DE102021201069A1 - Lumbar support elements made of plastic - Google Patents

Abstract

The invention relates to a lordosis support element for a lordosis device of a vehicle seat (100) made from at least one thermoplastic material, the lordosis support element being designed either• as a flat lordosis shield (1) which has a shield base structure ( 1') and at least one force absorbing element (2) made of the same or a different thermoplastic material, which is integrated into the basic structure (1'), or• as a flat lordosis mat (2') made of a thermoplastic material exclusively from force absorbing elements ( 2) which form the mat basic structure of the lordosis mat (2'), wherein• the at least one force absorbing element (2) of the lordosis shield (1) and the force absorbing elements (2) of the lordosis mat (2') are designed as plastic strands whose thermoplastic plastic material is fiber reinforced.

Description

The invention relates to a lordosis support element for a lordosis device of a vehicle seat made of a plastic material.

In more and more vehicles, vehicle seats are taking on the additional function of actively massaging the occupant to counteract muscle tension. A common design is the use of air bladders for the back area. The inflating and deflating of the air bubbles causes forces to act on so-called lumbar shields, which absorb these air bubbles, which act in addition to the forces which are formed by the weight and the movements of a seated occupant (passenger). The lumbar shields must be designed to absorb the force accordingly. On the one hand, the comfort for the passenger must be taken into account in the design. On the other hand, a lumbar shield that is too flexible leads to mechanical energy losses when inflating the air cushions, which leads to larger bubbles and thus to more powerful air pumps (compressors). Among other things, this has a negative impact on power consumption and the weight of the vehicle. If the lordosis shield is designed too softly for reasons of comfort, the lordosis shield can even be damaged by constant alternating stress (rhythmic blowing or filling and venting). A common type of lordosis shield is the use of large, ribbed, flat plastic plates. However, this design has the disadvantages mentioned above.

In very simple and therefore inexpensive designs, the lordosis shield is completely omitted. Then only a wire mat exists, in which the forces are introduced. However, the advantage of such a low-cost design leads to mechanical disadvantages and thus to a reduction in the effectiveness of the lumbar support function and the massage function.

In addition to the described pneumatic lordosis devices, electromechanical lordosis devices are also known, which can also optionally be equipped with a massage function. In the case of the electromechanical lordosis devices, the loading or deformation of the lordosis shield is lower, since the mechanics cannot produce such a large stroke in the direction of the user's upper body for structural reasons. However, this is also the disadvantage of the electromechanical lordosis devices.

The lordosis shields or the lordosis wire mats (without lordosis shield) of the conventional lordosis devices are designed in various geometric designs as required.

Reference is only made to the publication as an example DE 10 2007 034 187 A1 referenced, which describes a support mat for a seat of a motor vehicle, which consists of a) a single planar lumbar support element and b) a plurality of metallic anchor wires, wherein c) the lumbar support element consists of a plastic material and is injection molded around the anchor wires .

Furthermore, the publication describes a seat insert, in the form of a lumbar support, which is designed in the form of an elastic lattice mat, the seat insert having at least two longitudinal bars which are connected by transverse bars and hangers for suspension in a seat frame, the transverse bars being made of plastic exist and are molded onto the longitudinal rods. The lordosis support has a lordosis support element that can be arched by an arching mechanism, in the manner of a lordosis shield, which is designed or manufactured in one piece with at least one of the crossbars made of plastic.

The invention explained below relates to a lordosis support element, in particular a lordosis shield and a lordosis mat, which differ from the prior art, as explained below.

The object of the invention is to create a lordosis support element, in particular a lordosis shield and a lordosis mat, which can be produced more easily, the elastic properties being optimized and the disadvantages mentioned above with regard to the lack of force absorption possibilities being overcome.

The object is solved by the features in claims 1 and 13, preferred embodiments being taught in the subclaims.

According to the invention, an embodiment of a lordosis support element for a lordosis device of a vehicle seat made of at least one thermoplastic material is provided, in which the lordosis support element is designed as a flat lordosis shield, which has a shield base structure made of a thermoplastic material and at least one of the same or another thermoplastic material formed force absorbing element. The at least one force absorbing element or a force absorbing structure of at least one or more force absorbing elements is designed according to the invention as a plastic strand whose thermoplastic cal plastic material is fiber reinforced as explained in the following description and taught by the claims.

Another embodiment of a lordosis support element for a lordosis device of a vehicle seat made of at least one thermoplastic material is also provided according to the invention, in which the lordosis support element is designed as a flat lordosis mat. The flat lordosis mat is also made of a thermoplastic material, but is made exclusively of force absorbing elements. It is provided that the basic mat structure of the lordosis mat is made of force absorbing elements, which are designed as plastic strands whose thermoplastic material is fiber-reinforced, with the plastic strands, i.e. the force absorbing elements, being combined to form force absorbing structures made up of several force absorbing elements, as explained in the following description and the claims are taught.

• 1 einen Fahrzeugsitz in einer perspektivischen Strukturansicht mit einer herkömmlichen elektromechanischen Lordose-Vorrichtung mit einem Lordose-Stützelement in der Art eines Lordoseschildes;
• 2A ein erfindungsgemäßes Lordose-Stützelement in der Art eines Lordoseschildes in einer ersten Ausführungsform von seiner Vorderseite;
• 2B das erfindungsgemäße Lordoseschild gemäß 2A in der ersten Ausführungsform von seiner Rückseite;
• 3A ein erfindungsgemäßes Lordose-Stützelement in der Art eines Lordoseschildes in einer zweiten Ausführungsform von seiner Vorderseite;
• 3B das erfindungsgemäße Lordoseschild gemäß 3A in der zweiten Ausführungsform von seiner Rückseite;
• 3C eine erfindungsgemäße Kraftaufnahmestruktur, die gemäß den 3A, 3B in der Schild-Grundstruktur des Lordoseschildes gemäß der zweiten Ausführungsform angeordnet ist; und
• 4 ein erfindungsgemäßes Lordose-Stützelement in der Art einer Lordosematte gemäß einer sechsten Ausführungsform von seiner Vorderseite.

The invention is explained below with reference to the associated drawings. Show it:

• 1 a vehicle seat in a perspective structural view with a conventional electromechanical lordosis device with a lordosis support element in the manner of a lordosis shield;
• 2A a lordosis support element according to the invention in the manner of a lordosis shield in a first embodiment from its front side;
• 2 B according to the lordosis shield according to the invention 2A in the first embodiment, from its rear side;
• 3A a lordosis support element according to the invention in the manner of a lordosis shield in a second embodiment from its front side;
• 3B according to the lordosis shield according to the invention 3A in the second embodiment from its rear side;
• 3C a force absorbing structure according to the invention, according to the 3A , 3B is arranged in the shield basic structure of the lumbar shield according to the second embodiment; and
• 4 a lordosis support element according to the invention in the form of a lordosis mat according to a sixth embodiment from its front side.

For the purpose of description, a horizontal direction of the lordosis shield or mat shall be denoted “x”. “y” denotes the horizontal direction orthogonal to the x-direction, and “z” denotes the vertical direction of the lordosis shield or lordosis mat orthogonal to the x and y directions in the x/y plane. 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.

1 shows a vehicle seat 100 with an electromechanical lordosis device, which can optionally be equipped with a massage function. In the case of the electromechanical lordosis device, the loading or deformation of the conventional lordosis shield 1S shown is lower, since the mechanism cannot produce such a large lift in the direction of the upper body of the seated user for structural reasons. At the same time, however, this is also the disadvantage of such electromechanical lordosis devices.

Based on the state of the art, the lordosis support elements, in particular lordosis shields and lordosis mats, as explained above, have to be appropriately designed to absorb forces.

In order to achieve the object according to the invention, one aspect of the invention provides that the lumbar support element in the embodiment as a lumbar shield 1 is advantageously made entirely of plastic, which ensures that the lumbar shield 1 is lightweight.

A plastic is preferably used either without fiber reinforcement or with fiber reinforcement, which is introduced in an injection molding process in a tool provided for this purpose, which maps the contour of the lumbar shield 1 .

In a preferred embodiment of the invention, the fibers of a fiber-reinforced plastic are basalt, natural, aramid, carbon or glass fibers or bundles thereof, which are impregnated with a plastic matrix.

Plastic matrix means that the spaces between the fibers are impregnated with the plastic, resulting in the matrix of the plastic material depending on the respective spaces.

The fiber-reinforced plastic for the production of the flat Lordoseschildes 1 is available as a granulate G, which either as a so-called short fiber material G _K (fine granulate with short fiber length) or as so-called long fiber material G _L (coarse granulate with longer fiber length), resulting in different plastic matrices depending on the application in the finished state of the lumbar shield 1.

The fiber length of the granules G _K , G _L is therefore dependent on the predeterminable average length of the granules.

In order to achieve the object according to the invention, a further aspect of the invention provides that force absorbing elements 2 are formed in an advantageous manner, which are designed as a rod or string. Rods or strings are also referred to as so-called rods.

The rods or strings have a fiber material that is impregnated with a plastic matrix, the fibers of the fiber material likewise preferably being basalt, natural, aramid, carbon or glass fibers or bundles thereof.

The rods and strings can be processed into a granulate G, which is prepared for further processing either as short-fiber material (fine granulate G _K with short fiber length) or as long-fiber material (coarse granulate G _L with longer fiber length), as explained below. The fiber length of the granules G _K , G _L depends on the predeterminable average length of the granules.

In other words, a preliminary product according to the invention is present either as a stick in packaging that is cheap for Euro pallets or as a stick or string as rolled goods on a roll.

It is clear that both the actual flat lordosis shield 1 and the force absorption elements 2, the rods or strings are made of fibers, in particular of basalt, natural, aramid, carbon fibers or bundles thereof, which are impregnated with a plastic matrix. The rods or strings are preferably produced from the same materials as the granules G _K or G _L , particularly preferably on one and the same production line. The granules G _K and G _L are thus also precursors according to the invention for the production of the lumbar support elements.

The rods and strings of the force absorbing element 2 and the material for producing the lordosis shield 1 are preferably made of the same plastic material, as just mentioned, with the plastic matrix used, in particular polyamide [PA] or polypropylene [PP], which is mixed with the fiber material, in particular Basalt, natural, aramid, carbon or glass fibers or bundles thereof, in particular reinforced.

In other words, short-fiber, long-fiber or non-reinforced plastics are used to design the flat lordosis shield 1 in the intermediate areas of an integrated force-absorbing structure 20 of force-absorbing elements 2, with the plastic being in granulate Go (without fibers) or in the form of a plastic matrix in fine granulate G _K with a short fiber length or as coarse granules G _L with a longer fiber length.

In other words, it is provided that the rods and strings, i.e. the force absorbing elements 2 of the integrated force absorbing structure 20, are formed from the same matrix material, with the rods and strings being formed as endless fiber-reinforced plastic strands, the fibers being encased with a plastic, preferably between are impregnated in the individual fibers of a bundle in the manner of a plastic matrix.

The special feature of the force absorbing element 2 is that it can be produced as a rod or string in a quasi-endless manner and is therefore available for further processing in one of the two forms as a rod or as a quasi-endless string. According to the invention, the rods (rods and strings) or the force absorbing elements 2 are semi-finished products of the injection molding material with which the flat part of the lumbar shield 1 is then also produced.

In this context according to the invention, semi-finished product means that the rods, bars and strings are not granulated to form short or long fiber granules G _K , G _L , but are cut to length and used to form a continuous fiber-reinforced plastic strand, as explained below.

In other words, it is provided that the rods or strings are formed in a predeterminable length from the continuous fiber-reinforced plastic strand or a continuous fiber-reinforced strand of a plastic matrix.

These aspects of the invention result in the rigidity of the lordosis shield 1 for absorbing the forces being formed by the endless fiber-reinforced force absorbing elements 2 (as will be explained below), while the structure of the lordosis shield 1 in the intermediate areas between the integrated force absorbing elements 2 ensures the flexibility of the lordosis shield 1 (As will be explained) contributes in its entirety, or causes the flexibility of the lumbar shield 1 itself. With others In other words, the continuous fiber-reinforced force absorbing elements 2 form a kind of skeleton in a flexible body that can be reversibly deformed elastically by the plastic in the intermediate areas of the elements of the skeleton.

In one embodiment, the lordosis support element is not a lordosis shield 1, but a lordosis mat 2'—without any plastic material in the spaces—as will be explained below.

In the following description, reference is made to force absorbing elements 2 which form different force absorbing structures 20, as will be explained below.

The embodiments of the force absorbing structures 20 are identified by the letters A, B, C, with a first force absorbing structure 20A in 2 is shown.

First embodiment 20A:

In the 2A and 2 B a lumbar shield 1 according to the first embodiment is shown with a force absorbing structure 20A, wherein 2A shows a front side (facing the occupant in the use position), while the 2 B a reverse shows.

It is clear that this lumbar shield 1 is the actual shield as a shield base structure 1 ′, in which at least one force absorbing element 2 is arranged “integrated”, which is designed as a first force absorbing structure 20A.

The first force absorbing structure 20A is designed in such a way that individual force absorbing elements 2 are arranged parallel to one another according to the direction definition, lying in the y-direction in this patent application, in the subsequent installation situation of the lumbar shield 1 .

In this embodiment, the force absorbing elements 2 themselves are not connected to one another or are only connected to one another by the plastic, ie the plastic matrix of the shield basic structure 1 ′ of the lumbar shield 1 . The plastic matrix surrounds the force absorbing elements 2.

The shield basic structure 1′ of the lumbar shield 1 consists of plastic in granular form Go (without fibers) or matrix material, ie plastic as fine granules G _K with short fibers or matrix material as coarse granules G _L with longer fibers.

Rods and strings of the force absorbing elements 2 are designed as endless fiber-reinforced plastic strands, the fibers being coated with a plastic, preferably impregnated between the individual fibers of a bundle in the manner of a plastic matrix. The rods and strings of the force absorbing elements 2 are cut to the desired length and have, as in the 2A and 2 B becomes clear, different lengths.

During production, i.e. during the injection molding process, the shield basic structure 1' of the lordosis shield 1 encloses the force absorbing elements 2 in the sense of reinforcements of the shield basic structure 1', with the material of the shield basic structure 1' of the lordosis shield 1 filling the gaps between the force absorbing elements 2 closes and encloses the force absorbing elements 2 (without material connection) or the material of the shield basic structure 1' of the lordosis shield 1 closes the gaps between the force absorbing elements 2 and encloses the force absorbing elements 2 (with material connection), as will be explained below.

The rods, i.e. the force absorbing elements 2, are arranged in the component according to the load, with the fiber direction of the rods also being arranged in the y-direction, whereby a force absorbing structure 20A in the manner of a skeleton is advantageously unidirectional horizontally "in one direction". aligned fibers is formed, which are integrated into the shield basic structure 1 'of the lumbar shield 1.

According to the embodiment shown, it is provided that the force absorbing structure 20A is either fully integrated into the material (cf 3A and 3B , 3C ) is “embedded”, or only partially integrated, i.e. only partially “embedded”, as by 2 B is clarified.

According to the exemplary embodiment, the force absorbing elements 2 are only “partially” “embedded” on the back of the lordosis shield 1 as the shield basic structure 1′ in the material of the lordosis shield 1 and form prominent horizontal ribs or a prominent rib structure.

The in the 2A and 2 B The first embodiment 20A shown is only one of a large number of possible embodiments.

Second embodiment 20B:

A second embodiment 20B of a force absorbing structure 20B can, for example a cross-lattice structure according to 3A , 3B , 3C be.

According to the 3A , 3B and 3C the force absorbing structure 20B is, for example, fully integrated into the material, ie “embedded”. The shield basic structure 1 'is in the 3A and 3B Shown transparent to reveal the "embedded" force absorbing structure 20B.

During production, i.e. in the injection molding process, the shield basic structure 1' of the lumbar shield 1 encloses the force absorbing elements 2 arranged as a cross-lattice structure, and therefore as a force absorbing structure 20B, in the sense of reinforcements of the shield basic structure 1', with the material of the shield basic structure 1' of the lordosis shield 1 either encloses the gaps between the force absorbing elements 2 without any material connection or the material of the shield basic structure 1' of the lordosis shield 1 at least partially fuses with the material in the gaps between the force absorbing elements 2 with a material connection, as will be explained below.

In the illustrated embodiment, the shield basic structure 1 ′ of the lumbar shield 1 is designed entirely as a solid material body and therefore has no openings.

In other configurations, the shield basic structure 1′ of the lumbar shield 1 can also be designed essentially shield-like as a solid material body, but in which local openings (not shown) are provided for weight reduction and/or for arranging components of a lordosis mechanism and/or a massage mechanism are.

the 2A , 2 B and the 3A , 3B and 3C show, for example, openings in the shield basic structure 1' of the lumbar shield 1 in the form of weight-reducing indentations on the edge, which are arranged in various conceivable positions - outside the structure of the force absorbing elements 2 - to illustrate the invention as representative of technically required local openings of different sizes and shapes .

It goes without saying that such local openings are provided in particular when components of the lordosis mechanism and/or the massage mechanism are to be integrated into the shield basic structure 1′ of the lordosis shield 1, which is seen as an aspect of the invention.

It goes without saying that the force absorbing elements 2 of the force absorbing structure 20B designed as a cross-lattice structure can also only be “partially” embedded in the material of the shield basic structure 1′ of the lumbar shield 1, and only partially in the shield on one or both sides -Basic structure 1 'of Lordoseschildes 1 can form embedded rib structure, as for example in connection with the description of 2 B is revealed.

3C shows an example of the force absorbing structure 20B in the form of a lattice structure as a subassembly without the shield basic structure 1 'of the lordosis shield 1. With this force absorbing structure 20B, the reinforcement advantageously takes place above all in a local center Z of the lordosis shield 1, while the reinforcing effect is lower towards the outside is held to cause a concave curvature of the lumbar shield 1 as the shield base structure 1 ′ of the lordosis shield 1 from the local center Z for the purpose of comfort for the occupant seated on the vehicle seat 100 . The force absorbing elements 2 are closer together in the local center Z than in the edge area of the force absorbing structure 20B, as a result of which the curvature in the outer area of the force absorbing structure 20 compared to the area in the local center Z is advantageously possible.

Third embodiment 20C:

In another third embodiment 20C (not shown), the force absorbing structure 20C can be a frame structure in which the force absorbing element(s) 2 forms a continuous or interrupted peripheral frame which essentially corresponds to the contour of the lumbar shield 1 as the shield basic structure 1' .

Fourth embodiment 20D:

In another fourth embodiment 20D (not shown), the force absorbing structure 20D can be a meandering structure in which the force absorbing element(s) 2 form a continuous or interrupted meander.

Fifth embodiment 20E:

In another fifth embodiment 20E (not shown), the force absorbing structure 20E can be made up of individual strands according to FIGS 2A and 2 B or lattice structures according to 3A and 3B , 3C be in combination, with the alignment or orientation being freely selectable.

A special case of a lordosis support element is in 4 shown.

Sixth embodiment 20F:

The sixth force absorbing structure 20F made up of force absorbing elements 2 forms a lordosis mat 2' as a lordosis support element, which in the exemplary embodiment is designed as a cross-lattice structure according to the second embodiment 20B as a mat basic structure which is additionally combined with a frame structure. No individual strands of force absorbing elements 2 are provided. In other words, all of the force absorbing elements 2 are connected to one another and are connected at the ends to the frame structure.

Provision is made for the force absorbing elements 2 to be arranged parallel to one another and lying horizontally and vertically in the y-direction and in the z-direction according to the direction definition in this patent application in the subsequent installation situation of the lumbar shield 1 .

The force absorbing elements 2, which form the cross-lattice structure, are also all of the same length in this embodiment, but not necessarily--as shown--arranged at equal distances from one another. For example, an accumulation of force absorbing elements 2 in the local center Z can also result in a greater reinforcing effect in this area.

In this sixth embodiment 20F, the large-area encapsulation of the rods, that is to say the force absorbing elements 2 or the cross lattice frame structure, is therefore omitted. The frame is particularly important if the lordosis support element is not overmoulded, but rather the force absorbing structure 20F itself forms the mat basic structure of the lordosis mat 2'. The frame thus forms the shield-like structure of the lordosis mat 2' at the edge, which is formed by the shield basic structure 1' of the lordosis shield 1 in the previous embodiments.

It goes without saying that the force absorbing structure 20F presented as a lumbar mat 2' can also be used in a shield basic structure 1' of a lordosis shield 1 formed from the force absorbing structure 20F and the shield basic structure 1'.

It applies to all embodiments that the force absorbing elements 2 of the force absorbing structures 20A, 20B, 20C, 20D, 20E, 20F in one plane (y/z plane) or in several planes (y/z planes) (compare the 2A , 2 B and 3A , 3B , 3C ) the shield basic structure 1 'of the actual lumbar shield 1 can be arranged.

For rod and injection molding material production:

As already mentioned in the component structure, the rods are individual fiber bundles that are impregnated with a plastic matrix and are in the form of a cable or string in endless form.

Provision is preferably made for the rods to be produced in a common production line in addition to the granules G _K , G _L provided as overmolding material. The granules G _K , G _L are used for the injection molding processes. This means that the respective granulate G _K , G _L is used in the production of the shield basic structure 1 ′ of the lumbar shield 1 according to the invention, unless it is an overmoulding material without fiber reinforcement, in which case a thermoplastic material without fiber material is of course used.

The granulate is available either as so-called short-fiber material G _K or as so-called long-fiber material G _L . This depends on the average length of the granules. In contrast to this material, the rods are produced endlessly and can then be cut to a desired length.

The rods can have a long fiber length that is theoretically endless. Lengths of 10 cm to 1 km, particularly preferably between 70 cm and 500 m, are preferably produced.

The advantage of the same material between rods and overmolding material consists particularly advantageously in the type purity achieved. This affects both the production and the possible improved recycling.

In a preferred embodiment, it is provided that the plastic material of the rods melts (at least partially) when the overmolding material is added in the injection molding process or another manufacturing process, so that in a preferred embodiment it is materially connected to the same plastic of the injected overmolding material without making contact to lose the fibers or fiber bundles.

During recycling, only the thermoplastic matrix and the fibers are then present, which leads to pure separation, since the above-mentioned material equality is then exclusively one type of thermoplastic material and a single type of fiber, with the fibers being different due to the meltability of the respective type of thermoplastic material very easy to separate from the plastic.

The advantage of the endless unidirectional fiber bundles in the rods, i.e. in particular in the force absorbing elements 2, is, as already mentioned, the increased possible force absorption and thus the transmission of higher forces, since this mainly depends on the fibers and their length, with the Fibers from the granulates G _K and G _L are shorter compared to endless fibers, but cause the desired force absorption function.

Especially at higher vehicle temperatures, where short- or long-fiber-reinforced thermoplastic components reach their mechanical limits due to their temperature-dependent softening, these unidirectional fiber strands in the force absorbing elements 2 make a significant contribution to the stability of the component, in particular the lordosis shield 1 and the lordosis mat 2'. This is particularly advantageous with regard to simultaneous use with a seat heater or when using the vehicle in so-called hot or super hot countries with high levels of solar radiation.

The production of a lordosis support element according to the invention, in particular the production of the lordosis shield 1, is explained in addition below.

The lordosis shield 1 is preferably produced from a thermoplastic material in an injection molding process.

Alternatively, other methods such as plastic compression molding may be used to manufacture the lordosis shield 1.

The rods prepared as semi-finished products, i.e. the individual force absorbing elements 2 or, preferably, the force absorbing structures 20A, 20B, 20C, 20D, 20E produced as a subassembly are placed in an injection molding tool and then preferably with the same material as the material of the force absorbing elements 2 or force absorbing structures 20A, 20B, 20C, 20D, 20E completely or at least partially (with a material connection to the force absorbing elements 2 or without a material connection to the force absorbing elements 2) injection molded/overmolded.

This procedure ensures unidirectional fiber strands within the shield basic structure 1 'with or without material connection to the rods, through the rods arranged as before in the injection molding tool, which are preferably made of the same plastic and preferably with the short provided in the granulate G _K , G _L - Are surrounded or long fibers of the encapsulation material explained.

The insertion process step, the rods prepared as semi-finished products, ie the individual force absorbing elements 2 or preferably the force absorbing structures 20A, 20B, 20C, 20D, 20E produced as a sub-assembly, is ideally automated and ensures rapid cycling during manufacture.

The rods prepared as semi-finished products, i.e. the individual force absorbing elements 2 or preferably the force absorbing structures 20A, 20B, 20C, 20D, 20E produced as a subassembly, are preferably produced in an injection molding process in which the shield basic structure 1' is produced. upstream step.

As mentioned above, the individual force absorbing elements 2 or the force absorbing structures 20A, 20B, 20C, 20D, 20E, 20F can be present in a wide variety of geometric shapes, with the selection of the arrangement of the force absorbing elements 2 being subject to the requirements placed on the components. The simplest type are individual force absorbing elements 2.

However, a type of force absorbing structure 20A, 20B, 20C, 20D, 20E and/or a frame is preferably formed in order to produce a subassembly from individual strands, which is advantageously also easier to handle for the further process steps.

If the force absorbing structures do not have any almost straight-line force absorbing elements 2 and individual strands are to be formed in loops or meanders as force absorbing structures, it is provided that several adjacent or three-dimensionally curved rods are formed.

These loops or meanders can preferably be produced from a quasi-endless strand of plastic made of rods and strings by heating the plastic of the rods (rods and strings) to a temperature at which the rods can be deformed into the desired geometric shape due to their thermoplastic nature.

Due to their flexibility, the fibers contained are brought into their new position together with the plastic surrounding them, forming a changed new plastic matrix, without the fibers themselves having to be heated to their melting temperature.

It is provided that the heated plastic, ie the heated plastic matrix of a fiber-reinforced rod, is brought into its deformable thermoplastic temperature range, so that the desired force absorption can be achieved meelement 2 is deformable on a contouring device. The contouring device has, for example, an outer contour that corresponds to the desired contour or position of the force absorbing element 2 to be produced, which can advantageously be deformed into any permanent desired shape after the thermoplastic material has hardened.

For example, it is also conceivable that the malleable force absorbing element 2 is wound over distinctive contouring deflection points, which forms a contour based on these deflection points.

This contouring device or the contouring deflection points can be arranged to produce a semi-finished product outside the injection mold or inside the injection mold.

For example, it is proposed that the force absorbing elements 2, the rods, are inserted in a straight line into the injection mold and the force absorbing element is reshaped by closing the injection mold, in that the force absorbing elements 2 are either deformed by their gravity after heating or the explained contours are formed in the injection mold Devices act on the at least one force absorbing element 2.

It is provided that the force absorbing element 2 solidifies again after the end of the supply of heat, namely in the predetermined shape.

In a preferred embodiment, the tool is constructed in such a way that the at least one force absorbing element 2 is held under prestress and, after heating, is cooled and solidified again under prestress. In this case, the prestressing is selected only to such an extent that it has a positive effect on the mechanical properties of the force absorbing elements 2 and the force absorbing elements 2 do not tend to break or tear as a result of overstressing.

It is also provided that the contouring device or the contouring deflection points for the geometric configuration or reconfiguration of the at least one force absorbing element 2 are arranged in the tool such that they cannot be lost or replaced.

If the force absorbing element(s) 2 or the force absorbing structures 20A, 20B, 20C, 20D, 20E, 20F are to be fused after their prefabrication with the shield basic structure 1' of the lumbar shield 1, i.e. materially connected, it is provided that the elements or Heat is again supplied to structures so that at least the upper layer of the elements or structures melts in the desired layer depth. This process can preferably also be brought about by the fact that the thermoplastic matrix added in the manufacturing process to design the shield base structure 1' is heated to a temperature and added which is sufficient to melt the elements or structures consisting of the elements it is ensured that the strand structures are not lost through melting or melting.

The fusion with the shield base structure 1' is preferably provided.

Welding or fusing by the heated plastics material of the force absorbing elements 2 themselves is preferred to other joining methods such as gluing, where additional material has to be added to make the glue joint. Insofar as gluing is used, the adhesive can advantageously be that plastic which is also used for injection molding the shield base structure 1'.

In particular, the crossing points of the force absorbing elements 2 shown in the figures should preferably - without the addition of additional plastic material - be welded or fused to one another as a pre-produced semi-finished product or in the injection mold after the force absorbing elements 2 have been inserted and welded or fused to one another with the shield basic structure 1' of the lumbar shield 1 will.

It is also conceivable to insert the rods in a straight line into the injection molding tool and to bring about rod reshaping by closing the temperature-controlled tool.

The mold is ideally designed in such a way that the rods are kept under a preload which, if not chosen too large, has a positive effect on the mechanical properties of the rods and the lumbar shield structure and at the same time prevents the rods from falling out of the mold before overmolding fall or change position.

However, the geometric design of the tool can already lead to the rods or the rod structures remaining/remaining captive in the tool.

The main advantages of the inventive design of the lordosis shield 1 and the Lordo sematten 2' and the way it is produced are the weight savings combined with low material, process and component costs, the mechanical stability and the simple way of recycling at the end of the component's life. The previously described material equality (purity of type) of the material of the force absorbing element 2 and the lordosis shield 1 is of particular advantage, since production is simplified and a uniform recycling process is possible. In addition, as a further advantage, the fatigue strength of the lordosis shield 1 or the lordosis mat 2' is increased.

Reference List

100

vehicle seat

1S

Lumbar shield (state of the art)

1

Lumbar shield with basic structure 1' and force absorption element/s 2

1'

Shield basic structure of the lordosis shield

2'

Lordosis mat made of force absorbing elements 2

G

granules

Go

Granules without fibers

GC

Granules with short fiber length (short fiber granules)

GL

Granules with longer fiber length (long fiber granules)

2

force absorbing element

20

force absorbing structure

20A

first embodiment of the force absorbing structure

20B

second embodiment of the force absorbing structure

20c

third embodiment of the force absorbing structure (not shown)

20D

fourth embodiment of the force absorbing structure (not shown)

20E

fifth embodiment of the force absorbing structure (not shown)

20F

sixth embodiment of the force absorbing structure

Z

local center

x

horizontal direction orthogonal to y and z

y

horizontal direction orthogonal to x and z

e.g

vertical direction orthogonal to x and y

QUOTES INCLUDED IN DESCRIPTION

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Patent Literature Cited

• DE 102007034187 A1 [0006]

Claims (16)

Lordosis support element for a lordosis device of a vehicle seat (100) made of at least one thermoplastic material, wherein the lordosis support element either • is designed as a flat lordosis shield (1) which has a shield base structure (1') made from a thermoplastic material and at least one force absorbing element (2) made from the same or a different thermoplastic material, which is integrated into the base structure (1') is integrated, or • is designed as a flat lordosis mat (2') made of a thermoplastic material exclusively from force absorbing elements (2) which form the mat basic structure of the lordosis mat (2'), wherein • the at least one force absorbing element (2) of the lordosis shield (1) and the force absorbing elements (2) of the lordosis mat (2') are designed as plastic strands whose thermoplastic material is fibre-reinforced. Lordosis support element claim 1 , characterized in that the thermoplastic material of the base structure (1') and the thermoplastic material of the force absorbing element (2) consist of different or the same thermoplastic materials, in particular of a thermoplastic material - polyamide [PA] or polypropylene [PP] - consist. Lordosis support element claim 1 , characterized in that the plastic material of the shield base structure (1') is a fiber-free thermoplastic plastic material. Lordosis support element claim 1 , characterized in that the plastic material of the shield basic structure (1 ') and the at least one force absorbing element (2) is a fiber-reinforced thermoplastic material, the fibers and / or fiber bundles, in particular basalt, natural, aramid, carbon or glass fibers has, which are impregnated with the thermoplastic material surrounding the fibers and / or fiber bundles. Lordosis support element claim 1 , characterized in that at least one or more force absorbing element(s) (2) is/are integrated into the shield base structure (1`) of the lordosis shield (1), in particular partially into the base structure (1') or completely into the shield base structure (1` ) embedded, arranged. Lordosis support element claim 5 , characterized in that the at least one force absorbing element (2) is integrated in a pretensioned state in the thermoplastic material of the shield base structure (1), in particular partially embedded in the base structure (1') or completely embedded in the base structure (1'). is/are. Lumbar support element according to the claims 1 and 5 or 1 and 6 , characterized in that at least one plastic strand is arranged as an individual strand and/or several individual plastic strands are arranged as force absorbing element(s) (2) in the thermoplastic material of the shield basic structure (1'), with several individual strands being arranged in such a way that predeterminable geometric force absorbing structures (20A , 20B, 20C, 20D, 20E, 20F), at least one of the force absorption structures (20A, 20B, 20C, 20D, 20E, 20F) being integrated into the basic structure (1') of the lumbar shield (1). Lordosis support element claim 4 , characterized in that the at least one single plastic strand as the force absorbing element(s) (2) is a preliminary product which is formed from the fiber material (fibers and/or fiber bundles) and the thermoplastic plastic material, the fiber material being combined with the plastic material under thermal decomposition of the thermoplastic plastic material is impregnated, the preliminary product being processed into a rod or string after the plastic material has hardened, the rod or string being cut to length to form the at least one individual plastic strand as a force-transmitting element (2) with free ends. Lordosis support element claim 4 , characterized in that the at least one single plastic strand as the force absorbing element(s) (2) is a preliminary product which is formed from the fiber material (fibers and/or fiber bundles) and the thermoplastic plastic material, the fiber material being combined with the plastic material under thermal decomposition of the thermoplastic plastic material is impregnated, with the preliminary product being processed into a rod or string after the plastic material has hardened, with the rod or string being cut to length to form the at least one individual plastic strand as a force-transmitting element (2) with free ends, and the rods or the cut-to-length strings being subjected to further thermal decomposition of the thermoplastic material are connected to form a force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F). Lordosis support element claim 1 , characterized in that the to a force absorbing structure (20F) connected plastic individual strands with respect to a desired force unidirectionally along at least one or more spatial direction(s) (x, y, z) in at least one spatial plane. Lordosis support element claim 7 , characterized in that the at least one individual plastic strand as force absorbing element(s) (2) or the individual plastic strands connected to form a force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) are unidirectional with regard to the desired force absorbing direction within the shield base structure (1'). are arranged oriented along at least one or more spatial directions (x, y, z) in at least one spatial plane. Lordosis support element claim 10 or 11 , characterized in that the plastic individual strands as force absorbing element/s (2) or force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) consist of several plastic individual strands in at least one of the several spatial planes within the shield basic structure (1') of the lumbar shield ( 1) or mat basic structure of the lordosis mat (2 ') are arranged parallel to each other in several levels. Method for producing a support element in the form of a lordosis shield (1) with the following steps: I - impregnating a fiber material made of fibers and/or fiber bundles with one or the other thermally broken down thermoplastic material (G, Go) with a predeterminable percentage by weight of the fiber material, wherein the respective thermoplastic material (G, Go) hardens and a semi-finished profile, in particular as a rod or string, is present; IA - short cutting of the semi-finished profile and production of a short fiber granulate (G _K ), optionally from the semi-finished profile of one or the other thermoplastic material; IB - Long cut of the semi-finished profile and manufacture of a long fiber granulate (G _L ), optionally from the semi-finished profile of one or the other thermoplastic material; II - producing at least one force absorbing element (2) or a force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) comprising several force absorbing elements (2) by cutting to length the profile semi-finished product produced in step I, in particular the rod or string; III - inserting the at least one force absorbing element (2) or force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) into a tool which has the negative form of the shield basic structure (1') of the lumbar shield (1); IV - heating and introducing the granulate (G) without fibers (Go) or a short fiber granulate (G _K ) or a long fiber granulate (G _L ) and V - injection molding or compression molding of the granulate (G; Go, G _K , G _L ) within the Tool for producing the positive mold of the shield basic structure (1') of the lordosis shield (1), which has the force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) comprising at least one force absorbing element (2) or the several force absorbing elements (2). , which is/are integrated into the shield basic structure (1') of the lordosis shield (1) in a stationary, form-fitting manner. procedure after Claim 13 , characterized in that the at least one force absorbing element (2) or the force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) is prestressed in the tool by at least one clamping element belonging to the tool. procedure after Claim 13 , characterized in that the temperature of the plastic material of the granules (G; Go, G _K , G _L ) is selected according to step IV such that the thermoplastic material of the at least one spent in the hardened state in the tool according to step III force absorbing element ( 2) or the force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) is at least partially melted, so that not only a stationary positive connection, but also a material connection between the thermoplastic material of the shield base structure (1') and the at least a force absorbing element (2) or the force absorbing elements (2) of the force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) and the force absorbing elements (2) among themselves. procedure after Claim 13 , characterized in that the thermoplastic material of the at least one force absorbing element (2) or the force absorbing elements (2) of the force absorbing structure (20A, 20B, 20C, 20D, 20E, 20F) and the thermoplastic material of the shield base structure (1') are the same thermoplastic plastic material or different thermoplastic plastic materials is/are used.

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