EP1268153A1 - Foam part and method for producing the same - Google Patents

Foam part and method for producing the same

Info

Publication number
EP1268153A1
EP1268153A1 EP01931544A EP01931544A EP1268153A1 EP 1268153 A1 EP1268153 A1 EP 1268153A1 EP 01931544 A EP01931544 A EP 01931544A EP 01931544 A EP01931544 A EP 01931544A EP 1268153 A1 EP1268153 A1 EP 1268153A1
Authority
EP
European Patent Office
Prior art keywords
foam
area
pocket
network
soft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01931544A
Other languages
German (de)
French (fr)
Inventor
Horst Steinmeier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Adient Seating Ltd and Co KG
Original Assignee
Johnson Controls Ltd and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Controls Ltd and Co KG filed Critical Johnson Controls Ltd and Co KG
Publication of EP1268153A1 publication Critical patent/EP1268153A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0461—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
    • B29C44/0469—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other provided with physical separators between the different materials, e.g. separating layers, mould walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/129—Enhancing adhesion to the preformed part using an interlayer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/24983—Hardness

Definitions

  • the invention relates to a foam part made of polyurethane or the like, in particular for use as a support for backrests, seats or the like of vehicle seats, with a first area made of foam with a first composition and a second area made of foam with a second composition, and to a process for producing the foam part.
  • Backrests, seats and the like of vehicle seats are increasingly padded with foam parts made of polyurethane (PUR) and then covered with covers made of fabric, leather or the like.
  • PUR polyurethane
  • To produce the foam parts liquid polyurethane is injected into a mold, which is then closed and heated, so that the polyurethane foams and the foam part is given the desired shape.
  • a hard foam area can be provided under the soft foam, which ensures comfortable seating, by means of which the shape stability of the seat cushion is increased.
  • the production of such a horizontally divided two-zone foam part is relatively complex and therefore expensive.
  • a soft foam is first injected and foamed into a mold and the foam part is returned to the mold after passing through the foaming device and then the hard foam material is sprayed on and foamed.
  • This will Although a one-piece connection between hard and soft foam is achieved, this process requires a manufacturing time of a few hours. A precise zone separation between soft and hard foam is also not possible. It is also known to produce the hard and soft foam areas separately and then to glue them together. However, this additional work step increases the costs significantly, whereby the very large numbers of items, particularly when manufacturing seats in the automotive sector, must be taken into account.
  • the object of the invention is therefore to improve the economy in the production of a two-zone foam part.
  • a network of polyethylene, jute, gauze, fleece or the like is arranged between the first (soft foam) and second (hard foam) region of the foam part.
  • This network which is arranged in the parting plane between the first and second regions of the foam part, permits rapid and economical production, with precise zone separation being possible.
  • the separation level formed by the network is preferably in a horizontal plane of the foam part.
  • the network is designed as a pocket into which the second area is foamed.
  • a special contour of the hard foam area can also be specified inside the foam part through the pocket.
  • the pocket is essentially wedge-shaped in the open state, while according to a second embodiment it is essentially cuboid.
  • Seat cushions are usually formed with a central area, which essentially serves as a seat, and a side area, which is placed over the side edges of the mostly metallic seat frame.
  • the separation between soft and hard foam is provided only in the central area, while the side area consists entirely of soft foam. This can simplify the design of the manufacturing mold, since the network only has to be spanned in the middle area.
  • the invention also relates to a method for producing a foam part described above, wherein foam with a first composition, in particular soft foam, is first introduced into a mold and foamed, a network then being arranged, in particular stretched, over the foam, and finally a foam material with a second composition, in particular hard foam, is introduced into the mold and foamed over the network.
  • foam with a first composition in particular soft foam
  • a network then being arranged, in particular stretched, over the foam
  • a foam material with a second composition in particular hard foam
  • the network is designed as a pocket, in particular the corner points of the pocket facing the upper side of the mold are attached to the cover of the mold and the foam material with the second composition is introduced into the pocket and foamed there.
  • Show it: 1 is a schematic partial section through a foam part according to a first embodiment of the invention
  • FIG. 2 shows a schematic partial section through a foam part according to a second embodiment of the invention
  • FIG. 3 shows a schematic partial section through a foam part according to a third embodiment of the invention
  • Fig. 4 schematically shows a bag that the inclusion of the
  • Hard foam area serves, and
  • Fig. 5 shows another embodiment of a bag for receiving the
  • the foam part 1 shown in FIGS. 1 to 3 made of polyurethane (PUR) or the like has a first area 2 made of soft foam and a second area 3 made of hard foam arranged above it.
  • the properties of the first and second areas 2, 3 are determined in the usual way by adding a different amount of isocyanate to the polyurethane. The higher the isocyanate content, the greater the hardness of the foam.
  • any other suitable additive which influences the hardness properties can of course also be added to the polyurethane.
  • the orientation of the foam part shown in the drawings corresponds to the usual production of the foam part 1, in which the soft foam area is formed first and then the hard foam area. When arranged on vehicle seats, the foam part 1 is turned over so that the hard foam area 3 faces the mostly metallic seat frame. The The driver or passenger sits on the soft, comfortable soft foam area 2.
  • a network or fabric 4 made of polyethylene, jute, gauze, fleece or the like is provided in order to separate the areas from one another.
  • the network is permeable, on the one hand to make the passage of gases when foaming in and on the other hand to enable a connection of the two foam areas, which pass through the openings of the network to a small extent on the other side when foaming.
  • the foam part 1a is divided into two areas 2, 3 only in its central area 5, which usually serves as a seat, by the network 4, while a side area 6, which is stretched over the side edges of the seat frame, consists of soft foam.
  • the separation between the first area 2 and the third area 3 by the network 4 is provided both in the middle area 5 and in the side area 6.
  • the network 4 can either be designed as a simple network, which is stretched over the first area 2, or as a pocket 7, as shown in FIGS. 4 and 5.
  • a pocket 7a shown in FIG. 4 it has triangular side walls 8, 9, so that the pocket 7a is wedge-shaped in the open state.
  • the pocket 7b shown in FIG. 5 according to the second embodiment is essentially cuboid with rectangular side walls 10, 11 and a bottom 12.
  • the seams 13 of the pockets 7a, b are sewn or welded depending on the network material selected.
  • the foam part according to the invention is produced by first injecting a soft foam material into a foam mold and foaming it by heating. Immediately after foaming, the mold can be opened and the network 4, which may be designed as a pocket 7a, b, can be stretched over the soft foam 2.
  • a separate clamping frame can be used for this, so that there is a three-part shape consisting of a lower part, clamping frame and molded cover.
  • the corner points 15, 16 of the pocket 7a, b facing the mold top are fastened to the lid of the mold and the rigid foam material is injected into the pocket 7a, b and foamed by heating.
  • the separate tenter frame can be dispensed with here.
  • the pocket 7a, b is expanded in the central region, so that the bulged shape of the rigid foam region 3 shown in FIG. 3 results.
  • a desired contour for the hard foam area and thus also for the soft foam area can be achieved via the pocket 7a, b, by means of which the seating properties can be influenced.
  • the foam part 1 can be removed from the mold after about 4 minutes, it still having a gelatinous consistency. After about 72 hours, the foam part 1 has completely reacted.
  • the foam When foaming, the foam clings to the network 4, so that a reliable connection between the first and second regions 2, 3 is achieved without additional gluing being necessary.

Abstract

The plastic foam element for covering backrest, seat and other surfaces of motor vehicle seats comprises two foam layers (2, 3) with different compositions, and a netting consisting of a plastic material, jute, gauze or a similar item located between these layers.

Description

Schaumteil und Verfahren zu seiner HerstellungFoam part and process for its production
Die Erfindung bezieht sich auf ein Schaumteil aus Polyurethan oder dgl., insbesondere zur Verwendung als Auflage für Rückenlehnen, Sitzflächen oder dgl. von Fahrzeugsitzen, mit einem ersten Bereich aus Schaum mit einer ersten Zusammensetzung und einem zweiten Bereich aus Schaum mit einer zweiten Zusammensetzung, sowie auf ein Verfahren zur Herstellung des Schaumteils.The invention relates to a foam part made of polyurethane or the like, in particular for use as a support for backrests, seats or the like of vehicle seats, with a first area made of foam with a first composition and a second area made of foam with a second composition, and to a process for producing the foam part.
Rückenlehnen, Sitzflächen und dgl. von Fahrzeugsitzen werden zunehmend mit Schaumteilen aus Polyurethan (PUR) gepolstert und anschließend mit Bezügen aus Stoff, Leder oder dgl. überzogen. Zur Herstellung der Schaumteile wird flüssiges Polyurethan in eine Form eingespritzt, die anschließend geschlossen und beheizt wird, so dass das Polyurethan aufschäumt und das Schaumteil die gewünschte Form erhält. Um einen besonderen Sitzkomfort zu gewährleisten, ist es zudem bekannt, das Schaumteil in Zonen mit unterschiedlichen Eigenschaften, insbesondere Härtegraden zu unterteilen. So kann unter dem ein bequemes Sitzen gewährleistenden Weichschaum ein Hartschaumbereich vorgesehen sein, über den die Formstabilität des Sitzpolters erhöht wird. Die Herstellung eines derartigen horizontal geteilten Zweizonenschaumteil ist jedoch relativ aufwendig und daher teuer. Üblicherweise wird zunächst ein Weichschaum in eine Form eingespritzt und aufgeschäumt und das Schaumteil nach Durchlaufen der Schäumvorrichtung in der Form wieder zurückgeführt und dann das Hartschaummaterial aufgespritzt und aufgeschäumt. Hierdurch wird zwar eine einstückige Verbindung zwischen Hart- und Weichschaum erreicht, doch benötigt dieses Verfahren eine Herstellzeit von einigen Stunden. Auch ist keine genaue Zonentrennung zwischen Weich- und Hartschaum möglich. Es ist auch bekannt, den Hart- und Weichschaumbereich getrennt herzustellen und anschließend zu verkleben. Dieser zusätzliche Arbeitsschritt erhöht jedoch die Kosten wesentlich, wobei die insbesondere bei der Sitzherstellung im Automobilbereich sehr großen Stückzahlen zu berücksichtigen sind.Backrests, seats and the like of vehicle seats are increasingly padded with foam parts made of polyurethane (PUR) and then covered with covers made of fabric, leather or the like. To produce the foam parts, liquid polyurethane is injected into a mold, which is then closed and heated, so that the polyurethane foams and the foam part is given the desired shape. In order to ensure special seating comfort, it is also known to divide the foam part into zones with different properties, in particular degrees of hardness. Thus, a hard foam area can be provided under the soft foam, which ensures comfortable seating, by means of which the shape stability of the seat cushion is increased. However, the production of such a horizontally divided two-zone foam part is relatively complex and therefore expensive. Usually, a soft foam is first injected and foamed into a mold and the foam part is returned to the mold after passing through the foaming device and then the hard foam material is sprayed on and foamed. This will Although a one-piece connection between hard and soft foam is achieved, this process requires a manufacturing time of a few hours. A precise zone separation between soft and hard foam is also not possible. It is also known to produce the hard and soft foam areas separately and then to glue them together. However, this additional work step increases the costs significantly, whereby the very large numbers of items, particularly when manufacturing seats in the automotive sector, must be taken into account.
Aufgabe der Erfindung ist es daher, die Wirtschaftlichkeit bei der Herstellung eines Zweizonenschaumteils zu verbessern.The object of the invention is therefore to improve the economy in the production of a two-zone foam part.
Dies wird mit der Erfindung im Wesentlichen dadurch erreicht, dass zwischen dem ersten (Weichschaum) und zweiten (Hartschaum) Bereich des Schaumteils ein Netzwerk aus Polyethylen, Jute, Gaze, Vlies oder dgl. angeordnet ist. Dieses in der Trennungsebene zwischen den ersten und zweiten Bereichen des Schaumteils angeordnete Netzwerk erlaubt eine schnelle und wirtschaftliche Herstellung, wobei eine genaue Zonentrennung möglich ist.This is essentially achieved with the invention in that a network of polyethylene, jute, gauze, fleece or the like is arranged between the first (soft foam) and second (hard foam) region of the foam part. This network, which is arranged in the parting plane between the first and second regions of the foam part, permits rapid and economical production, with precise zone separation being possible.
Die durch das Netzwerk gebildete Trennungsebene liegt vorzugsweise in einer horizontalen Ebene des Schaumteils.The separation level formed by the network is preferably in a horizontal plane of the foam part.
Gemäß einer bevorzugten Ausgestaltung der Erfindung ist das Netzwerk als Tasche ausgebildet, in die der zweite Bereich eingeschäumt ist. Durch die Tasche kann eine spezielle Kontur des Hartschaumbereiches auch im Inneren des Schaumteiles vorgegeben werden.According to a preferred embodiment of the invention, the network is designed as a pocket into which the second area is foamed. A special contour of the hard foam area can also be specified inside the foam part through the pocket.
Gemäß einer ersten Ausführungsform ist die Tasche im geöffneten Zustand im Wesentlichen keilförmig, während sie gemäß einer zweiten Ausführungsform im Wesentlichen quaderförmig ist. Sitzpolster werden üblicherweise mit einem mittleren Bereich, der im Wesentlichen als Sitzfläche dient, und einem Seitenbereich, der über die Seitenkanten des meist metallischen Sitzgestelles gelegt wird, ausgebildet. Gemäß einer Ausführungsform der Erfindung ist die Trennung zwischen Weich- und Hartschaum nur im mittleren Bereich vorgesehen, während der Seitenbereich vollständig aus Weichschaum besteht. Hierdurch kann die Gestaltung der Herstellform vereinfacht werden, da das Netzwerk lediglich im mittleren Bereich aufgespannt werden muss. Es ist jedoch, wie bei einer anderen Ausführungsform vorgesehen, auch möglich, die Trennung zwischen Weich- und Hartschaum sowohl im mittleren Bereich als auch im Seitenbereich vorzusehen.According to a first embodiment, the pocket is essentially wedge-shaped in the open state, while according to a second embodiment it is essentially cuboid. Seat cushions are usually formed with a central area, which essentially serves as a seat, and a side area, which is placed over the side edges of the mostly metallic seat frame. According to one embodiment of the invention, the separation between soft and hard foam is provided only in the central area, while the side area consists entirely of soft foam. This can simplify the design of the manufacturing mold, since the network only has to be spanned in the middle area. However, as provided for in another embodiment, it is also possible to provide the separation between soft and hard foam both in the middle area and in the side area.
Die Erfindung betrifft auch ein Verfahren zur Herstellung eines oben beschriebenen Schaumteiles, wobei zunächst Schaum mit einer ersten Zusammensetzung, insbesondere Weichschaum, in eine Form eingebracht und aufgeschäumt wird, wobei dann ein Netzwerk über dem Schaum angeordnet, insbesondere gespannt wird, und wobei schließlich ein Schaummaterial mit einer zweiten Zusammensetzung, insbesondere Hartschaum, über dem Netzwerk in die Form eingebracht und aufgeschäumt wird.The invention also relates to a method for producing a foam part described above, wherein foam with a first composition, in particular soft foam, is first introduced into a mold and foamed, a network then being arranged, in particular stretched, over the foam, and finally a foam material with a second composition, in particular hard foam, is introduced into the mold and foamed over the network.
Ist das Netzwerk als Tasche ausgebildet, so werden insbesondere die der Oberseite der Form zugewandten Eckpunkte der Tasche am Deckel der Form befestigt und das Schaummaterial mit der zweiten Zusammensetzung in die Tasche eingebracht und dort aufgeschäumt.If the network is designed as a pocket, in particular the corner points of the pocket facing the upper side of the mold are attached to the cover of the mold and the foam material with the second composition is introduced into the pocket and foamed there.
Die Erfindung wird nachfolgend anhand von Ausführungsbeispielen und der Zeichnung näher beschrieben.The invention is described below with reference to exemplary embodiments and the drawing.
Es zeigen: Fig. 1 einen schematischen Teilschnitt durch ein Schaumteil gemäß einer ersten Ausführungsform der Erfindung,Show it: 1 is a schematic partial section through a foam part according to a first embodiment of the invention,
Fig. 2 einen schematischen Teilschnitt durch ein Schaumteil gemäß einer zweiten Ausführungsform der Erfindung,2 shows a schematic partial section through a foam part according to a second embodiment of the invention,
Fig. 3 einen schematischen Teilschnitt durch ein Schaumteil gemäß einer dritten Ausführungsform der Erfindung,3 shows a schematic partial section through a foam part according to a third embodiment of the invention,
Fig. 4 schematisch eine Tasche, die der Aufnahme desFig. 4 schematically shows a bag that the inclusion of the
Hartschaumbereiches dient, undHard foam area serves, and
Fig. 5 eine andere Ausführungsform einer Tasche zur Aufnahme desFig. 5 shows another embodiment of a bag for receiving the
Hartschaumbereiches.Foam area.
Das in den Fig. 1 bis 3 dargestellte Schaumteil 1 aus Polyurethan (PUR) oder dgl. weist einen ersten Bereich 2 aus Weichschaum, und einen darüber angeordneten zweiten Bereich 3 aus Hartschaum auf. Die Eigenschaften der ersten und zweiten Bereiche 2, 3 werden in üblicher Weise dadurch festgelegt, dass dem Polyurethan ein unterschiedlich hoher Isozyanat-Anteil zugegeben wird. Je höher der Isozyanat-Anteil, desto größer die Härte des Schaumes. Anstelle des Isozyanates kann dem Polyurethan selbstverständlich auch jeglicher andere geeignete, die Härteeigenschaften beeinflussender Zusatz zugegeben werden. Es sei darauf hingewiesen, dass die in den Zeichnungen dargestellte Ausrichtung des Schaumteiles der üblichen Herstellung des Schaumteils 1 entspricht, bei der zuerst der Weichschaumbereich und dann darauf der Hart-schaumbereich ausgebildet wird. Bei der Anordnung auf Fahrzeugsitzen wird das Schaumteil 1 umgedreht, so dass der Hartschaumbereich 3 dem meist metallischen Sitzgestell zugewandt ist. Der Fahrer oder Mitfahrer sitzt somit auf dem weichen, bequemen Weichschaumbereich 2.The foam part 1 shown in FIGS. 1 to 3 made of polyurethane (PUR) or the like has a first area 2 made of soft foam and a second area 3 made of hard foam arranged above it. The properties of the first and second areas 2, 3 are determined in the usual way by adding a different amount of isocyanate to the polyurethane. The higher the isocyanate content, the greater the hardness of the foam. Instead of the isocyanate, any other suitable additive which influences the hardness properties can of course also be added to the polyurethane. It should be pointed out that the orientation of the foam part shown in the drawings corresponds to the usual production of the foam part 1, in which the soft foam area is formed first and then the hard foam area. When arranged on vehicle seats, the foam part 1 is turned over so that the hard foam area 3 faces the mostly metallic seat frame. The The driver or passenger sits on the soft, comfortable soft foam area 2.
Zwischen dem ersten Bereich (Weichschaum) 2 und dem zweiten Bereich (Hartschaum) 3 ist ein Netzwerk oder Gewebe 4 aus Polyethylen, Jute, Gaze, Vlies oder dgl. vorgesehen, um die Bereiche voneinander zu trennen. Das Netzwerk ist durchlässig um zum Einen beim Einschäumen den Durchtritt von Gasen zu gestalten und zum Anderen eine Verbindung der beiden Schaumbereiche zu ermöglichen, die beim Aufschäumen durch die Öffnungen des Netzwerkes in geringem Maße auf die jeweils andere Seite durchtreten.Between the first area (soft foam) 2 and the second area (hard foam) 3, a network or fabric 4 made of polyethylene, jute, gauze, fleece or the like is provided in order to separate the areas from one another. The network is permeable, on the one hand to make the passage of gases when foaming in and on the other hand to enable a connection of the two foam areas, which pass through the openings of the network to a small extent on the other side when foaming.
Bei der Ausführungsform gemäß Fig. 1 ist das Schaumteil 1a lediglich in seinem mittleren Bereich 5, der üblicherweise als Sitzfläche dient, durch das Netzwerk 4 in zwei Bereiche 2, 3 unterteilt, während ein Seitenbereich 6, der über die Seitenkanten des Sitzgestells gespannt wird, aus Weichschaum besteht.In the embodiment according to FIG. 1, the foam part 1a is divided into two areas 2, 3 only in its central area 5, which usually serves as a seat, by the network 4, while a side area 6, which is stretched over the side edges of the seat frame, consists of soft foam.
Bei dem Schaumteil 1b gemäß Fig. 2 ist die Trennung zwischen ersten Bereich 2 und dritten Bereich 3 durch das Netzwerk 4 sowohl im mittleren Bereich 5 als auch im Seitenbereich 6 vorgesehen.2, the separation between the first area 2 and the third area 3 by the network 4 is provided both in the middle area 5 and in the side area 6.
Das Netzwerk 4 kann entweder als einfaches Netz ausgebildet sein, das über den ersten Bereich 2 gespannt wird, oder als Tasche 7, wie es in den Fig. 4 und 5 dargestellt ist. Bei der in Fig. 4 dargestellten ersten Ausführungsform einer Tasche 7a weist diese dreieckige Seitenwände 8, 9 auf, so dass die Tasche 7a in geöffnetem Zustand keilförmig ausgebildet ist.The network 4 can either be designed as a simple network, which is stretched over the first area 2, or as a pocket 7, as shown in FIGS. 4 and 5. In the first embodiment of a pocket 7a shown in FIG. 4, it has triangular side walls 8, 9, so that the pocket 7a is wedge-shaped in the open state.
Die in Fig. 5 dargestellte Tasche 7b gemäß der zweiten Ausführungsform ist im Wesentlichen quaderförmig mit rechteckigen Seitenwänden 10, 11 und einem Boden 12 ausgebildet. Die Nähte 13 der Taschen 7a, b sind in Abhängigkeit von dem gewählten Netzwerkmaterial genäht oder geschweißt. Die Herstellung des erfindungsgemäßen Schaumteiles erfolgt, indem zunächst ein Weichschaummaterial in eine Schäumform eingespritzt und durch Erwärmen aufgeschäumt wird. Unmittelbar nach dem Aufschäumen kann die Form geöffnet und das ggf. als Tasche 7a, b ausgebildete Netzwerk 4 über dem Weichschaum 2 gespannt werden. Hierzu kann ein gesonderter Spannrahmen verwendet werden, so dass sich eine dreiteilige Form bestehend aus Unterteil, Spannrahmen und Formdeckel ergibt. Bei Verwendung einer Tasche 7a, b werden die der Formoberseite zugewandten Eckpunkte 15, 16 der Tasche 7a, b am Deckel der Form befestigt und das Hartschaummaterial in die Tasche 7a, b eingespritzt und durch Erwärmen aufgeschäumt. Dies ist in den Fig. 4 und 5 durch den Pfeil X dargestellt. Hierbei kann auf den gesonderten Spannrahmen verzichtet werden. Beim Aufschäumen des Hartschaumes in die Tasche 7a, b wird die Tasche 7a, b im mittleren Bereich aufgeweitet, so dass sich die in Fig. 3 dargestellte ausgebauchte Form des Hart-schaumbereiches 3 ergibt. Somit lässt sich über die Tasche 7a, b eine gewünschte Kontur für den Hartschaumbereich und damit ebenso für den Weichschaumbereich erreichen, durch die die Sitzeigenschaften beeinflusst werden können.The pocket 7b shown in FIG. 5 according to the second embodiment is essentially cuboid with rectangular side walls 10, 11 and a bottom 12. The seams 13 of the pockets 7a, b are sewn or welded depending on the network material selected. The foam part according to the invention is produced by first injecting a soft foam material into a foam mold and foaming it by heating. Immediately after foaming, the mold can be opened and the network 4, which may be designed as a pocket 7a, b, can be stretched over the soft foam 2. A separate clamping frame can be used for this, so that there is a three-part shape consisting of a lower part, clamping frame and molded cover. When using a pocket 7a, b, the corner points 15, 16 of the pocket 7a, b facing the mold top are fastened to the lid of the mold and the rigid foam material is injected into the pocket 7a, b and foamed by heating. This is shown in FIGS. 4 and 5 by the arrow X. The separate tenter frame can be dispensed with here. When the rigid foam is foamed into the pocket 7a, b, the pocket 7a, b is expanded in the central region, so that the bulged shape of the rigid foam region 3 shown in FIG. 3 results. A desired contour for the hard foam area and thus also for the soft foam area can be achieved via the pocket 7a, b, by means of which the seating properties can be influenced.
Das Schaumteil 1 kann nach etwa 4 Minuten entformt werden, wobei es noch eine gallertartige Konsistenz aufweist. Nach ca. 72 Stunden ist das Schaumteil 1 vollständig ausreagiert.The foam part 1 can be removed from the mold after about 4 minutes, it still having a gelatinous consistency. After about 72 hours, the foam part 1 has completely reacted.
Beim Aufschäumen verkrallt sich der Schaum mit dem Netzwerk 4, so dass eine zuverlässige Verbindung zwischen den ersten und zweiten Bereichen 2, 3 erreicht wird, ohne dass eine zusätzliche Klebung erforderlich wäre.When foaming, the foam clings to the network 4, so that a reliable connection between the first and second regions 2, 3 is achieved without additional gluing being necessary.
Mit der Erfindung wird somit eine wirtschaftliche Herstellung eines horizontalen Zweizonenschaumes ohne Verlängerung der Prozesszeiten beim Schäumvorgang und mit genauer Zonentrennung zwischen den harten und weichen Bereichen ermöglicht. With the invention is thus an economical production of a horizontal two-zone foam without extending the process times Foaming process and with precise zone separation between the hard and soft areas.
BezugszeichenlisteLIST OF REFERENCE NUMBERS
1 Schaumteil1 foam part
2 erster Bereich2 first area
3 zweiter Bereich3 second area
4 Netzwerk4 network
5 mittlerer Bereich5 middle area
6 Seitenbereich6 side area
7a,b Tasche7a, b pocket
8 Seitenwand8 side wall
9 Seitenwand9 side wall
10 Seitenwand10 side wall
11 Seitenwand11 side wall
12 Boden12 bottom
13 Naht13 seam
14 Naht14 seam
15 Eckpunkt15 corner point
16 Eckpunkt 16 corner point

Claims

Patentansprüche claims
1. Schaumteil aus Polyurethan oder dgl., insbesondere zur Verwendung als Auflage für Rückenlehnen, Sitzflächen oder dgl. von Fahrzeugsitzen, mit einem ersten Bereich (2) aus Schaum mit einer ersten Zusammensetzung und einem zweiten Bereich (3) aus Schaum mit einer zweiten Zusammensetzung, dadurch gekennzeichnet, dass zwischen dem ersten und dem zweiten Bereich (2, 3) ein Netzwerk (4) aus Polyethylen, Jute, Gaze, Vlies oder dgl. angeordnet ist.1. Foam part made of polyurethane or the like, in particular for use as a support for backrests, seats or the like of vehicle seats, with a first area (2) made of foam with a first composition and a second area (3) made of foam with a second composition , characterized in that a network (4) made of polyethylene, jute, gauze, fleece or the like is arranged between the first and the second region (2, 3).
2. Schaumteil nach Anspruch 1, dadurch gekennzeichnet, dass die durch das Netzwerk (4) gebildete Trennungsebene in einer horizontalen Ebene des Schaumteils (1) liegt.2. Foam part according to claim 1, characterized in that the separation plane formed by the network (4) lies in a horizontal plane of the foam part (1).
3. Schaumteil nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das Netzwerk (4) als Tasche (7a, b) ausgebildet ist, in die der zweite Bereich (3) eingeschäumt ist.3. Foam part according to claim 1 or 2, characterized in that the network (4) is designed as a pocket (7a, b) into which the second region (3) is foamed.
4. Schaumteil nach Anspruch 3, dadurch gekennzeichnet, dass die Tasche (7a) in geöffnetem Zustand im Wesentlichen keilförmig ist.4. foam part according to claim 3, characterized in that the pocket (7a) is substantially wedge-shaped in the open state.
5. Schaumteil nach Anspruch 3, dadurch gekennzeichnet, dass die Tasche (7b) im Wesentlichen quaderförmig ist.5. foam part according to claim 3, characterized in that the pocket (7b) is substantially cuboid.
6. Schaumteil nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der erste Bereich (2) ein Weichschaum ist und dass der zweite Bereich (3) ein Hartschaum ist.6. Foam part according to one of the preceding claims, characterized in that the first region (2) is a soft foam and that the second region (3) is a rigid foam.
7. Schaumteil nach einem der vorhergehenden Ansprüche mit einem mittleren Bereich (5), der im Wesentlichen als Sitzfläche dient, und einem Seitenbereich (6) zur Befestigung am Fahrzeugsitz, dadurch gekennzeichnet, dass die Trennung zwischen Weich- und Hartschaum nur im mittleren Bereich7. foam part according to one of the preceding claims with a central region (5), which essentially serves as a seat, and a side region (6) for attachment to the vehicle seat, characterized in that that the separation between soft and hard foam only in the middle area
(5) vorgesehen ist, und dass der Seitenbereich (6) aus Weichschaum besteht.(5) is provided, and that the side region (6) consists of soft foam.
8. Schaumteil nach einem der Ansprüche 1 bis 6, mit einem mittleren Bereich (5), der im Wesentlichen als Sitzfläche dient, und einem Seitenbereich8. foam part according to one of claims 1 to 6, with a central region (5), which essentially serves as a seat, and a side region
(6) zur Befestigung am Fahrzeugsitz, dadurch gekennzeichnet, dass die Trennung zwischen Weich- und Hartschaum sowohl im mittleren Bereich (5) als auch im Seitenbereich (6) vorgesehen ist.(6) for attachment to the vehicle seat, characterized in that the separation between soft and hard foam is provided both in the central area (5) and in the side area (6).
9. Verfahren zur Herstellung eines Schaumteils nach einem der vorhergehenden Ansprüche, wobei ein Schaum mit einer ersten Zusammensetzung, insbesondere ein Weichschaum, in eine Form eingebracht und aufgeschäumt wird, wobei ein Netzwerk über den Schaum angeordnet, insbesondere gespannt wird und wobei ein Schaummaterial mit einer zweiten Zusammensetzung, insbesondere ein Hartschaum, über dem Netzwerk in die Form eingebracht und aufgeschäumt wird.9. A method for producing a foam part according to one of the preceding claims, wherein a foam with a first composition, in particular a soft foam, is introduced and foamed into a mold, a network being arranged over the foam, in particular stretched, and wherein a foam material with a second composition, in particular a rigid foam, is introduced into the mold and foamed over the network.
10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass das Netzwerk als Tasche ausgebildet wird, dass die der Oberseite der Form zugewandten Eckpunkte der Tasche am Deckel der Form befestigt werden und dass das Schaummaterial in der zweiten Zusammensetzung in die Tasche eingebracht und dort aufgeschäumt wird. 10. The method according to claim 9, characterized in that the network is designed as a pocket, that the corner points of the pocket facing the top of the mold are attached to the cover of the mold and that the foam material is introduced into the pocket and foamed there in the second composition ,
EP01931544A 2000-04-03 2001-03-23 Foam part and method for producing the same Withdrawn EP1268153A1 (en)

Applications Claiming Priority (3)

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DE10016350 2000-04-03
DE10016350A DE10016350A1 (en) 2000-04-03 2000-04-03 Foam part and process for its production
PCT/EP2001/003303 WO2001074557A1 (en) 2000-04-03 2001-03-23 Foam part and method for producing the same

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EP01931544A Withdrawn EP1268153A1 (en) 2000-04-03 2001-03-23 Foam part and method for producing the same

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EP (2) EP1142683B1 (en)
AT (1) ATE359162T1 (en)
AU (1) AU2001258293A1 (en)
DE (3) DE10016350A1 (en)
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DE50112309D1 (en) 2007-05-24
WO2001074557A1 (en) 2001-10-11
ATE359162T1 (en) 2007-05-15
EP1142683A2 (en) 2001-10-10
DE10016350A1 (en) 2001-10-31
DE20014059U1 (en) 2001-08-16
EP1142683B1 (en) 2007-04-11
EP1142683A3 (en) 2002-06-05
AU2001258293A1 (en) 2001-10-15
US20030180513A1 (en) 2003-09-25

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