

Preferably, a ratio of a length of the surface portion 18 to the length of the third surface section 13c a value from a range of 0.15 to 0.44, more preferably from a range of 0.22 to 0.27, most preferably from 0.27 to.

Preferably, a ratio of a length of the surface portion 16 to the sum of the lengths of the surface section 18 and the third surface portion 13c a value from a range of 0.24 to 0.55, more preferably from a range of 0.30 to 0.40, most preferably from 0.36 to. The sum of the lengths of the surface section 18 and the third surface portion 13c here corresponds to the length of the fourth section at the same time 1d in the component width direction 1y ,

The length of the surface section 16 preferably has a value from a range of 20 mm to 30 mm, preferably 25 mm with a tolerance of +/- 1 mm.

The length of the surface section 18 preferably has a value from a range of 10 mm to 20 mm, preferably 15 mm with a tolerance of +/- 2 mm.

The length of the surface section 13c preferably has a value from a range of 45 mm to 65 mm, preferably 55 mm with a tolerance of +/- 2 mm.

At the fourth section 1d is at one of the second section 1b opposite side a mounting element 29 , in the form of a blind hole, for mounting the component 1 arranged on a body of the commercial vehicle.

All disclosed in the application documents features are claimed as essential to the invention, provided they are new individually or in combination over the prior art.

LIST OF REFERENCE NUMBERS

1; 1'

component

1a-1d; 1'a-1'd

section

1x; 1'x

Component depth direction

1y; 1'y

Component width direction

1z; 1'z

Component height direction

2a, 2b

upholstery part

3

foil

4

PVC artificial leather

5a

Flexible foam material

5b

coating material

6

Tool

6a, 6b

mold

7

lower part

8th

Soft foam cover

9

coating cover

10

cut

11

release agent

13a-13c; 16a, 16b; 18a, 18b

 surface section

14a-14c

forming element

15a-15c

air channel

19

bottom

20

heater

21

top

22a, 22b

edge side

23a, 23b, 23c

Boundary surface

24a, 24b

supporting

25a, 25b, 29

mounting element

26a, 26b

Storage facility

27a, 27b

supporting

28a, 28b

guide channel

30

contraption

Claims (10)

Method for producing a component ( 1 ; 1' ), which preferably a padded part ( 2a ; 2 B ) of a vehicle seat, using a tool with a first tool mold, which has a lower part ( 7 ) and a soft foam lid ( 8th ), and a second tool mold, which the lower part ( 7 ) and a coating lid ( 9 ), comprising the following method steps: a) inserting and drawing in a blank ( 10 ) of a water and gas-tight envelope material in the lower part ( 7 ) by applying a negative pressure, wherein a shell-shaped first section ( 1a ; 1'a ) of the component ( 1 ; 1' b) introducing and distributing a flexible foam component mixture into the lower part ( 7 c) closing the first tool mold, d) reacting the flexible foam component mixture into a soft foam material ( 5a ), one with the first section ( 1a ; 1'a ) by means of a first surface section ( 13a second section ( 1b ; 1'b ) of the component ( 1 ; 1' ) forms the second section ( 1b ; 1'b ) a second ( 13b ) and a third cover-free surface section ( 13c ) e) opening and removing the soft foam cover ( 8th ), f) Placing a third section ( 1c ; 1'c ) of the component ( 1 ; 1' ), preferably in the form of a film ( 3 ), on the second surface section ( 13b ) of the second section ( 1b ; 1'b g) closing the second tool mold, h) introducing a coating material mixture into the closed second mold mold, i) curing the coating material mixture to form a coating material ( 5b ), which has a watertight fourth section ( 1d ; 1'd ) of the component ( 1 ; 1' ), the fourth section ( 1d ; 1'd ) is arranged so that it covers the third surface section ( 13c ) of the second section ( 1b ; 1'b ) completely covers, j) opening and removing the cover ( 9 ), k) removing the component ( 1 ; 1' ). Method according to claim 1, characterized in that in step i) the fourth section ( 1d ; 1'd ) is arranged so that it the third surface section ( 13c ) of the second section ( 1b ; 1'b ) adjacent surface sections ( 16 ; 18 ) of the first ( 1a ; 1'a ) and / or the third section ( 1c ; 1'c ) of the component ( 1 ; 1' ) at least partially covers. Method according to one of the preceding claims, characterized in that after step a) a heating device ( 20 ), preferably in the form of an electric heating grid, on the flexible foam lid ( 8th ) is mounted. Method according to claim 3, characterized in that the heating device ( 20 ) with the first tool mold closed spaced from the first section ( 1a ; 1'a ) of the component is arranged and in step b) is enveloped by the flexible foam component mixture. Method according to one of the preceding claims, characterized in that prior to step a) in the lower part ( 7 ) at least one three-dimensional shaped element ( 14a . 14b . 14c ) is inserted, which at least one in the finished component ( 1 ; 1' ) superficially arranged and open air conditioning channel ( 15a . 15b . 15c ) trains. Method according to one of the preceding claims, characterized in that after step a) the flexible foam lid ( 8th ) and / or the coating lid ( 9 ) with a release agent ( 11 ) is sprayed. Method according to one of the preceding claims, characterized in that prior to step a) the blank ( 10 ) of the Hüllwerkstoffs by cutting the sheet-like Hüllwerkstoffs, which preferably consists of PVC, is formed and then heated. Component ( 1 ; 1' ), preferably upholstered part of a vehicle seat ( 2 ) and preferably produced by a process according to any one of claims 1-7, which at least on one upper side ( 21 ) and margins ( 22a . 22b ) a first shell-shaped section ( 1a ; 1'a ) and one with the first section ( 1a ; 1'a ) by means of a first surface section ( 13a second section ( 1b ; 1'b ) of the component ( 1 ; 1' ) in the form of a soft foam material ( 5a ), the second section ( 1b ; 1'b ) and the first section ( 1a ; 1'a ) facing away from the second ( 13b ) and third surface section ( 13c ), characterized in that a third section ( 1c ; 1'c ) of the component ( 1 ; 1' ) in the form of a film ( 3 ) on the second surface section ( 13b ) of the second section ( 1b ; 1'b ), a fourth section ( 1d ; 1'd ) of the component ( 1 ; 1' ) in the form of a coating material ( 5b ) the third surface section ( 13c ) of the second section ( 1b ; 1'b ) is arranged completely covering. Component ( 1 ; 1' ) according to claim 8, characterized in that the fourth section ( 1d ; 1'd ) of the component ( 1 ; 1' ) Surface sections ( 16 ; 18 ) of the first ( 1a ; 1'a ) and / or the third section ( 1c ; 1'c ) of the component ( 1 ; 1' ) is arranged at least partially covering. Component ( 1 ; 1' ) according to one of claims 8 or 9, characterized in that a heating device ( 20 ), preferably in the form of a heating grid, within the second section ( 1b ; 1'b ) and the first section ( 1a ; 1'a ) of the component ( 1 ; 1' ) is arranged at a distance.

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