DE102016224496B4 - Method for producing a bladder that can be filled with pressure medium, a bladder that can be filled with pressure medium, and a pneumatic adjustment device for a seat - Google Patents

Abstract

Method for producing a bladder (BL) that can be filled with pressure medium (DM) as an actuating element (BL1, BL2, BL3) for a seat, in particular a vehicle seat (FZS), with the following steps:
- Production of a preform (VF) in the form of a flat element (FE) made of plastic by means of injection molding in such a way that a first partial element (TE1) and a second partial element (TE2) are connected to one another at at least one transition section (UA),
- Bringing the first partial element (TE1) of the flat element (FE) to coincidence with the second partial element (TE2) of the flat element (FE),
- Connecting the first partial element (TE1) to the second partial element (TE2) along one or more connecting seams (VN) in order to create a bladder chamber (BK) that can be filled with pressure medium (DM).

Description

The present invention relates to a method for producing a bladder that can be filled with pressure medium as a (pneumatic) actuating element for a seat, in particular a vehicle seat. Furthermore, the present invention relates to a bladder itself which can be filled with pressure medium and which can be used as an actuating element (pneumatic adjustment device) for a seat, in particular a vehicle seat.

In modern vehicle seats, there are bladders that can be filled with a pressure medium, in particular with a gaseous pressure medium such as compressed air, as actuating elements in the area of the seat surface or seat back (also referred to as the seat contact surface), and can be supplied with the pressure medium via a respective pressure medium line. By filling a respective bladder with pressure medium, its volume is increased, so that the properties of a seat backrest or a seat surface can be changed in terms of contour. To fill the respective bladders with the pressure medium, this is first generated by a pressure medium source, for example a compressor or a compressor device, and fed to a respective bladder via a corresponding control valve, in particular an electropneumatic valve of a control device.

It is conceivable that an arrangement just described is produced from one or more bladders with respective associated pressure medium lines. It is conceivable that the respective bubbles are produced from two or more flexible separate foils, in which case the respective foils must first be correctly positioned relative to one another in order to form a respective bubble, and then welded to one another at a connecting seam. The resulting foil arrangements may then also have to be cut to form a finished bubble. Particularly in the case of pneumatic adjustment devices with a large number of bladders, a great deal of process engineering effort is required to produce such an adjustment device for adjusting the contour of a vehicle seat with high quality.

The document U.S. 6,413,597 B1 discloses a method of making a resin bag. At this time, a first resin sheet and a heat-resistant sheet are stacked and placed in a cavity of a mold. The diameter of the heat-resistant sheet is smaller than that of the first resin sheet, so that part of the first resin sheet is exposed outside the heat-resistant sheet. After injecting resin into the cavity, the resin is pressed into the cavity and expands there, so that a second resin sheet is formed, which is bonded to the first resin sheet at the outer periphery thereof.

The document DE 60 2005 004 699 T2 discloses an instrument panel crossmember for a motor vehicle, having a metallic tubular structural element which is attached to the A-pillars of the motor vehicle and at least one air duct for conducting air into the passenger compartment of the motor vehicle, the air duct being at least partially arranged in the metallic structural element is.

The document DE 10 2014 217 429 A1 discloses a pressure medium distributor, in particular for a pneumatic adjustment arrangement of a vehicle seat. This has a distributor element, which consists of at least a first and a second foil, which are connected to one another along a connecting seam in order to form a first and at least a second pressure medium chamber.

The document DE 20 2014 103 870 U1 discloses an active bolster for mounting to an interior trim surface of a passenger compartment in a motor vehicle, having a plastic molded, expandable front wall that unfolds toward a passenger in the passenger compartment, a plastic molded rear wall that extends around a substantially sealed perimeter the front wall to form an inflatable bladder, the rear wall having a generator receptacle defined by a raised recess wall with a generator opening. Before they are connected to form a bubble, the front wall and the rear wall are two separate parts and must be brought into alignment before the connection, which means increased production costs.

The object of the present invention is therefore to create a possibility of minimizing the procedural outlay for producing an actuating element for a seat, in particular a vehicle seat.

This object is solved by the subject matter of the independent claims. Advantageous configurations are the subject matter of the dependent claims.

According to a first aspect of the invention, a method is created for producing a bladder that can be filled with pressure medium and that can serve as an actuating element for a seat, in particular a vehicle seat. In a first step, a preform in the form of a flat element is produced from a plastic by means of injection molding puts. It is also possible to produce several corresponding preforms at once by means of injection molding. The flat element is in particular an element that is flexible or deformable. In a further step, a first partial element of the flat element is brought into congruence with a second partial element of the flat element, which are connected to one another at at least one transition section. Finally, the first partial element is connected to the second partial element along one or more connecting seams in such a way as to create a bladder chamber between the two partial elements that can be filled with pressure medium. By using an injection molding process to manufacture the preform or the flat element serving as the starting element, this can already be manufactured in almost any shape, so that post-processing steps such as cutting out, cutting to size, attaching special geometric shapes are no longer necessary . In this way, the procedural complexity in the production of a bladder that can be filled with pressure medium is reduced.

Due to the fact that the two partial elements are already connected, they also experience a certain alignment with one another, so that the handling and the arrangement for the subsequent connection process is simplified, for example compared to separate partial elements (individual foils). In addition, bubbles of higher quality can be produced if the two sub-elements are already aligned and fixed by the transition section, since the alignment can then be carried out in a simple manner.

According to one embodiment of the method, the flat element is produced as a thin-walled, flexible element or as a flexible foil. In this way, lightweight bladders that can be easily installed in a vehicle seat can be produced.

In this context, it is conceivable for the flat element to be folded at the at least one transition section in order to bring the first to second partial elements into alignment. As already mentioned, due to the connection of the two partial elements, there is a specific alignment at the transition section, so that the manufacturing process of the bladders can be carried out with high quality.

Furthermore, it is conceivable that when the flat element is produced, the transition section has an angular area or is designed as a kink, from which the first partial element starts or extends at a certain angle to the second partial element. The angle between the two partial elements can in particular be between 20° and 90°. The advantage of this angle between the two partial elements, which is already formed during injection molding, is that a folding process that is necessary before or for the connection process, in which the two partial elements are brought into contact with one another, basically means mechanical stress for the section of the flat element, in which a kink is formed in order to ultimately be able to bring the two partial elements into contact. However, if the crease is incorporated during the manufacture of the flat element, a defined crease point is already provided on the flat element for the folding process, which reduces the mechanical stress and also increases the quality of the finished bladder.

According to a further embodiment, the flat element is produced by means of an injection molding tool which has a cavity for shaping the flat element. The injection mold can also have a number of cavities for shaping corresponding flat elements. In particular, the sprue or the sprue system of the injection mold can be arranged in such a way that it lies in the region of the transition section. In particular with two symmetrical first and second partial elements, the transition section represents a central section from which the heated plastic material spreads symmetrically during the injection molding process in order to also form high-quality and stable partial elements. If there are several cavities in the injection mold, a runner can also be arranged in the area of a transition section.

According to a further aspect of the method, it is conceivable to also mold at least one connecting piece for a corresponding pressure medium line for filling or emptying pressure medium into or out of the pressure medium chamber on the flat element when producing the flat element. In this case, the at least one connecting piece can be molded on, in particular in the region of the at least one transition section.

According to a further embodiment, it is conceivable when producing the flat element, further structures such as fastening elements, surface structures, specific geometries (radii, etc.), travel limiters for the expansion of the bladder chamber when it is filled with compressed air, guide elements or receptacles for pressure medium lines, etc to mold to the flat element. Since all of this can be done in a single injection molding process, this further reduces the manufacturing complexity.

According to a further aspect, the first partial element is connected to the second partial element by a connecting seam in the form of a welded joint, which is produced in particular by a welding process, for example a high-frequency welding process. However, it is also conceivable to produce another type of connection, for example a joint connection by gluing, in order to form a bubble chamber between the two partial elements.

According to a second aspect of the invention, a bladder that can be filled with pressure medium is created, which can serve as an actuating element for a seat, in particular a vehicle seat. The bladder that can be filled with pressure medium has a flat element made of plastic that is produced by injection molding and has a first partial element and a second partial element, with the flat element being designed in such a way that the first element and the second element are connected to one another at at least one transition section to the are covered. The flat element or the two sub-elements are designed to be flexible or changeable in shape in order in particular later to provide a bubble chamber which can be changed in shape when filled with pressure medium. Furthermore, the bladder that can be filled with pressure medium has one or more connecting seams, along which the first partial element is connected to the second partial element in such a way as to create a bladder chamber that can be filled with pressure medium. Injection molding manufacture provides a simple and high quality bladder for use as an actuator in a seat.

According to one configuration of the bladder, the flat element is designed as a flexible foil. According to one configuration of the bladder, it is conceivable that the flat element has a kink or angle area at the transition section, from which the first partial element starts at an angle to the second partial element. The angle can preferably be 20° to 90°.

According to a third aspect, a pneumatic adjustment arrangement for a seat, in particular a vehicle seat, is created which has a bladder that can be filled with pressure medium according to the above description or an embodiment thereof. Furthermore, the pneumatic adjustment arrangement has a control unit (in particular with one or more valves) which is designed to fill the bladder that can be filled with pressure medium with pressure medium or to empty it via at least one corresponding pressure medium line.

Advantageous configurations of the method are applicable to the bladder and the pneumatic adjustment device and can also be regarded as advantageous configurations of the bladder and the pneumatic adjustment device, and vice versa.

• 1 eine schematische Darstellung eines Fahrzeugsitzes gemäß einer Ausführungsform der Erfindung, bei dem in der Sitzanlagefläche im Bereich der Rückenlehne eine Vielzahl von Blasen als Stellelemente für eine Beeinflussung der Kontur der Sitzanlagefläche des Fahrzeugsitzes angeordnet sind;
• 2 eine schematische Darstellung eines Verfahrens zum Herstellen einer mit Druckmittel befüllbaren Blase als Stellelement für einen Fahrzeugsitz gemäß einer Ausführungsform der Erfindung;
• 3 einen schematischen Querschnitt eines Übergangsbereichs mit angeformtem Anschlussstutzen entlang der Achse A-A von 2C;

Exemplary embodiments of the present invention will now be explained in more detail below with reference to the attached drawings. Show it:

• 1 a schematic representation of a vehicle seat according to an embodiment of the invention, in which in the seat contact surface in the backrest a plurality of bubbles are arranged as adjusting elements for influencing the contour of the seat contact surface of the vehicle seat;
• 2 a schematic representation of a method for producing a bladder that can be filled with pressure medium as an actuating element for a vehicle seat according to an embodiment of the invention;
• 3 a schematic cross section of a transition region with a molded connection piece along the axis AA of 2C ;

Let it be up first 1 referenced, in which a vehicle seat FZS is shown. This vehicle seat includes a seat pad SPO and a back pad RPO. A seat surface SF on the seat cushion SPO and a backrest RL on the back cushion RPO each form a section of a seat contact surface of the vehicle seat FZS. On the part of the seat contact surface that is formed by the backrest, three bladders BL1, BL2 and BL3 are provided as part of a pneumatic adjustment device PVV for adjusting the seat contact surface (in this specific case the backrest RL). The three bubbles are located below a foam pad SAU, which is again covered by a fabric cover BZO. Here, the respective bladders BL1 - BL3 are attached to the back pad RPO by respective attachment portions BF1 for the bladder BL1, BF2 for the bladder BL2, and BF3 for the bladder BL3. It is also conceivable that the three bladders BL1-BL3 are attached to a carrier mat, which then interacts with the back padding RPO or is attached to it. in the in 1 In the example shown, the three bladders BL1-BL3 are intended to serve as lordosis bladders for forming a lumbar support for a vehicle occupant. It is conceivable here to use, for example, only two or one bladder, or four or more bladders instead of three bladders for the adjusting device. Moreover, it is also conceivable to use the corresponding bubbles as massage bubbles.

The adjustment device PVV also has pressure medium lines DL1, DL2 and DL3, via which the bladders BL1, BL2 and BL3 each have a Adapter element AL of a control device STG can be connected in the vehicle seat FZS. The control unit STG serves to provide pressure medium, such as air, via a pressure medium source DQ (such as a compressor), with the air being able to be made available from pressure medium selectively via the pressure medium lines DL1 - DL3 to the bladders BL1 - BL3, in particular via electropneumatic valves . Depending on the driver's wishes, the bladders BL1 - BL3 can be inflated selectively in order to change the contour K in the area of the lumbar spine and to optimally support the occupant's spine.

As bubbles BL1 - BL3 bubbles can be used here, for example, as they are according to the 2 getting produced. This will be explained below.

Let's start with the 2 referenced, in which a schematic sequence of a method for producing a bladder is shown as an actuating element for a pneumatic adjustment device PVV of a vehicle seat. In a first step, a preform or a base body is produced by means of injection molding.

Injection molding (also known as injection molding or as an injection molding process) is a primary shaping process that is mainly used in plastics processing. With this process, molded parts that can be used directly can be produced in large quantities in an economical manner. For this purpose, the respective material or the molding compound (in particular made of a thermoplastic material) is plasticized in an injection unit and injected into an injection mold using an injection molding machine. A cavity is formed in the injection mold; H. the cavity of the tool determines the shape and surface structure of the injection molded part.

Correspondingly, in 2A schematically shows an injection mold SGW, in which there is a cavity HR, which has the shape of the preform for the production of a bladder. The tool SGW has a sprue AG through which a plasticized molding compound FM (in particular made of a thermoplastic material) is injected into the cavity HR. This molding compound FM is distributed in the cavity to ultimately assume the shape of a preform for a later bubble. It is also possible to produce several corresponding preforms at the same time by means of injection molding with a tool that has corresponding cavities.

According to a second step, the molding compound FM cools down in the mold and the mold is opened so that the finished preform VF can be removed. Such a preform VF is then in 2 B shown in a schematic front view. Due to the use of an injection molding process to produce the preform VF, it has been molded with various geometric shapes during its manufacture. For example, the preform VF has attachment sections BFA and BFB for later attachment to a vehicle seat as required. In addition, a radius RA is introduced at the lower portion. As just mentioned, it is possible to give the preform VF a complex structure during injection molding. With reference already to 2C it can be seen that the preform VF is designed as a flat element FE, which consists of a first partial element TE1 and a second partial element TE2, which are connected to one another in a transition section UA. When presented in 2 B only the first partial element TE1 can be seen, while the second partial element is covered by the first partial element. As further in 2 B As can be seen, there is a connecting piece ASS in the region of the transition section UA, through which pressure medium, in particular air, can later be admitted into or discharged from a bubble chamber formed by the preform VF.

In order to produce said bladder chamber, it is now necessary to bring the first partial element TE1 and the second partial element TE2 into contact with one another in order to connect the two partial elements in a fluid-tight manner. An advantage that can be achieved in particular when producing the preform VF by injection molding is that the transition section UA connecting the two partial elements TE1 and TE2 already forms an angular area or kink from which the two partial elements TE1 and TE2 in a predetermined angle W emanate or stretch away. In the present case, the angle W is equal to 20 degrees. This pre-formation of the angle W in the transition section UA now facilitates the in 2C illustrated folding process according to the arrows F, by means of which the two sections TE1 and TE2 are to be brought into contact with one another.

like it in 2D is shown, the two partial elements TE1 and TE2 are brought into contact with one another after the folding process. The sub-elements TE1 and TE2 are now connected to one another at predetermined positions or lines in such a way as to form a pressure medium-tight bladder chamber between the sub-elements TE1 and TE2. For this purpose, a welding tool consisting of a lower part USW and an upper part OSW is used, which connects the two partial elements TE1 and TE2 to one another at the predetermined points, in particular by high-frequency welding, to form corresponding connecting seams, here Form welds at the predetermined points.

After the corresponding weld seams have been formed, the finished bladder is created, as shown in 2E is shown. Like the preform, this has the fastening sections BFA and BFB as well as the connecting piece ASS in the transition area UA. The bladder BL now also has a pressure medium-tight bladder chamber BK, into which pressure medium can be admitted through the connecting piece ASS, in order to increase the volume of the bladder chamber or bladder BL and thus exert an actuating effect on a contour of a vehicle seat. like it in 2 is shown, the connecting seam VN is arranged close to the outer contour of the bladder BL in order to achieve the largest possible volume for the bladder chamber BK.

It's up now 3 referenced, in which an enlarged schematic representation of the transition region along the line AA of 2C is shown. The connecting piece can be seen enlarged again here, which has a tapering area VJ at its front end in order to make it easier to attach a pressure medium line DL to the connecting piece ASS. It can also be seen that pressure medium DM, which flows via the pressure medium line DL into the connecting piece ASS, can then flow through this into the bladder chamber BK.

In summary, it can be mentioned again that the production of a preform by means of injection molding can reduce the procedural effort involved in the production of a bladder, since on the one hand all the necessary geometric elements, such as fastenings, angles, radii, etc. are already made during injection molding in one step can be formed and then only a single preform has to be folded and welded.

By forming a connecting piece during injection molding, it is therefore not necessary in a further step, in particular before or during the folding process 2C introduce a corresponding compressed air line between the two sub-elements TE1 and TE2 in order to create a pressure medium connection between the bladder chamber BK and its surroundings.

However, if no connection piece ASS is formed during the injection molding process, it is also conceivable according to one embodiment to introduce a pressure medium line between the sub-elements TE1 and TE2 before or during the folding process, so that then during the welding step according to 2D this welded pressure medium line creates a connection between the bladder chamber and the environment of the bladder.

Claims (12)

Method for producing a bladder (BL) that can be filled with pressure medium (DM) as an actuating element (BL1, BL2, BL3) for a seat, in particular a vehicle seat (FZS), with the following steps: - Production of a preform (VF) in the form of a flat element (FE) made of plastic by means of injection molding in such a way that a first partial element (TE1) and a second partial element (TE2) are connected to one another at at least one transition section (UA), - Bringing the first partial element (TE1) of the flat element (FE) to coincidence with the second partial element (TE2) of the flat element (FE), - Connecting the first partial element (TE1) to the second partial element (TE2) along one or more connecting seams (VN) in order to create a bladder chamber (BK) that can be filled with pressure medium (DM). procedure after claim 1 , in which the flat element (FE) is manufactured as a flexible film. procedure after claim 1 or 2 , in which the flat element (FE) is folded at the at least one transition section (UA) for bringing the first and second partial elements (TE1, TE2) into alignment. procedure after claim 1 until 3 , in which the production of the flat element (FE) of the transition section (UA) is formed as a kink from which the first partial element (TE1) at an angle (W), in particular between 20 degrees and 90 degrees, to the second partial element ( TE2) goes out. Procedure according to one of Claims 1 until 4 , in which the production of the flat element (FE) takes place by means of an injection mold (SGW) which has a cavity (HR) for shaping the flat element, with a sprue (AG) of the injection mold (SGW) in the region of the transition section (UA) is arranged. Procedure according to one of Claims 1 until 5 , in which at least one connecting piece (ASS) for a corresponding pressure medium line for filling or emptying pressure medium (DM) into or out of the bladder chamber (BK) is also formed on the flat element (FE) during the manufacture of the flat element (FE). . Procedure according to one of Claims 1 until 6 , In which further structures, such as fasteners, in the manufacture of the flat element (BFA, BFB), surface structures, are formed on the flat element. Procedure according to one of Claims 1 until 7 , in which the connection of the first partial element (TE1) to the second partial element (TE2) takes place by means of welding, in particular by means of high-frequency welding. Bladder (BL) that can be filled with pressure medium (DM) as an actuating element (BL1, BL2, BL3) for a seat, in particular a vehicle seat (FZS), with the following features: - A flat element (FE) produced by injection molding and made of plastic, which has a first sub-element (TE1) and a second sub-element (TE2) which are connected to one another at at least one transition section (UA) and brought to coincide with one another; - One or more connecting seams (VN) along which the first partial element (TE1) is connected to the second partial element (TE2) in order to create a bladder chamber (BK) that can be filled with pressure medium. blow after claim 9 , In which the flat element (FE) is designed as a flexible film. blow after claim 9 or 10 , In which the transition section (UA) has a kink, from which the first partial element (TE1) at an angle (W), in particular between 20 degrees and 90 degrees, to the second partial element (TE2) emanates. Pneumatic adjusting device (PW) for a seat, in particular a vehicle seat (FZS), with the following features: - a bladder (BL) that can be filled with pressure medium (DM) according to one of claims 9 until 11 ; - A control unit (STG), which is connected via a pressure medium line (DL; DL1, DL2, DL3) to the pressure medium (DM) fillable bladder (BL; BL1, BL2, BL3) in order to fill it with pressure medium (DM). and/or empty.

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