WO2024047304A1 - Method for manufacturing seat padding and padding associated therewith - Google Patents

Method for manufacturing seat padding and padding associated therewith Download PDF

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Publication number
WO2024047304A1
WO2024047304A1 PCT/FR2023/051255 FR2023051255W WO2024047304A1 WO 2024047304 A1 WO2024047304 A1 WO 2024047304A1 FR 2023051255 W FR2023051255 W FR 2023051255W WO 2024047304 A1 WO2024047304 A1 WO 2024047304A1
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WO
WIPO (PCT)
Prior art keywords
padding
fibers
seat
curtain
entanglement
Prior art date
Application number
PCT/FR2023/051255
Other languages
French (fr)
Inventor
Mathieu Cluet
Benoît GAZANIOL
Original Assignee
Faurecia Sièges d'Automobile
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 Faurecia Sièges d'Automobile filed Critical Faurecia Sièges d'Automobile
Publication of WO2024047304A1 publication Critical patent/WO2024047304A1/en

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Classifications

    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/255—Flow control means, e.g. valves
    • B29C48/2556—Flow control means, e.g. valves provided in or in the proximity of dies
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/345—Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/771—Seats
    • 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

Definitions

  • the present disclosure relates to a method of manufacturing a seat cushion comprising a 3D tangle of continuous thermoplastic fibers arranged irregularly, typically randomly.
  • the present disclosure also relates to a seat padding typically obtained by such a manufacturing process, as well as a seat comprising such padding.
  • the present disclosure relates to the field of automobile vehicle seats which comprise a typically metallic structure, typically with a seat frame and a backrest frame.
  • the structure is classically obtained by stamping techniques.
  • the seats still have padding, including a layer of seat padding and a layer of back padding which provide softness to the seat and back, and contribute to comfort in the seat.
  • the seat and back paddings are conventionally made of urethane polymer foam, and shaped in molds. Polyurethane foam padding is satisfactory, but can retain moisture in humid conditions.
  • a process for manufacturing a seat cushion such as a seat or back cushion, in which the cushion is obtained comprising a 3D tangle of continuous thermoplastic fibers. arranged irregularly forming loops welded together by:
  • thermoplastic polymer in an extrusion die comprising extrusion nozzles distributed in a lengthwise direction and in a widthwise direction of the extrusion die, generating a curtain of melted, falling continuous fibers by gravity,
  • said molding cavity may comprise a bottom and sides, and in which the bottom is a bottom having projecting and/or recessed reliefs;
  • the nozzles can be controllable, configured so as to be able to change the shape of the curtain of fibers, and in which a logic processing unit is provided comprising a control module comprising a microprocessor and a memory comprising instructions for, in /A/ , control the nozzles so as to generate a curtain of molten fibers, of variable shape during extrusion following the length direction X and/or the width direction Y of the extrusion die;
  • said logic unit controls the nozzles so as in /B/ to fill the relief(s) in the hollow of the mold, prior to the relief(s) projecting from the molding tool.
  • the bottom of the molding cavity may comprise:
  • a central portion following a projecting relief, configured to conform a central part of a front face of the padding facing the occupant of the seat intended to receive the user's buttocks for the seat padding or the back of the occupant for a back padding, and - lateral portions, on either side, of the central portion, following two hollow reliefs, configured so as to form two side flanges of the padding, projecting from the central part, on the front face, the side flanges configured to ensure lateral support for the occupant.
  • the logic unit controls the nozzles so as to generate a curtain of fibers located on a central portion of the molding tooling, so as to form on a dorsal face of the padding, opposite the front face, a central portion, of a seat padding, projecting relative to lateral portions of the dorsal face, located on the back of the two side flanges.
  • the solidification of the 3D tangle of fibers is obtained by immersion in a cooling liquid with control of the movement of the molding tool relative to a free surface of the coolant, for example by immersing the molding tooling in the coolant, and in which, for example, the free surface is moved in a motorized manner in order to obtain the solidification of the 3D entanglement by immersion in the coolant.
  • cooling liquid subsequent to reception of the curtain of melted continuous fibers falling by gravity into a molding cavity, and for example following a duration of less than 4 seconds between reception of the curtain of fiber generating the 3D entanglement, and immersion of 3D entanglement.
  • the padding may have all or part of the following characteristics:
  • the fibers have a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
  • the 3D tangle of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , for example between 45 kg/m 3 and 65 kg/m 3 ,
  • the composition of the fibers comprises at least 95% by weight of PET, and for example the fiber composition comprises by weight, 95% to 99% of PET, 1% to 5% of a second polymer distinct from PET such as PTT or PBT.
  • the nozzles may comprise nozzles configured to generate hollow fibers and solid fibers, and in which possibly the logic processing unit controls the nozzles to change over time the nature of the fibers of the curtain, namely solid fibers, for example over a first period of extrusion, then hollow fibers over a second period of extrusion.
  • the present disclosure relates to a seat or back padding of a seat capable of being obtained according to the method of the present disclosure, the padding comprising a 3D tangle of continuous thermoplastic fibers arranged irregularly, typically randomly, forming loops welded together between the fibers, and in which:
  • the fibers are hollow fibers and/or solid fibers, with a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
  • composition of the fibers comprising at least 95% by weight of PET
  • the 3D entanglement of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , and for example between 45 kg/m 3 and 65 kg/m 3 , and in which the 3D entanglement of continuous fibers has a front face conforming to a molding cavity of a molding tool.
  • the present disclosure relates to a vehicle seat comprising:
  • a typically metallic structure comprising a seat structure and/or a back structure
  • a padding such as a back padding or a seat padding, resting on the structure
  • the shaped face comprises a central part, and two projecting side flanges intended to ensure lateral support of the occupant.
  • the dorsal face opposite the front face, comprises a central portion, projecting relative to two portions sides of the padding, and in which:
  • the central portion of the dorsal face is inserted between two puddles of the seat structure while the two lateral portions respectively rest on the two flanges, and/or
  • the central portion of the dorsal face is inserted between two uprights of the backrest structure while the two lateral portions come to rest respectively on the two uprights.
  • FIG. 1 shows is a view of equipment configured for implementing the method according to the present disclosure, comprising:
  • an extrusion die comprising nozzles distributed in a lengthwise direction and in a width (transverse) direction of the extrusion die, generating a curtain of melted continuous fibers, falling by gravity,
  • a molding tool comprising a molding cavity, open towards the extrusion die, directly above the die, configured to receive the curtain of melted continuous fibers falling by gravity into the molding cavity of the molding tool molding so as to generate a 3D tangle of fibers in an irregular or random distribution with fusion of loops between the continuous fibers,
  • a logic processing unit comprising a control module having a microprocessor and a memory configured for controlling the extrusion nozzles, and controlling the descent of the molding tool into the cooling liquid, in a motorized manner .
  • FIG. 2A illustrates a first phase of the process for which the logic unit controls the nozzles so as to fill only the hollow reliefs of the molding cavity, on either side of a central portion of the molding cavity, the nozzles of the extrusion die located to the right of the projecting relief on the central portion of the molding cavity being kept closed by the logic unit.
  • FIG. 2B shows a second phase, consecutive to the first phase, for which the logic unit opens all of the extrusion nozzles so that the curtain of molten fibers fills the entire surface of the molding cavity in the direction longitudinal and in the transverse direction of the molding cavity.
  • FIG. 2C shows a third phase, consecutive to the second phase, for which the logic unit only opens nozzles so that the curtain of molten fibers fills the central portion of the molding tool located between the two hollow reliefs, in seen to form on the dorsal face of the padding, a central portion projecting relative to two lateral portions of the dorsal face.
  • FIG. 2D shows on the left a moment of the third phase consecutive to Figure 2C, and on the right, after demolding, a padding formed from a 3D tangle of fibers in a typically random irregular distribution with fusion of loops between the continuous fibers, the padding having a front face shaped by the molding cavity of the molding tool, and a back face not shaped by the molding tool.
  • FIG. 3 shows a seat structure, comprising:
  • a seat structure comprising two flanges extending in parallel from a rear edge of the seat and to a front edge of the seat, as well as spacers between flanges, and, - a backrest structure comprising two uprights, extending in parallel, from a rear portion of the seat to an upper crosspiece of the backrest structure.
  • FIG. 4 is a view of the assembly of a seat padding on the seat structure, the padding having on its dorsal face a central portion interposed between two flanges of the seat structure and lateral portions respectively resting on the flanges, the padding fixed to the structure by a cap covering the front face molded by the tooling.
  • FIG. 5 is a view of a seat structure comprising:
  • a seat structure comprising two flanges extending in parallel from a rear edge of the seat and to a front edge of the seat, as well as spacers between flanges, and notably a metal suspension extending in support between a front spacer and a rear spacer,
  • a backrest structure comprising two uprights, extending in parallel, from a rear portion of the seat to an upper crosspiece of the backrest structure, and notably, a metal suspension extending between the two uprights of the folder structure.
  • FIG. 6 is a view of the assembly of a seat padding on the seat structure via a support between the padding and the structure.
  • the present disclosure firstly concerns equipment configured for implementing the method according to the present disclosure, comprising: - an extrusion die 2 comprising nozzles 20 distributed along a length direction X and along a width direction Y (transverse) of the extrusion die, configured to generate a curtain of melted continuous fibers, falling by gravity,
  • a molding tool OM comprising a molding cavity CAV, open towards the extrusion die 2, directly above the extrusion die, the tool being configured to receive the curtain R of melted continuous fibers falling through gravity in the CAV molding cavity of the OM molding tool so as to generate a 3D entanglement of fibers according to an irregular distribution, typically obtained randomly, with fusion of loops between the continuous fibers,
  • a logic processing unit U comprising a microprocessor and a memory containing control instructions.
  • the instructions can be configured for controlling the extrusion nozzles, or even controlling the descent of the molding tool in a motorized manner, along guide G.
  • the length direction X and the width direction Y typically extend along a horizontal plane; the molding tooling being typically positioned vertically above the extrusion die.
  • the molding cavity extends between flanks FI1, FI2, FI3, FL4, in particular two end flanks FI1 and FI3 at two longitudinal ends of the molding tool, spaced along the length direction two lateral flanks on the sides of the mold spaced in the width direction Y.
  • the extrusion nozzles 20 are distributed along the length direction X and along the width direction Y of the extrusion die.
  • the nozzles 20 are configured in a matrix to generate, at least temporarily, a curtain of molten continuous fibers covering the entire surface of the molding cavity, extending from one side of the mold to the other, namely a curtain extending from one end flank FI1 to the other end flank FI2 in the length direction X and extending from one side flank FL2 to the other side flank FL4 in the width direction Y.
  • the nozzles can advantageously be controllable (individually, or at least in subgroups), configured so as to be able to change the shape of the curtain of fibers, in particular along the longitudinal direction X and/or or along the transverse direction Y.
  • control of the nozzles individually or at the very least in subgroups can allow the development of 3D entanglements of complex shape, and according to an embodiment based on a mode of additive manufacturing inspired by stereolithography.
  • Said processing logic unit U then preferably comprises a control module typically comprising a microprocessor and a memory comprising instructions for, in /A/, controlling the nozzles so as to generate a curtain of fibers, of variable shape at course of the extrusion, in particular variable in the longitudinal direction Z, which can be variable in the longitudinal direction X, and/or variable in the transverse direction Y in the molding tool.
  • a control module typically comprising a microprocessor and a memory comprising instructions for, in /A/, controlling the nozzles so as to generate a curtain of fibers, of variable shape at course of the extrusion, in particular variable in the longitudinal direction Z, which can be variable in the longitudinal direction X, and/or variable in the transverse direction Y in the molding tool.
  • the padding to be manufactured can typically be designed and determined by CAD software in a given format, then can be exported in a format such as STL format.
  • the STL file is transmitted to the control module of the logic unit U.
  • the control module cuts the padding into slices of typically fixed thickness in the vertical direction Z. During manufacturing, the control module controls the nozzles of the extrusion die to successively produce the different sections of the padding.
  • Figures 2A to 2D illustrate by way of example, different views of the filling of the molding tool during extrusion with a view to obtaining a padding, of complex shape, which has a face FF front (molded by the molding cavity) notably comprising lateral flanges Bl projecting relative to a central part PC of the front face FL.
  • Such a geometry of the front face makes it possible to obtain by molding a cushioning geometry, in particular of the seat or backrest, guaranteeing good lateral support for the occupant.
  • the padding may include a dorsal face FD (not molded by the molding cavity) comprising a central portion PCE projecting relative to the lateral portions PL.
  • the central PCE portion can typically have a thickness of between 20 mm and 120 mm.
  • Such a geometry of the dorsal face FD can be configured to rest against a seat structure, and in particular advantageously without having to use an intermediate plastic shell between the padding and the structure to allow its integration.
  • the present disclosure relates to a process for manufacturing a MAT seat cushion, such as a seat or back cushion, and in which the cushion is obtained comprising a 3D entanglement, referenced 1, of continuous thermoplastic fibers arranged irregularly or randomly forming loops welded together by:
  • thermoplastic polymer in the extrusion die 2 comprising extrusion nozzles 20 distributed in a length direction X and in a width direction Y of the extrusion die, generating a curtain R of continuous melted fibers, falling by gravity,
  • the temperature of the extrusion carried out in /A/ in the extrusion die can be between 180°C and 240°C.
  • the extrusion die is typically supplied with thermoplastic granules.
  • the fibers can have a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm.
  • the 3D tangle of the MAT padding can have an apparent density of between 20 kg/m 3 and 70 kg/m 3 , for example between 45 kg/m 3 and 65 kg/m 3 .
  • the composition of the fibers may comprise at least 95% by weight of PET, and for example the fiber composition comprises by weight, 95% to 99% of PET, 1% to 5% of a second polymer distinct from PET such as PTT or PBT.
  • the padding obtained after demolding of the tooling has a front face FF molded by the molding cavity CAV, and a back face not molded by the molding cavity .
  • the sides of the padding can be molded by the sides of the molding cavity.
  • the molded front face FF advantageously has a higher surface finish than the back face (of better quality) and is typically turned towards the occupant of the seat.
  • the cover preferably covers the front face FF molded by the tooling, and as illustrated for information purposes in Figure 4. In other words the cover does not does not cover the dorsal surface which has a more irregular surface condition.
  • the bottom F of the molding cavity is a bottom having projecting and recessed reliefs RS, RC.
  • Figures 2A to 2B disclose by way of example, a mold section along a plane YX, having a bottom with a projecting relief RS on a central portion of the section, and two hollow reliefs RC, on either side and on the other side of this central portion in the Y direction.
  • Such hollow reliefs can be shaped for the molding of the side flanges Bl. These side flanges project relative to a central part PC of the padding from the front face FF.
  • said logic unit controls the nozzles so as in /B/ to fill the hollow relief(s) RC of the tooling with molding, prior to the projecting relief(s) RS of the molding tool.
  • the extrusion begins, during a first phase, by the generation of a curtain of fibers melted into two distinct parts which only fill the two hollow reliefs RC for the molding of the tubes lateral, and not a central part of the tools between these two reliefs.
  • Figure 2B is a consecutive view of the extrusion which shows a second phase consecutive to the first phase for which the logic unit U opens all of the nozzles so that the curtain fills the entire section, cavity molding, namely not only the projecting relief RS on the central part, but the two hollow reliefs.
  • the bottom of the mold can comprise:
  • a central portion following a projecting relief RS, configured to conform a central part PC of a front face FF of the padding facing the occupant of the seat intended to receive the user's buttocks for the seat padding or the back of the occupant for backrest padding, and
  • the logic unit U controls the nozzles 20 so as to generate in /A/ a curtain of fibers located on a portion central part of the molding tool, so as to form on a dorsal face FD of the padding, opposite the front face, a central portion PCE projecting relative to lateral portions PL of the dorsal face FD, located on the back of the two BL side flanges.
  • Such a geometry of the dorsal face FD, comprising a central portion PCE projecting (in the direction Z) relative to lateral portions PL can allow integration of the padding MT on the structure 3, and as illustrated for indicative in Figure 4, directly, i.e. without using an intermediate plastic shell to allow integration.
  • the free surface SL can be moved in a motorized manner in order to obtain the solidification of the 3D entanglement by immersion in the cooling liquid LF, progressively during additive manufacturing, subsequent to receipt of the curtain of melted continuous fibers falling by gravity into the molding cavity, and preferably following a duration of less than 4s between reception of the curtain of fibers generating the 3D entanglement, and immersion of the 3D entanglement.
  • the motorized movement of the molding tool OM relative to the free surface SD of the cooling liquid can be obtained by immersing the molding tool OM in a motorized manner in a reservoir containing the liquid. cooling.
  • the processing logic unit U in particular its control module, can control and synchronize the control of the nozzles 20 and the motorized movement of the free surface SL of the cooling liquid.
  • the nozzles 20 may comprise nozzles 20 configured to generate hollow fibers and/or nozzles configured to generate solid fibers.
  • the logic processing unit can also optionally control the nozzles to change over time the nature of the fibers of the curtain, namely for example solid fibers, for example over a first period of extrusion, then hollow fibers over a second period of extrusion.
  • Full fibers can preferably be used, superficially on the front face FF intended to be in contact with the occupant of the seat in order to form a first “soft” layer, and preferably hollow, “structural” fibers on the the remainder of the thickness of the padding below this first layer to form a structural underlay.
  • the present disclosure also relates to a MAT padding for the seat or back of a seat suitable for being obtained according to the method according to the present disclosure.
  • the MAT padding comprises a 3D tangle of continuous thermoplastic fibers arranged irregularly, randomly, forming loops welded together between the fibers, and in which:
  • the fibers are hollow fibers and/or solid fibers, for example with a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
  • the composition of the fibers comprising in particular at least 95% by weight of PET
  • the 3D entanglement of the padding has an apparent density for example between 20kg/m 3 and 70 kg/m 3 , and for example between 45 kg /m 3 and 65 kg/m 3 .
  • continuous fibers in “continuous fibers” is meant the fact that the fibers are of length much greater than the diameter of the fibers, and due to the process which is described above, typically at least by a ratio 100, even 500, even 1000.
  • the fibers typically extend from a first end on a first edge of the 3D entanglement and to a second end on a second edge of the AD entanglement , opposite the first edge.
  • the 3D tangle of continuous fibers has a front face FF conforming to a molding cavity CAV of a molding tool OM, whereas the dorsal face FD is not conforming to a molding cavity .
  • the present disclosure also relates to a vehicle seat comprising:
  • a typically metallic structure 3 comprising a seat structure 3A and/or a backrest structure 3B,
  • a MAT padding such as a back padding or a seat padding, resting on the structure
  • the seat padding preferably extends:
  • the back padding preferably extends:
  • the shaped front face FF may comprise a central part PC, and two projecting lateral flanges BL intended to ensure lateral support of the occupant.
  • the dorsal face FD opposite the front face FF, can comprise a central portion PCE, projecting relative to two lateral portions PL of the padding, and in which:
  • the central portion PCE of the dorsal face is inserted between the two puddles 31 of the seat structure 3A while the two lateral portions PL respectively come to rest on the two flanges 31,
  • the central portion PCE of the dorsal face is inserted between the two uprights 32 of the back structure 3B while the two lateral portions PL respectively bear on the two uprights 32.
  • the lateral portions PL, on the dorsal face can respectively have grooves, on the back of the lateral flange BL, inside which the flanges 31 of the seat padding can fit, or even the uprights of the back padding.
  • Such grooves used to fit the structure together contribute to the correct centering of the padding on the structure 3.
  • the cover can be fixed on the structure 3 and in particular so as to ensure that the MT padding is maintained on the structure 3.
  • the padding in particular for the backrest or seat, can be assembled on the seat structure, supported on a SUP suspension and as illustrated in Figure 5.
  • the seat structure 3A can thus include a suspension, typically metallic, connecting a front spacer and a rear spacer of the seat structure.
  • the backrest structure 3B can thus include a suspension, typically metallic, connecting the uprights of the backrest structure.
  • the padding can be associated with an ST support, typically pre-assembled with the padding, and which is configured to allow the assembly of the padding on the seat structure via ST Support.

Abstract

The present disclosure relates to a method for manufacturing seat padding, wherein the padding obtained comprises a 3D entanglement of randomly arranged continuous thermoplastic fibres forming loops that are welded together, which method comprises the steps of: - /A/ extruding a thermoplastic polymer through an extrusion die (2) comprising extrusion nozzles (20) distributed along a lengthwise direction and along a widthwise direction of the extrusion die, causing a curtain (R) of melted continuous fibres to fall by gravity, - /B/ receiving the curtain of melted continuous fibres that fall by gravity in a moulding cavity (CAV) of a moulding tool (OM) so as to generate a 3D entanglement of the fibres according to an irregular or random distribution with fused loops between the continuous fibres, - /C/ solidifying the 3D fibre entanglement conformed to the shape of the moulding cavity by immersing it in a cooling liquid.

Description

Description Description
Titre : Procédé de fabrication d’une matelassure de siège et matelassure en tant que telle Title: Process for manufacturing seat cushioning and cushioning as such
[0001] La présente divulgation est relative à un procédé de fabrication d’une matelassure de siège comprenant un enchevêtrement 3D de fibres thermoplastiques, continues disposées irrégulièrement, typiquement aléatoirement. [0001] The present disclosure relates to a method of manufacturing a seat cushion comprising a 3D tangle of continuous thermoplastic fibers arranged irregularly, typically randomly.
[0002] La présente divulgation concerne encore une matelassure de siège typiquement obtenue par un tel procédé de fabrication, ainsi qu’un siège comprenant une telle matelassure. [0002] The present disclosure also relates to a seat padding typically obtained by such a manufacturing process, as well as a seat comprising such padding.
Domaine technique Technical area
[0003] La présente divulgation relève du domaine des sièges de véhicules automobiles qui comprennent une structure typiquement métallique, avec typiquement un châssis d’assise et un châssis de dossier. La structure est classiquement obtenue par les techniques d’emboutissage. Les sièges comportent encore des matelassures, y compris une couche de matelassure d’assise et une couche de matelassure de dossier qui confèrent le moelleux de l’assise et du dossier, et participent au confort au siège. [0003] The present disclosure relates to the field of automobile vehicle seats which comprise a typically metallic structure, typically with a seat frame and a backrest frame. The structure is classically obtained by stamping techniques. The seats still have padding, including a layer of seat padding and a layer of back padding which provide softness to the seat and back, and contribute to comfort in the seat.
Technique antérieure Prior art
[0004] Les matelassures d’assise et de dossier sont classiquement en mousse de polymère d'uréthane, et mises en forme dans des moules. Les matelassures en mousse de polyuréthane donnent satisfaction, mais peuvent en condition humide, conserver l’humidité. [0004] The seat and back paddings are conventionally made of urethane polymer foam, and shaped in molds. Polyurethane foam padding is satisfactory, but can retain moisture in humid conditions.
Résumé Summary
[0005] La présente divulgation vient améliorer la situation. [0005] This disclosure improves the situation.
[0006] Il est proposé, selon un premier aspect, un procédé de fabrication d’une matelassure de siège, telle qu’une matelassure d’assise ou de dossier, dans lequel on obtient la matelassure comprenant un enchevêtrement 3D de fibres thermoplastiques, continues disposées irrégulièrement formant des boucles soudées entre elles par : [0006] According to a first aspect, a process for manufacturing a seat cushion, such as a seat or back cushion, is proposed, in which the cushion is obtained comprising a 3D tangle of continuous thermoplastic fibers. arranged irregularly forming loops welded together by:
- /A/ Extrusion d’un polymère thermoplastique dans une filière d’extrusion comprenant des buses d’extrusion réparties suivant une direction en longueur et suivant un direction en largeur de la filière d’extrusion, générant un rideau de fibres continues fondues, chutant par gravité, - /A/ Extrusion of a thermoplastic polymer in an extrusion die comprising extrusion nozzles distributed in a lengthwise direction and in a widthwise direction of the extrusion die, generating a curtain of melted, falling continuous fibers by gravity,
- /B/ Réception du rideau de fibres continues fondues chutant par gravité dans une cavité de moulage d’un outillage de moulage de sorte à générer un enchevêtrement 3D de fibres selon une répartition irrégulière, typiquement aléatoire, avec fusion de boucles entre les fibres continues, - /B/ Receiving the curtain of melted continuous fibers falling by gravity into a molding cavity of a molding tool so as to generate a 3D entanglement of fibers in an irregular, typically random distribution, with fusion of loops between the continuous fibers ,
- /C/ Solidification de l’enchevêtrement 3D de fibres conformé à la cavité de moulage par immersion dans un liquide de refroidissement. - /C/ Solidification of the 3D tangle of fibers conforming to the molding cavity by immersion in a cooling liquid.
[0007] Les caractéristiques exposées dans les paragraphes suivants peuvent, optionnellement, être mises en œuvre. Elles peuvent être mises en œuvre indépendamment les unes des autres ou en combinaison les unes avec les autres :[0007] The characteristics set out in the following paragraphs can optionally be implemented. They can be implemented independently of each other or in combination with each other:
- ladite cavité de moulage peut comprendre un fond et des flancs , et dans lequel le fond est un fond présentant des reliefs en saillie et/ou en creux ; - said molding cavity may comprise a bottom and sides, and in which the bottom is a bottom having projecting and/or recessed reliefs;
- les buses peuvent être pilotables, configurées de sorte à pouvoir changer la forme du rideau de fibres, et dans lequel on fournit une unité logique de traitement comprend un module de commande comprenant un microprocesseur et une mémoire comprenant des instructions pour, en /A/, piloter les buses de sorte à générer un rideau de fibres fondues, de forme variable au cours du l’extrusion suivant la direction en longueur X et/ou la direction en largeur Y de la filière extrusion ; - the nozzles can be controllable, configured so as to be able to change the shape of the curtain of fibers, and in which a logic processing unit is provided comprising a control module comprising a microprocessor and a memory comprising instructions for, in /A/ , control the nozzles so as to generate a curtain of molten fibers, of variable shape during extrusion following the length direction X and/or the width direction Y of the extrusion die;
- en /A/ ladite unité logique pilote les buses de sorte en /B/ à garnir le ou les relief(s) en creux du moule, préalablement au(x) relief(s) en saillie de l’outillage de moulage. - in /A/ said logic unit controls the nozzles so as in /B/ to fill the relief(s) in the hollow of the mold, prior to the relief(s) projecting from the molding tool.
[0008] Selon un mode de réalisation, le fond de la cavité de moulage peut comprendre : [0008] According to one embodiment, the bottom of the molding cavity may comprise:
- une portion centrale, suivant un relief en saillie, configurée pour conformer une partie centrale d’une face frontale de la matelassure tournée vers l’occupant du siège destinée à recevoir le fessier de l’utilisateur pour la matelassure d’assise ou le dos de l’occupant pour une matelassure de dossier, et - des portions latérales, de part et d’autre, de la portion centrale, suivant deux reliefs en creux, configurés de sorte à former deux boudins latéraux de la matelassure, en saillie de la partie centrale, sur la face frontale, les boudins latéraux configurés pour assurer un maintien latéral de l’occupant. - a central portion, following a projecting relief, configured to conform a central part of a front face of the padding facing the occupant of the seat intended to receive the user's buttocks for the seat padding or the back of the occupant for a back padding, and - lateral portions, on either side, of the central portion, following two hollow reliefs, configured so as to form two side flanges of the padding, projecting from the central part, on the front face, the side flanges configured to ensure lateral support for the occupant.
[0009] Selon un mode de réalisation du procédé, en /A/, au moins sur une phase finale de l’extrusion, l’unité logique pilote les buses de sorte à générer un rideau de fibres localisé sur une portion centrale de l’outillage de moulage, de sorte à former sur une face dorsale de la matelassure, opposée à la face frontale, une portion centrale, d’une matelassure d’assise, saillante par rapport à des portions latérales de la face dorsale, situés au dos des deux boudins latéraux. [0009] According to one embodiment of the method, in /A/, at least in a final phase of the extrusion, the logic unit controls the nozzles so as to generate a curtain of fibers located on a central portion of the molding tooling, so as to form on a dorsal face of the padding, opposite the front face, a central portion, of a seat padding, projecting relative to lateral portions of the dorsal face, located on the back of the two side flanges.
[0010] Selon un mode de réalisation du procédé, en /C/, on obtient la solidification de l’enchevêtrement 3D de fibres par immersion dans un liquide de refroidissement avec contrôle du déplacement de l’outillage de moulage par rapport à une surface libre du liquide de refroidissement, par exemple en plongeant l’outillage de moulage dans le liquide de refroidissement, et dans lequel, par exemple, la surface libre est déplacée de manière motorisée afin d’obtenir la solidification de l’enchevêtrement 3D par immersion dans le liquide de refroidissement, postérieurement à la réception du rideau de fibres continues fondues chutant par gravité dans une cavité de moulage, et par exemple suivant une durée inférieure à 4 secondes entre la réception du rideau du fibre générant l’enchevêtrement 3D, et l’immersion de l’enchevêtrement 3D. [0010] According to one embodiment of the method, in /C/, the solidification of the 3D tangle of fibers is obtained by immersion in a cooling liquid with control of the movement of the molding tool relative to a free surface of the coolant, for example by immersing the molding tooling in the coolant, and in which, for example, the free surface is moved in a motorized manner in order to obtain the solidification of the 3D entanglement by immersion in the coolant. cooling liquid, subsequent to reception of the curtain of melted continuous fibers falling by gravity into a molding cavity, and for example following a duration of less than 4 seconds between reception of the curtain of fiber generating the 3D entanglement, and immersion of 3D entanglement.
[0011] De manière générale, la matelassure peut présenter tout ou partie des caractéristiques suivantes : [0011] Generally speaking, the padding may have all or part of the following characteristics:
- les fibres sont de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm, - the fibers have a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
- l’enchevêtrement 3D de la matelassure présente une masse volumique apparente comprise entre 20kg/m3 et 70 kg/m3, par exemple entre 45 kg/m3 et 65 kg/m3,- the 3D tangle of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , for example between 45 kg/m 3 and 65 kg/m 3 ,
- la composition des fibres comprend au moins 95% en poids de PET, et par exemple la composition en fibre comprend en poids, 95% à 99% de PET, 1 % à 5% d’un second polymère distinct du PET tel que PTT ou PBT. [0012] De manière générale, les buses peuvent comprendre des buses configurées pour générer des fibres creuses et des fibres pleines, et dans lequel éventuellement l’unité logique de traitement pilote les buses pour changer au cours du temps la nature des fibres du rideau, à savoir des fibres pleines, par exemple sur une première période de l’extrusion, puis des fibres creuses sur une deuxième période de l’extrusion. - the composition of the fibers comprises at least 95% by weight of PET, and for example the fiber composition comprises by weight, 95% to 99% of PET, 1% to 5% of a second polymer distinct from PET such as PTT or PBT. [0012] Generally speaking, the nozzles may comprise nozzles configured to generate hollow fibers and solid fibers, and in which possibly the logic processing unit controls the nozzles to change over time the nature of the fibers of the curtain, namely solid fibers, for example over a first period of extrusion, then hollow fibers over a second period of extrusion.
[0013] Selon un second aspect, la présente divulgation est relative à une matelassure d’assise ou de dossier d’un siège susceptible être obtenue selon la procédé de la présente divulgation, la matelassure comprenant un enchevêtrement 3D de fibres continues thermoplastiques disposées irrégulièrement, typiquement aléatoirement, formant des boucles soudées entre elles entre les fibres, et dans laquelle : [0013] According to a second aspect, the present disclosure relates to a seat or back padding of a seat capable of being obtained according to the method of the present disclosure, the padding comprising a 3D tangle of continuous thermoplastic fibers arranged irregularly, typically randomly, forming loops welded together between the fibers, and in which:
- les fibres sont des fibres creuses et/ou fibres pleines, de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm, - the fibers are hollow fibers and/or solid fibers, with a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
- la composition des fibres comprenant au moins 95% en poids de PET, - the composition of the fibers comprising at least 95% by weight of PET,
- l’enchevêtrement 3D de la matelassure présente une masse volumique apparente comprise entre 20kg/m3 et 70 kg/m3, et par exemple entre 45 kg/m3 et 65 kg/m3, et dans laquelle l’enchevêtrement 3D de fibres continues présente une face frontale conformée à une cavité de moulage d’un outillage de moulage. - the 3D entanglement of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , and for example between 45 kg/m 3 and 65 kg/m 3 , and in which the 3D entanglement of continuous fibers has a front face conforming to a molding cavity of a molding tool.
[0014] Selon un troisième aspect, la présente divulgation est relative à un siège de véhicule comprenant : [0014] According to a third aspect, the present disclosure relates to a vehicle seat comprising:
- une structure typiquement métallique comprenant une structure d’assise et/ou une structure de dossier, - a typically metallic structure comprising a seat structure and/or a back structure,
- une matelassure, selon la présente divulgation, telle qu’une matelassure de dossier ou une matelassure d’assise, en appui sur la structure, - a padding, according to this disclosure, such as a back padding or a seat padding, resting on the structure,
- éventuellement une coiffe, recouvrant la face frontale de la matelassure. - possibly a cap, covering the front face of the padding.
[0015] Selon un mode de réalisation du siège, la face conformée comprend une partie centrale, et deux boudins latéraux en saillie destinés à assurer le maintien latéral de l’occupant. [0015] According to one embodiment of the seat, the shaped face comprises a central part, and two projecting side flanges intended to ensure lateral support of the occupant.
[0016] Selon un mode de réalisation du siège, la face dorsale, opposée à la face frontale, comprend une portion centrale, saillante par rapport à deux portions latérales de la matelassure, et dans lequel : [0016] According to one embodiment of the seat, the dorsal face, opposite the front face, comprises a central portion, projecting relative to two portions sides of the padding, and in which:
- pour une matelassure d’assise, la portion centrale de la face dorsale s’intercale entre deux flaques de la structure d’assise alors que les deux portions latérales viennent respectivement en appui sur les deux flasques, et/ou - for a seat cushion, the central portion of the dorsal face is inserted between two puddles of the seat structure while the two lateral portions respectively rest on the two flanges, and/or
- pour une matelassure de dossier, la portion centrale de la face dorsale s’intercale entre deux montants de la structure de dossier alors que les deux portions latérales viennent respectivement en appui sur les deux montant. - for a back padding, the central portion of the dorsal face is inserted between two uprights of the backrest structure while the two lateral portions come to rest respectively on the two uprights.
Brève description des dessins Brief description of the drawings
[0017] D’autres caractéristiques, détails et avantages apparaîtront à la lecture de la description détaillée ci-après, et à l’analyse des dessins annexés, sur lesquels :[0017] Other characteristics, details and advantages will appear on reading the detailed description below, and on analyzing the appended drawings, in which:
Fig. 1 Fig. 1
[0018] [Fig. 1] montre est une vue d’un équipement configuré pour la mise en œuvre du procédé selon la présente divulgation, comprenant : [0018] [Fig. 1] shows is a view of equipment configured for implementing the method according to the present disclosure, comprising:
- une filière d’extrusion comprenant des buses réparties suivant une direction en longueur et suivant un direction en largeur (transversale) de la filière d’extrusion, générant un rideau de fibres continues fondues, chutant par gravité, - an extrusion die comprising nozzles distributed in a lengthwise direction and in a width (transverse) direction of the extrusion die, generating a curtain of melted continuous fibers, falling by gravity,
- un outillage de moulage comprenant une cavité de moulage, ouverte vers la filière d’extrusion, à l’aplomb de la filière, configuré pour la réception du rideau de fibres continues fondues chutant par gravité dans la cavité de moulage de l’outillage de moulage de sorte à générer un enchevêtrement 3D de fibres selon une répartition irrégulière ou aléatoire avec fusion de boucles entre les fibres continues, - a molding tool comprising a molding cavity, open towards the extrusion die, directly above the die, configured to receive the curtain of melted continuous fibers falling by gravity into the molding cavity of the molding tool molding so as to generate a 3D tangle of fibers in an irregular or random distribution with fusion of loops between the continuous fibers,
- des guides autorisant la descente de l’outillage de moulage dans un réservoir contenant un liquide de refroidissement assurant la solidification de l’enchevêtrement , - guides allowing the molding tool to be lowered into a tank containing a cooling liquid ensuring the solidification of the entanglement,
- une unité logique de traitement comprenant un module de commande présentant un micro-processeur et une mémoire configurés pour le pilotage des buses d’extrusion, et la commande de la descente de l’outillage de moulage dans le liquide de refroidissement, de manière motorisée. - a logic processing unit comprising a control module having a microprocessor and a memory configured for controlling the extrusion nozzles, and controlling the descent of the molding tool into the cooling liquid, in a motorized manner .
Fig. 2A [0019] [Fig. 2A] illustre une première phase du procédé pour laquelle l’unité logique pilote les buses de sorte à garnir uniquement des reliefs en creux de la cavité de moulage, de part et d’autre d’une portion centrale de la cavité de moulage, les buses de la filière d’extrusion situées au droit du relief en saille sur la portion centrale de la cavité de moulage étant maintenues fermées par l’unité logique. Fig. 2A [0019] [Fig. 2A] illustrates a first phase of the process for which the logic unit controls the nozzles so as to fill only the hollow reliefs of the molding cavity, on either side of a central portion of the molding cavity, the nozzles of the extrusion die located to the right of the projecting relief on the central portion of the molding cavity being kept closed by the logic unit.
Fig. 2B Fig. 2B
[0020] [Fig. 2B] montre une deuxième phase, consécutive à la première phase, pour laquelle l’unité logique ouvre l’ensemble des buses d’extrusion de sorte que le rideau de fibres fondues garnisse la totalité de la surface de la cavité de moulage suivant la direction longitudinale et suivant la direction transversale de la cavité de moulage. [0020] [Fig. 2B] shows a second phase, consecutive to the first phase, for which the logic unit opens all of the extrusion nozzles so that the curtain of molten fibers fills the entire surface of the molding cavity in the direction longitudinal and in the transverse direction of the molding cavity.
Fig. 2C Fig. 2C
[0021] [Fig. 2C] montre une troisième phase, consécutive à la deuxième phase, pour laquelle l’unité logique ouvre uniquement des buses de sorte que le rideau de fibres fondues garnisse la portion centrale de l’outillage de moulage située entre les deux reliefs en creux, en vue de former sur la face dorsale de la matelassure, une portion centrale en saillie par rapport à deux portions latérales de la face dorsale. [0021] [Fig. 2C] shows a third phase, consecutive to the second phase, for which the logic unit only opens nozzles so that the curtain of molten fibers fills the central portion of the molding tool located between the two hollow reliefs, in seen to form on the dorsal face of the padding, a central portion projecting relative to two lateral portions of the dorsal face.
Fig. 2D Fig. 2D
[0022] [Fig. 2D] montre à gauche un instant de la troisième phase consécutif à la figure 2C, et à droite, après démoulage, une matelassure formée d’un enchevêtrement 3D de fibres selon une répartition irrégulière typiquement aléatoire avec fusion de boucles entre les fibres continues, la matelassure présentant une face frontale conformée par la cavité de moulage de l’outillage de moulage, et une face dorsale non conformée par l’outillage de moulage. [0022] [Fig. 2D] shows on the left a moment of the third phase consecutive to Figure 2C, and on the right, after demolding, a padding formed from a 3D tangle of fibers in a typically random irregular distribution with fusion of loops between the continuous fibers, the padding having a front face shaped by the molding cavity of the molding tool, and a back face not shaped by the molding tool.
Fig. 3 Fig. 3
[0023] [Fig. 3] montre une structure de siège, comprenant : [0023] [Fig. 3] shows a seat structure, comprising:
- une structure d’assise comprenant deux flasques s’étendant en parallèle depuis un bord arrière de l’assise et jusqu’à un bord avant de l’assise, ainsi que des entretoises entre flasques, et, - une structure de dossier comprenant deux montants, s’étendant en parallèle, depuis une portion arrière de l’assise jusqu’ à une traverse supérieure de la structure de dossier. - a seat structure comprising two flanges extending in parallel from a rear edge of the seat and to a front edge of the seat, as well as spacers between flanges, and, - a backrest structure comprising two uprights, extending in parallel, from a rear portion of the seat to an upper crosspiece of the backrest structure.
Fig. 4 Fig. 4
[0024] [Fig. 4] est une vue du montage d’une matelassure d’assise sur la structure d’assise, la matelassure présentant sur sa face dorsale une portion centrale intercalée entre deux flasques de la structure d’assise et des portions latérales respectivement en appui sur les flasques, la matelassure fixée à la structure par une coiffe recouvrant la face frontale moulée par l’outillage. [0024] [Fig. 4] is a view of the assembly of a seat padding on the seat structure, the padding having on its dorsal face a central portion interposed between two flanges of the seat structure and lateral portions respectively resting on the flanges, the padding fixed to the structure by a cap covering the front face molded by the tooling.
Fig. 5 Fig. 5
[0025] [Fig. 5] est une vue d’une structure de siège comprenant : [0025] [Fig. 5] is a view of a seat structure comprising:
- une structure d’assise comprenant deux flasques s’étendant en parallèle depuis un bord arrière de l’assise et jusqu’à un bord avant de l’assise, ainsi que des entretoises entre flasques, et de manière notable une suspension métallique s’étendant en appui entre une entretoise avant et une entretoise arrière, - a seat structure comprising two flanges extending in parallel from a rear edge of the seat and to a front edge of the seat, as well as spacers between flanges, and notably a metal suspension extending in support between a front spacer and a rear spacer,
- une structure de dossier comprenant deux montants, s’étendant en parallèle, depuis une portion arrière de l’assise jusqu’ à une traverse supérieure de la structure de dossier, et de manière notable, une suspension métallique s’étendant entre les deux montants de la structure de dossier. - a backrest structure comprising two uprights, extending in parallel, from a rear portion of the seat to an upper crosspiece of the backrest structure, and notably, a metal suspension extending between the two uprights of the folder structure.
Fig. 6 Fig. 6
[0026] [Fig. 6] est une vue du montage d’une matelassure d’assise sur la structure d’assise par l’intermédiaire d’un support entre la matelassure et la structure. [0026] [Fig. 6] is a view of the assembly of a seat padding on the seat structure via a support between the padding and the structure.
Description des modes de réalisation Description of embodiments
[0027] Les dessins et la description ci-après contiennent, pour l’essentiel, des éléments de caractère certain. Ils pourront donc non seulement servir à mieux faire comprendre la présente divulgation, mais aussi contribuer à sa définition, le cas échéant. [0027] The drawings and the description below contain, for the most part, elements of a certain nature. They can therefore not only be used to better understand this disclosure, but also contribute to its definition, if necessary.
[0028] La présente divulgation concerne tout d’abord un équipement configuré pour la mise en œuvre du procédé selon la présente divulgation, comprenant : - une filière d’extrusion 2 comprenant des buses 20 réparties suivant une direction en longueur X et suivant un direction en largeur Y (transversale) de la filière d’extrusion, configurée pour générer un rideau de fibres continues fondues, chutant par gravité, [0028] The present disclosure firstly concerns equipment configured for implementing the method according to the present disclosure, comprising: - an extrusion die 2 comprising nozzles 20 distributed along a length direction X and along a width direction Y (transverse) of the extrusion die, configured to generate a curtain of melted continuous fibers, falling by gravity,
- un outillage de moulage OM comprenant une cavité de moulage CAV, ouverte vers la filière d’extrusion 2, à l’aplomb de la filière d’extrusion, l’outillage étant configuré pour la réception du rideau R de fibres continues fondues chutant par gravité dans la cavité de moulage CAV de I’ outillage de moulage OM de sorte à générer un enchevêtrement 3D de fibres selon une répartition irrégulière, obtenue typiquement aléatoirement, avec fusion de boucles entre les fibres continues,- a molding tool OM comprising a molding cavity CAV, open towards the extrusion die 2, directly above the extrusion die, the tool being configured to receive the curtain R of melted continuous fibers falling through gravity in the CAV molding cavity of the OM molding tool so as to generate a 3D entanglement of fibers according to an irregular distribution, typically obtained randomly, with fusion of loops between the continuous fibers,
- éventuellement des guides G autorisant la descente de l’outillage de moulage dans un réservoir contenant un liquide de refroidissement, - possibly guides G allowing the molding tool to be lowered into a tank containing a cooling liquid,
- une unité logique de traitement U comprenant un micro-processeur et une mémoire contenant des instructions de commande. Les instructions peuvent être configurées pour le pilotage des buses d’extrusion, voire la commande de la descente de l’outillage de moulage de manière motorisée, le long de guide G. - a logic processing unit U comprising a microprocessor and a memory containing control instructions. The instructions can be configured for controlling the extrusion nozzles, or even controlling the descent of the molding tool in a motorized manner, along guide G.
[0029] La direction en longueur X et la direction en largeur Y s’étendent typiquement selon un plan horizontal ; l’outillage de moulage étant positionné typiquement verticalement à l’aplomb de la filière d’extrusion. The length direction X and the width direction Y typically extend along a horizontal plane; the molding tooling being typically positioned vertically above the extrusion die.
[0030] La cavité de moulage s’étend entres des flancs FI1 , FI2, FI3, FL4, en particulier deux flancs d’extrémité FI1 et FI3 à deux extrémités longitudinales de l’outillage de moulage, espacés suivant la direction en longueur X et deux flancs latéraux sur les côtés du moules espacés suivant la direction en largeur Y. [0030] The molding cavity extends between flanks FI1, FI2, FI3, FL4, in particular two end flanks FI1 and FI3 at two longitudinal ends of the molding tool, spaced along the length direction two lateral flanks on the sides of the mold spaced in the width direction Y.
[0031] Les buses 20 d’extrusion sont réparties suivant la direction en longueur X et suivant la direction en largeur Y de la filière d’extrusion. Les buses 20 sont configurées suivant une matrice pour générer, au moins temporairement, un rideau de fibres continues fondues couvrant la totalité de la surface de cavité de moulage, s’étendant d’un flanc à l’autre du moule, à savoir un rideau s’étendant d’un flanc d’extrémité FI1 à l’autre flanc d’extrémité FI2 suivant la direction en longueur X et s’étendant d’un flanc latéral FL2 à l’autre flanc latéral FL4 suivant la direction en largeur Y. [0032] Selon un mode de réalisation avantageux, les buses peuvent être avantageusement pilotables (individuellement, ou au moins par sous-groupes), configurées de sorte à pouvoir changer la forme du rideau de fibres, en particulier suivant la direction longitudinale X et/ou suivant la direction transversale Y. Un tel pilotage des buses individuellement ou à tout le moins en sous-groupes peut permettre l’élaboration d’enchevêtrement 3D de forme complexe, et selon un mode de réalisation reposant sur un mode de fabrication additive inspirée de la stéréolithographie. The extrusion nozzles 20 are distributed along the length direction X and along the width direction Y of the extrusion die. The nozzles 20 are configured in a matrix to generate, at least temporarily, a curtain of molten continuous fibers covering the entire surface of the molding cavity, extending from one side of the mold to the other, namely a curtain extending from one end flank FI1 to the other end flank FI2 in the length direction X and extending from one side flank FL2 to the other side flank FL4 in the width direction Y. [0032] According to an advantageous embodiment, the nozzles can advantageously be controllable (individually, or at least in subgroups), configured so as to be able to change the shape of the curtain of fibers, in particular along the longitudinal direction X and/or or along the transverse direction Y. Such control of the nozzles individually or at the very least in subgroups can allow the development of 3D entanglements of complex shape, and according to an embodiment based on a mode of additive manufacturing inspired by stereolithography.
[0033] Ladite unité logique de traitement U comprend alors de préférence un module de commande comprenant typiquement un microprocesseur et une mémoire comprenant des instructions pour, en /A/, piloter les buses de sorte à générer un rideau de fibres, de forme variable au cours du l’extrusion, en particulier variable suivant la direction longitudinale X et de préférence indépendamment, variable suivant la direction transversale Y. Un tel pilotage permet de générer des matelassures, en particulier de forme complexe, présentant en particulier une épaisseur suivant la direction verticale Z, qui peut être variable suivant la direction longitudinale X, et/ou variable suivant la direction transversale Y dans l’outillage de moulage. [0033] Said processing logic unit U then preferably comprises a control module typically comprising a microprocessor and a memory comprising instructions for, in /A/, controlling the nozzles so as to generate a curtain of fibers, of variable shape at course of the extrusion, in particular variable in the longitudinal direction Z, which can be variable in the longitudinal direction X, and/or variable in the transverse direction Y in the molding tool.
[0034] Un tel fonctionnement s’inspire des techniques de fabrication additive, en particulier de la stéréolithographie. La matelassure à fabriquer peut-être conçue et déterminée typiquement par un logiciel de CAO dans un format donné, puis peut être exporté dans un format tel que le format STL. [0034] Such operation is inspired by additive manufacturing techniques, in particular stereolithography. The padding to be manufactured can typically be designed and determined by CAD software in a given format, then can be exported in a format such as STL format.
[0035] Le fichier STL est transmis au module de commande de l’unité logique U. Le module de commande découpe la matelassure en tranches d’épaisseur typiquement fixe suivant la direction verticale Z. Lors de la fabrication le module de commande pilote les buses de la filière d’extrusion pour produire successivement les différentes tranches de la matelassure. The STL file is transmitted to the control module of the logic unit U. The control module cuts the padding into slices of typically fixed thickness in the vertical direction Z. During manufacturing, the control module controls the nozzles of the extrusion die to successively produce the different sections of the padding.
[0036] Les figures 2A à 2D illustrent à titre d’exemple, différentes vues du garnissage de l’outillage de moulage au cours de l’extrusion en vue de l’obtention d’une matelassure, de forme complexe, qui comporte une face frontale FF (moulée par la cavité de moulage) comprenant de manière notable des boudins latéraux Bl en saillie par rapport à une partie centrale PC de la face frontale FL. [0036] Figures 2A to 2D illustrate by way of example, different views of the filling of the molding tool during extrusion with a view to obtaining a padding, of complex shape, which has a face FF front (molded by the molding cavity) notably comprising lateral flanges Bl projecting relative to a central part PC of the front face FL.
[0037] Une telle géométrie de la face frontale permet d’obtenir par moulage une géométrie de matelassure, en particulier d’assise ou de dossier, garantissant un bon maintien latéral de l’occupant. [0037] Such a geometry of the front face makes it possible to obtain by molding a cushioning geometry, in particular of the seat or backrest, guaranteeing good lateral support for the occupant.
[0038] De manière notable encore, la matelassure peut comporter une face dorsale FD (non moulée par la cavité de moulage) comprenant une portion centrale PCE en saille par rapport à des portions latérale PL. La portion centrale PCE peut comporter typiquement une épaisseur comprise entre 20 mm et 120 mm [0038] Also notably, the padding may include a dorsal face FD (not molded by the molding cavity) comprising a central portion PCE projecting relative to the lateral portions PL. The central PCE portion can typically have a thickness of between 20 mm and 120 mm.
[0039] Une telle géométrie de la face dorsale FD peut être configurée pour se caler en appui sur une structure de siège, et notamment avantageusement sans avoir à utiliser une coque plastique intermédiaire entre la matelassure et la structure pour permettre son intégration. [0039] Such a geometry of the dorsal face FD can be configured to rest against a seat structure, and in particular advantageously without having to use an intermediate plastic shell between the padding and the structure to allow its integration.
[0040] Aussi, la présente divulgation est relative à un procédé de fabrication d’une matelassure MAT de siège, telle qu’une matelassure d’assise ou de dossier, et dans lequel on obtient la matelassure comprenant un enchevêtrement 3D, référencé 1 , de fibres thermoplastiques, continues disposées irrégulièrement ou aléatoirement formant des boucles soudées entre elles par : [0040] Also, the present disclosure relates to a process for manufacturing a MAT seat cushion, such as a seat or back cushion, and in which the cushion is obtained comprising a 3D entanglement, referenced 1, of continuous thermoplastic fibers arranged irregularly or randomly forming loops welded together by:
- /A/ Extrusion d’un polymère thermoplastique dans la filière d’extrusion 2 comprenant des buses d’extrusion 20 réparties suivant une direction en longueur X et suivant un direction en largeur Y de la filière d’extrusion, générant un rideau R de fibres continues fondues, chutant par gravité, - /A/ Extrusion of a thermoplastic polymer in the extrusion die 2 comprising extrusion nozzles 20 distributed in a length direction X and in a width direction Y of the extrusion die, generating a curtain R of continuous melted fibers, falling by gravity,
- /B/ Réception du rideau de fibres continues fondues chutant par gravité dans la cavité de moulage CAV de l’outillage de moulage OM de sorte à générer un enchevêtrement 3D de fibres selon une répartition irrégulière typiquement obtenue aléatoirement, avec fusion de boucles entre les fibres continues, ledit enchevêtrement 3D de fibres étant conformé à ladite cavité de moulage - /B/ Reception of the curtain of melted continuous fibers falling by gravity into the CAV molding cavity of the OM molding tool so as to generate a 3D entanglement of fibers according to an irregular distribution typically obtained randomly, with fusion of loops between the continuous fibers, said 3D tangle of fibers being shaped to said molding cavity
- /C/ Solidification de l’enchevêtrement 3D de fibres conformé à la cavité de moulage par immersion dans un liquide de refroidissement LF. [0041] La température de l’extrusion mise en œuvre en /A/ dans la filière d’extrusion peut être comprise entre 180°C et 240°C. La filière d’extrusion est typiquement alimentée en granulés thermoplastiques. - /C/ Solidification of the 3D tangle of fibers conforming to the molding cavity by immersion in an LF cooling liquid. [0041] The temperature of the extrusion carried out in /A/ in the extrusion die can be between 180°C and 240°C. The extrusion die is typically supplied with thermoplastic granules.
[0042] De manière générale, les fibres peuvent être de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm. [0042] Generally, the fibers can have a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm.
[0043] De manière générale, l’enchevêtrement 3D de la matelassure MAT peut présenter une masse volumique apparente comprise entre 20kg/m3 et 70 kg/m3, par exemple entre 45 kg/m3 et 65 kg/m3. [0043] Generally speaking, the 3D tangle of the MAT padding can have an apparent density of between 20 kg/m 3 and 70 kg/m 3 , for example between 45 kg/m 3 and 65 kg/m 3 .
[0044] De manière générale, la composition des fibres peut comprendre au moins 95% en poids de PET, et par exemple la composition en fibre comprend en poids, 95% à 99% de PET, 1 % à 5% d’un second polymère distinct du PET tel que PTT ou PBT. [0044] Generally, the composition of the fibers may comprise at least 95% by weight of PET, and for example the fiber composition comprises by weight, 95% to 99% of PET, 1% to 5% of a second polymer distinct from PET such as PTT or PBT.
[0045] Comme illustrée à titre d’exemple à droite de la figure 2D, la matelassure obtenue après démoulage de l’outillage présente une face frontale FF moulée par la cavité de moulage CAV, et une face dorsale non moulée par la cavité de moulage. Les flancs de la matelassure peuvent être moulés par les flancs de la cavité de moulage. [0045] As illustrated by way of example on the right of Figure 2D, the padding obtained after demolding of the tooling has a front face FF molded by the molding cavity CAV, and a back face not molded by the molding cavity . The sides of the padding can be molded by the sides of the molding cavity.
[0046] La face frontale FF moulée présente avantageusement un état de surface supérieure à la face dorsale (de meilleure qualité) et est typiquement tournée vers l’occupant du siège. Lorsque le siège présente une coiffe CF, typiquement textile, recouvrant en tension la matelassure, la coiffe recouvre de préférence la face frontale FF moulée par l’outillage, et telle qu’illustrée à titre indicatif à la figure 4. Autrement dit la coiffe ne recouvre pas la face dorsale qui présente un état de surface plus irrégulier. Selon un mode de réalisation, le fond F de la cavité de moulage est un fond présentant des reliefs en saillie et en creux RS, RC. The molded front face FF advantageously has a higher surface finish than the back face (of better quality) and is typically turned towards the occupant of the seat. When the seat has a cover CF, typically textile, covering the padding in tension, the cover preferably covers the front face FF molded by the tooling, and as illustrated for information purposes in Figure 4. In other words the cover does not does not cover the dorsal surface which has a more irregular surface condition. According to one embodiment, the bottom F of the molding cavity is a bottom having projecting and recessed reliefs RS, RC.
[0047] Les figures 2A à 2B divulgue à titre d’exemple, une section de moule suivant un plan YX, présentant un fond avec un relief en saillie RS sur une portion centrale de la section, et deux reliefs en creux RC, de part et d’autre de cette portion centrale suivant la direction Y. De tels reliefs en creux peuvent être conformés pour le moulage des boudins latéraux Bl. Ces boudins latéraux sont en saillie par rapport à une partie centrale PC de la matelassure depuis la face frontale FF. [0047] Figures 2A to 2B disclose by way of example, a mold section along a plane YX, having a bottom with a projecting relief RS on a central portion of the section, and two hollow reliefs RC, on either side and on the other side of this central portion in the Y direction. Such hollow reliefs can be shaped for the molding of the side flanges Bl. These side flanges project relative to a central part PC of the padding from the front face FF.
[0048] Lorsque le fond présente des reliefs en creux et en saille, de préférence en /A/ ladite unité logique pilote les buses de sorte en /B/ à garnir le ou les relief(s) en creux RC de l’outillage de moulage, préalablement au(x) relief(s) en saillie RS de l’outillage de moulage. [0048] When the bottom has hollow and projecting reliefs, preferably in /A/ said logic unit controls the nozzles so as in /B/ to fill the hollow relief(s) RC of the tooling with molding, prior to the projecting relief(s) RS of the molding tool.
[0049] Ainsi à la figure 2A, l’extrusion commence, lors d’une première phase, par la génération d’un rideau de fibres fondues en deux parties distinctes qui viennent garnir uniquement les deux reliefs en creux RC pour le moulage des boudins latéraux, et non une partie centrale de l’outillage entre ces deux reliefs. [0049] Thus in Figure 2A, the extrusion begins, during a first phase, by the generation of a curtain of fibers melted into two distinct parts which only fill the two hollow reliefs RC for the molding of the tubes lateral, and not a central part of the tools between these two reliefs.
[0050] La figure 2B est une vue consécutive de l’extrusion qui montre une deuxième phase consécutive à la première phase pour laquelle l’unité logique U ouvre l’ensemble des buses de sorte que le rideau garnisse la totalité de la section, cavité de moulage, à savoir non seulement le relief en saille RS sur la partie centrale, mais les deux reliefs en creux. [0050] Figure 2B is a consecutive view of the extrusion which shows a second phase consecutive to the first phase for which the logic unit U opens all of the nozzles so that the curtain fills the entire section, cavity molding, namely not only the projecting relief RS on the central part, but the two hollow reliefs.
[0051] Ainsi, et de manière avantageuse, le fond du moule peut comprendre :[0051] Thus, and advantageously, the bottom of the mold can comprise:
- une portion centrale, suivant un relief en saillie RS, configurée pour conformer une partie centrale PC d’une face frontale FF de la matelassure tournée vers l’occupant du siège destinée à recevoir le fessier de l’utilisateur pour la matelassure d’assise ou le dos de l’occupant pour une matelassure de dossier, et - a central portion, following a projecting relief RS, configured to conform a central part PC of a front face FF of the padding facing the occupant of the seat intended to receive the user's buttocks for the seat padding or the back of the occupant for backrest padding, and
- des portions latérales, de part et d’autre, de la portion centrale, suivant deux reliefs en creux RC, configurés de sorte à former deux boudins latéraux BL de la matelassure, en saillie de la partie centrale PC, sur la face frontale FF, les boudins latéraux configurés pour assurer un maintien latéral de l’occupant. - lateral portions, on either side, of the central portion, following two hollow reliefs RC, configured so as to form two lateral flanges BL of the padding, projecting from the central part PC, on the front face FF , the side flanges configured to ensure lateral support for the occupant.
[0052] Selon un mode de réalisation, en /A/, au moins sur une phase finale de l’extrusion, l’unité logique U pilote les buse 20 de sorte à générer en /A/ un rideau de fibres localisé sur une portion centrale de l’outillage de moulage, de sorte à former sur une face dorsale FD de la matelassure, opposée à la face frontale, une portion centrale PCE saillante par rapport à des portions latérales PL de la face dorsale FD, situées au dos des deux boudins latéraux BL. [0053] Ainsi, aux figures 2C et 2D, on remarque que l’unité logique U pilote les buses, sur une troisième phase consécutive à la deuxième phase, de sorte à générer un rideau de fibres fondues qui vient garnir le relief en saillie RS sur la portion centrale de du fond, et non les deux reliefs en creux RC. [0052] According to one embodiment, in /A/, at least in a final phase of the extrusion, the logic unit U controls the nozzles 20 so as to generate in /A/ a curtain of fibers located on a portion central part of the molding tool, so as to form on a dorsal face FD of the padding, opposite the front face, a central portion PCE projecting relative to lateral portions PL of the dorsal face FD, located on the back of the two BL side flanges. [0053] Thus, in Figures 2C and 2D, we note that the logic unit U controls the nozzles, in a third phase consecutive to the second phase, so as to generate a curtain of molten fibers which fills the projecting relief RS on the central portion of the bottom, and not the two hollow reliefs RC.
[0054] Une telle géométrie de la face dorsale FD, comprenant une portion centrale PCE en saille (suivant la direction Z) par rapport à des portions latérales PL peut permettre une intégration de la matelassure MT sur la structure 3, et comme illustré à titre indicatif à la figure 4, directement, à savoir sans utiliser de coque plastique intermédiaire pour permettre l’intégration. [0054] Such a geometry of the dorsal face FD, comprising a central portion PCE projecting (in the direction Z) relative to lateral portions PL can allow integration of the padding MT on the structure 3, and as illustrated for indicative in Figure 4, directly, i.e. without using an intermediate plastic shell to allow integration.
[0055] De manière générale, en /C/ on peut obtenir la solidification de l’enchevêtrement 3D de fibres par immersion dans un liquide de refroidissement avec contrôle du déplacement de l’outillage de moulage par rapport à une surface libre SL du liquide de refroidissement. [0055] Generally speaking, in /C/ it is possible to obtain the solidification of the 3D tangle of fibers by immersion in a cooling liquid with control of the movement of the molding tool relative to a free surface SL of the cooling liquid. cooling.
[0056] La surface libre SL peut être déplacée de manière motorisée afin d’obtenir la solidification de l’enchevêtrement 3D par immersion dans le liquide de refroidissement LF, progressivement lors de la fabrication additive, postérieurement à la réception du rideau de fibres continues fondues chutant par gravité dans la cavité de moulage, et de préférence suivant une durée inférieure à 4s entre la réception du rideau de fibres générant l’enchevêtrement 3D, et l’immersion de l’enchevêtrement 3D. The free surface SL can be moved in a motorized manner in order to obtain the solidification of the 3D entanglement by immersion in the cooling liquid LF, progressively during additive manufacturing, subsequent to receipt of the curtain of melted continuous fibers falling by gravity into the molding cavity, and preferably following a duration of less than 4s between reception of the curtain of fibers generating the 3D entanglement, and immersion of the 3D entanglement.
[0057] A titre d’exemple, le déplacement motorisé de l’outillage de moulage OM par rapport à la surface libre SD du liquide de refroidissement peut être obtenu en plongeant l’outillage de moulage OM de manière motorisée dans une réservoir contenant le liquide de refroidissement. [0057] By way of example, the motorized movement of the molding tool OM relative to the free surface SD of the cooling liquid can be obtained by immersing the molding tool OM in a motorized manner in a reservoir containing the liquid. cooling.
[0058] De manière générale l’unité logique de traitement U, en particulier son module de commande peut commander et synchroniser le pilotage des buses 20 et le déplacement motorisé de la surface libre SL du liquide de refroidissement. [0058] Generally speaking, the processing logic unit U, in particular its control module, can control and synchronize the control of the nozzles 20 and the motorized movement of the free surface SL of the cooling liquid.
[0059] De manière générale, les buses 20 peuvent comprendre des buses 20 configurées pour générer des fibres creuses et/ou des buses configurées pour générer des fibres pleines. [0060] L’ unité logique de traitement peut encore éventuellement piloter les buses pour changer au cours du temps la nature des fibres du rideau, à savoir par exemple des fibres pleines, par exemple sur une première période de l’extrusion, puis fibres creuses sur une deuxième période de l’extrusion. [0059] Generally speaking, the nozzles 20 may comprise nozzles 20 configured to generate hollow fibers and/or nozzles configured to generate solid fibers. [0060] The logic processing unit can also optionally control the nozzles to change over time the nature of the fibers of the curtain, namely for example solid fibers, for example over a first period of extrusion, then hollow fibers over a second period of extrusion.
[0061] On peut utiliser de préférence des fibres pleines, superficiellement sur la face frontale FF destinée à être en contact avec l’occupant du siège afin de former une première couche « moelleuse, » et de préférence les fibres creuses, « structurelles » sur le reste de l’épaisseur de la matelassure en dessous de cette première couche pour former une sous-couche structurelle. [0061] Full fibers can preferably be used, superficially on the front face FF intended to be in contact with the occupant of the seat in order to form a first “soft” layer, and preferably hollow, “structural” fibers on the the remainder of the thickness of the padding below this first layer to form a structural underlay.
[0062] La présente divulgation est encore relative à une matelassure MAT d’assise ou de dossier d’un siège convenant pour être obtenue selon le procédé selon la présente divulgation. [0062] The present disclosure also relates to a MAT padding for the seat or back of a seat suitable for being obtained according to the method according to the present disclosure.
[0063] La matelassure MAT comprend un enchevêtrement 3D de fibres continues thermoplastiques disposées irrégulièrement, aléatoirement, formant des boucles soudées entre elles entre les fibres, et dans laquelle : [0063] The MAT padding comprises a 3D tangle of continuous thermoplastic fibers arranged irregularly, randomly, forming loops welded together between the fibers, and in which:
- les fibres sont des fibres creuses et/ou fibres pleines , par exemple de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm,- the fibers are hollow fibers and/or solid fibers, for example with a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
- la composition des fibres comprenant notamment au moins 95% en poids de PET, -l’enchevêtrement 3D de la matelassure présente une masse volumique apparente par exemple comprise entre 20kg/m3 et 70 kg/m3, et par exemple entre 45 kg/m3 et 65 kg/m3. - the composition of the fibers comprising in particular at least 95% by weight of PET, - the 3D entanglement of the padding has an apparent density for example between 20kg/m 3 and 70 kg/m 3 , and for example between 45 kg /m 3 and 65 kg/m 3 .
[0064] On entend par « continues » dans « fibres continues » le fait que les fibres sont de longueur très supérieure au diamètre des fibres, et du fait du procédé qui est décrit ci-avant, typiquement au moins d’un rapport 100, voire 500, voire 1000. [0064] By “continuous” in “continuous fibers” is meant the fact that the fibers are of length much greater than the diameter of the fibers, and due to the process which is described above, typically at least by a ratio 100, even 500, even 1000.
[0065] Bien souvent, et notamment comme compréhensible du procédé de fabrication, les fibres s’étendent typiquement depuis une première extrémité sur un premier bord de l’enchevêtrement 3D et jusqu’à une deuxième extrémité sur un deuxième bord de l’enchevêtrement AD, opposé au premier bord. [0066] De manière notable, l’enchevêtrement 3D de fibres continues présente une face frontale FF conformée à une cavité de moulage CAV d’un outillage de moulage OM, alors que la face dorsale FD n’est pas conformée à une cavité de moulage. Very often, and in particular as understood from the manufacturing process, the fibers typically extend from a first end on a first edge of the 3D entanglement and to a second end on a second edge of the AD entanglement , opposite the first edge. [0066] Notably, the 3D tangle of continuous fibers has a front face FF conforming to a molding cavity CAV of a molding tool OM, whereas the dorsal face FD is not conforming to a molding cavity .
[0067] La présente divulgation est encore relative à un siège de véhicule comprenant : [0067] The present disclosure also relates to a vehicle seat comprising:
- une structure 3 typiquement métallique comprenant une structure d’assise 3A et/ou une structure de dossier 3B, - a typically metallic structure 3 comprising a seat structure 3A and/or a backrest structure 3B,
- une matelassure MAT, selon la présente divulgation, telle qu’une matelassure de dossier ou une matelassure d’assise, en appui sur la structure, - a MAT padding, according to this disclosure, such as a back padding or a seat padding, resting on the structure,
- éventuellement une coiffe CF, recouvrant la face frontale de la matelassure. - possibly a CF cap, covering the front face of the padding.
[0068] La matelassure d’assise s’étend de préférence : [0068] The seat padding preferably extends:
- en longueur depuis un bord arrière de la structure d’assise 3A et jusqu’à un bord avant de la structure d’assise 3A, - in length from a rear edge of the seat structure 3A and to a front edge of the seat structure 3A,
- en largeur depuis un (premier) flasque 31 de la structure d’assise et jusqu’à un (deuxième) flasque 31 de la structure d’assise. - in width from a (first) flange 31 of the seat structure and up to a (second) flange 31 of the seat structure.
[0069] La matelassure de dossier s’étend de préférence : [0069] The back padding preferably extends:
- en longueur depuis un bord inférieur de la structure de dossier 3D et jusqu’à un bord supérieur de la structure de dossier 3B, - in length from a lower edge of the 3D backrest structure and to an upper edge of the 3B backrest structure,
- en largeur depuis un (premier) montant 32 de la structure de dossier et jusqu’à un (deuxième) montant 32 de la structure de dossier 3B. - in width from a (first) upright 32 of the backrest structure and up to a (second) upright 32 of the backrest structure 3B.
[0070] De manière générale, avantageusement, la face frontale FF conformée peut comprendre une partie centrale PC, et deux boudins latéraux BL en saillie destinés à assurer le maintien latéral de l’occupant. [0070] Generally speaking, advantageously, the shaped front face FF may comprise a central part PC, and two projecting lateral flanges BL intended to ensure lateral support of the occupant.
[0071] De manière avantageuse, la face dorsale FD, opposée à la face frontale FF, peut comprendre une portion centrale PCE, en saillante par rapport à deux portions latérales PL de la matelassure, et dans lequel : [0071] Advantageously, the dorsal face FD, opposite the front face FF, can comprise a central portion PCE, projecting relative to two lateral portions PL of the padding, and in which:
- pour une matelassure d’assise, la portion centrale PCE de la face dorsale s’intercale entre les deux flaques 31 de la structure d’assise 3A alors que les deux portions latérales PL viennent respectivement en appui sur les deux flasques 31 ,- for a seat cushion, the central portion PCE of the dorsal face is inserted between the two puddles 31 of the seat structure 3A while the two lateral portions PL respectively come to rest on the two flanges 31,
- pour une matelassure de dossier, la portion centrale PCE de la face dorsale s’intercale entre les deux montants 32 de la structure de dossier 3B alors que les deux portions latérales PL viennent respectivement en appui sur les deux montant 32. - for a back padding, the central portion PCE of the dorsal face is inserted between the two uprights 32 of the back structure 3B while the two lateral portions PL respectively bear on the two uprights 32.
[0072] On remarque que les portions latérales PL, sur la face dorsale peuvent respectivement présenter des gorges, au dos du boudin latéraux BL, à intérieur desquelles peuvent s’emboîter les flasques 31 de la matelassure d’assise, ou encore les montants de la matelassure de dossier. De telles gorges servant à l’emboitement de la structure participent au bon centrage de la matelassure sur la structure 3. [0072] We note that the lateral portions PL, on the dorsal face can respectively have grooves, on the back of the lateral flange BL, inside which the flanges 31 of the seat padding can fit, or even the uprights of the back padding. Such grooves used to fit the structure together contribute to the correct centering of the padding on the structure 3.
[0073] De manière générale, la coiffe peut être fixée sur la structure 3 et notamment de sorte à assurer le maintien de la matelassure MT sur la structure 3. [0073] Generally speaking, the cover can be fixed on the structure 3 and in particular so as to ensure that the MT padding is maintained on the structure 3.
[0074] La matelassure notamment de dossier ou de siège peut être assemblée sur la structure de siège, en appui sur une suspension SUP et comme illustrée à la figure 5, La structure d’assise 3A peut ainsi comprend une suspension, typiquement métallique, reliant une entretoise avant et une entretoise arrière de la structure d’assise. La structure de dossier 3B peut ainsi comprend une suspension, typiquement métallique, reliant les montants de la structure de dossier. [0074] The padding, in particular for the backrest or seat, can be assembled on the seat structure, supported on a SUP suspension and as illustrated in Figure 5. The seat structure 3A can thus include a suspension, typically metallic, connecting a front spacer and a rear spacer of the seat structure. The backrest structure 3B can thus include a suspension, typically metallic, connecting the uprights of the backrest structure.
[0075] Selon un autre mode de réalisation, notamment illustré à la figure 6, la matelassure peut être associée à un support ST, typiquement préassemblé à la matelassure, et qui est configuré pour permettre l’assemblage de la matelassure sur la structure de siège par l’intermédiaire du support ST. [0075] According to another embodiment, in particular illustrated in Figure 6, the padding can be associated with an ST support, typically pre-assembled with the padding, and which is configured to allow the assembly of the padding on the seat structure via ST Support.
Liste des signes de référence List of reference signs
[0076] - 1 : Enchevêtrement 3D de fibres thermoplastiques, [0076] - 1: 3D entanglement of thermoplastic fibers,
- 2. Filière d’extrusion, - 2. Extrusion die,
- 20. Buses, - 20. Nozzles,
- R. Rideau de fibres fondues, - R. Curtain of melted fibers,
- OM. Outillage de moulage, -OM. Molding tools,
- CAV. Cavité de moulage, - CAV. Molding cavity,
- F. Fond de la cavité de moulage, - F. Bottom of the molding cavity,
- FI1 , FI2, FI3, FI4. Flancs de la cavité de moulage, - FI1, FI2, FI3, FI4. Sidewalls of the molding cavity,
- RC. Reliefs en creux (fond), - RS. Relief en saillie (fond), - R.C. Hollow reliefs (background), - R.S. Projecting relief (background),
- FF. Face frontale (conformée par moulage) - F.F. Front face (shaped by molding)
- BL. Boudins latéraux (Face frontale), - BL. Side flanges (front face),
- PC. Partie centrale (Face frontale), - FD. Face dorsale (non conformée par moulage), -PC. Central part (Front face), - FD. Dorsal face (not shaped by molding),
- PCE. Portion centrale (Face dorsale) - PCE. Central portion (dorsal side)
- PL. Portions latérales (Face dorsale) - PL. Lateral portions (dorsal side)
- 3. Structure, - 3. Structure,
- 3A. Structure d’assise, - 3B. Structure de dossier, - 3A. Seating structure, - 3B. Folder structure,
- 31 . Flasques (structure d’assise), - 31. Flanges (seat structure),
- 32. Montants - 32. Amounts
- Guides (Outillage de moulage), - Guides (molding tools),
- MAT. Matelassure, - SUP. Suspension (Figure 5), - MAT. Quilting, - SUP. Suspension (Figure 5),
- ST. Support (Figure 6), - ST. Support (Figure 6),
- X, Y, Z. Direction longitudinale, direction transversale, et direction verticale. - X, Y, Z. Longitudinal direction, transverse direction, and vertical direction.
[0077] [0077]

Claims

Revendications Claims
[Revendication 1] Procédé de fabrication d’une matelassure (MAT) de siège, telle qu’une matelassure d’assise ou de dossier, dans lequel on obtient la matelassure comprenant un enchevêtrement 3D (1 ) de fibres thermoplastiques, continues disposées irrégulièrement formant des boucles soudées entre elles par : [Claim 1] Process for manufacturing a seat cushion (MAT), such as a seat or back cushion, in which the cushion is obtained comprising a 3D tangle (1) of continuous thermoplastic fibers arranged irregularly forming loops welded together by:
- /A/ Extrusion d’un polymère thermoplastique dans une filière d’extrusion (2) comprenant des buses d’extrusion (20) réparties suivant une direction en longueur (X) et suivant un direction en largeur (Y) de la filière d’extrusion, générant un rideau (R) de fibres continues fondues, chutant par gravité, - /A/ Extrusion of a thermoplastic polymer in an extrusion die (2) comprising extrusion nozzles (20) distributed in a length direction (X) and in a width direction (Y) of the die d extrusion, generating a curtain (R) of melted continuous fibers, falling by gravity,
- /B/ Réception du rideau de fibres continues fondues chutant par gravité dans une cavité de moulage (CAV) d’un outillage de moulage (OM) de sorte à générer un enchevêtrement 3D de fibres selon une répartition irrégulière avec fusion de boucles entre les fibres continues - /B/ Receiving the curtain of melted continuous fibers falling by gravity into a molding cavity (CAV) of a molding tool (OM) so as to generate a 3D entanglement of fibers according to an irregular distribution with fusion of loops between the continuous fibers
- /C/ Solidification de l’enchevêtrement 3D de fibres conformé à la cavité de moulage par immersion dans un liquide de refroidissement (LF). - /C/ Solidification of the 3D tangle of fibers conforming to the molding cavity by immersion in a cooling liquid (LF).
[Revendication 2] Procédé selon la revendication 1 , dans lequel dans lequel ladite cavité de moulage (CAV) comprend un fond (F) et des flancs (FI1 , FI2, FI3, FI4), et dans lequel le fond est un fond présentant des reliefs en saillie et/ou en creux (RS, RC). [Claim 2] Method according to claim 1, in which said molding cavity (CAV) comprises a bottom (F) and sides (FI1, FI2, FI3, FI4), and in which the bottom is a bottom having projecting and/or recessed reliefs (RS, RC).
[Revendication 3] Procédé selon la revendication 1 ou 2, dans lequel les buses sont pilotables, configurées de sorte à pouvoir changer la forme du rideau de fibres, et dans lequel on fournit une unité logique de traitement (U) comprend un module de commande comprenant un microprocesseur et une mémoire comprenant des instructions pour, en /A/, piloter les buses de sorte à générer un rideau de fibres fondues, de forme variable au cours du l’extrusion suivant la direction en longueur X et/ou la direction en largeur Y de la filière extrusion (2). [Claim 3] Method according to claim 1 or 2, in which the nozzles are controllable, configured so as to be able to change the shape of the curtain of fibers, and in which a logic processing unit (U) is provided comprising a control module comprising a microprocessor and a memory comprising instructions for, in /A/, controlling the nozzles so as to generate a curtain of molten fibers, of variable shape during extrusion following the length direction width Y of the extrusion die (2).
[Revendication 4] Procédé selon les revendications 2 et 3 dans lequel en /A/ ladite unité logique pilote les buses de sorte en /B/ à garnir le ou les relief(s) en creux du moule, préalablement au(x) relief(s) en saillie de l’outillage de moulage. [Claim 4] Method according to claims 2 and 3 in which in /A/ said logic unit controls the nozzles so as in /B/ to fill the relief(s) in the hollow of the mold, prior to the relief(s) ( s) projecting from the molding tooling.
[Revendication 5] Procédé selon l’une des revendication 1 à 4 pour l’obtention d’une matelassure de siège de dossier ou d’assise, dans lequel le fond comprend :[Claim 5] Method according to one of claims 1 to 4 for obtaining a backrest or seat padding, in which the bottom comprises:
- une portion centrale, suivant un relief en saillie (RS), configurée pour conformer une partie centrale (PC) d’une face frontale (FF) de la matelassure tournée vers l’occupant du siège destinée à recevoir le fessier de l’utilisateur pour la matelassure d’assise ou le dos de l’occupant pour une matelassure de dossier, et - a central portion, following a projecting relief (RS), configured to conform a central part (PC) of a front face (FF) of the padding facing the occupant of the seat intended to receive the user's buttocks for the seat cushion or the back of the occupant for a back cushion, and
- des portions latérales, de part et d’autre, de la portion centrale, suivant deux reliefs en creux (RC), configurés de sorte à former deux boudins latéraux (BL) de la matelassure, en saillie de la partie centrale (PC), sur la face frontale (FF), les boudins latéraux configurés pour assurer un maintien latéral de l’occupant. - lateral portions, on either side, of the central portion, following two hollow reliefs (RC), configured so as to form two lateral flanges (BL) of the padding, projecting from the central part (PC) , on the front face (FF), the side flanges configured to ensure lateral support for the occupant.
[Revendication 6] Procédé selon la revendication 3 et 5, dans lequel en /A/, au moins sur une phase finale de l’extrusion, l’unité logique (U) pilote les buses( 20) de sorte à générer en /A/ un rideau de fibres localisé sur une portion centrale de l’outillage de moulage, de sorte à former sur une face dorsale (FD) de la matelassure, opposée à la face frontale, une portion centrale (PCE), d’une matelassure d’assise, saillante par rapport à des portions latérales (PL) de la face dorsale (FD), situés au dos des deux boudins latéraux (BL). [Claim 6] Method according to claims 3 and 5, in which in /A/, at least in a final phase of the extrusion, the logic unit (U) controls the nozzles (20) so as to generate in /A / a curtain of fibers located on a central portion of the molding tool, so as to form on a dorsal face (FD) of the padding, opposite the front face, a central portion (PCE), of a padding d the seat, projecting relative to the lateral portions (PL) of the dorsal face (FD), located on the back of the two lateral flanges (BL).
[Revendication 7] Procédé selon l’une des revendications 1 à 6, dans lequel en /C/ on obtient la solidification de l’enchevêtrement 3D de fibres par immersion dans un liquide de refroidissement avec contrôle du déplacement de l’outillage de moulage (OM) par rapport à une surface libre (SL) du liquide de refroidissement, par exemple en plongeant l’outillage de moulage dans le liquide de refroidissement, et dans lequel la surface libre (SL) est déplacée de manière motorisée afin d’obtenir la solidification de l’enchevêtrement 3D par immersion dans le liquide de refroidissement (LF), postérieurement à la réception du rideau de fibres continues fondues chutant par gravité dans une cavité de moulage, suivant une durée inférieure à 4 secondes entre la réception du rideau du fibre générant l’enchevêtrement 3D, et l’immersion de l’enchevêtrement 3D. [Claim 7] Method according to one of claims 1 to 6, in which in /C/ solidification of the 3D tangle of fibers is obtained by immersion in a cooling liquid with control of the movement of the molding tool ( OM) relative to a free surface (SL) of the coolant, for example by immersing the molding tool in the coolant, and in which the free surface (SL) is moved in a motorized manner in order to obtain the solidification of the 3D entanglement by immersion in the cooling liquid (LF), subsequent to reception of the curtain of molten continuous fibers falling by gravity into a molding cavity, following a duration of less than 4 seconds between reception of the curtain of fiber generating 3D entanglement, and immersion of 3D entanglement.
[Revendication 8] Procédé selon l’une des revendications 1 à 7, dans lequel la matelassure (MAT) présente tout ou partie des caractéristiques suivantes : [Claim 8] Method according to one of claims 1 to 7, in which the padding (MAT) has all or part of the following characteristics:
- les fibres sont de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm, - the fibers have a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
- l’enchevêtrement 3D de la matelassure présente une masse volumique apparente comprise entre 20kg/m3 et 70 kg/m3, par exemple entre 45 kg/m3 et 65 kg/m3,- the 3D tangle of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , for example between 45 kg/m 3 and 65 kg/m 3 ,
- la composition des fibres comprend au moins 95% en poids de PET, et par exemple la composition en fibre comprend en poids, 95% à 99% de PET, 1 % à 5% d’un second polymère distinct du PET tel que PTT ou PBT. - the composition of the fibers comprises at least 95% by weight of PET, and for example the fiber composition comprises by weight, 95% to 99% of PET, 1% to 5% of a second polymer distinct from PET such as PTT or PBT.
[Revendication 9] Matelassure (MAT) d’assise ou de dossier d’un siège susceptible être obtenue selon la procédé selon l’une des revendications 1 à 8 comprenant un enchevêtrement 3D de fibres continues thermoplastiques disposées aléatoirement, formant des boucles soudées entre elles entre les fibres, et dans laquelle : [Claim 9] Cushioning (MAT) for the seat or back of a seat capable of being obtained according to the method according to one of claims 1 to 8 comprising a 3D entanglement of continuous thermoplastic fibers arranged randomly, forming loops welded together between the fibers, and in which:
- les fibres sont des fibres creuses et/ou fibres pleines, de diamètre compris entre 0,2 mm et 2 mm, préférentiellement entre 0,3 mm et 1 ,5 mm, - the fibers are hollow fibers and/or solid fibers, with a diameter of between 0.2 mm and 2 mm, preferably between 0.3 mm and 1.5 mm,
- la composition des fibres comprenant au moins 95% en poids de PET, - the composition of the fibers comprising at least 95% by weight of PET,
- l’enchevêtrement 3D de la matelassure présente une masse volumique apparente comprise entre 20kg/m3 et 70 kg/m3, et par exemple entre 45 kg/m3 et 65 kg/m3, et dans laquelle l’enchevêtrement 3D de fibres continues présente une face frontale (FF) conformée à une cavité de moulage (CAV) d’un outillage de moulage (OM). - the 3D entanglement of the padding has an apparent density of between 20kg/m 3 and 70 kg/m 3 , and for example between 45 kg/m 3 and 65 kg/m 3 , and in which the 3D entanglement of continuous fibers have a front face (FF) shaped to a molding cavity (CAV) of a molding tool (OM).
[Revendication 10] Siège de véhicule comprenant : [Claim 10] Vehicle seat comprising:
- une structure (3) typiquement métallique comprenant une structure d’assise (3A) et/ou une structure de dossier (3B), - a typically metallic structure (3) comprising a seat structure (3A) and/or a backrest structure (3B),
- une matelassure (MAT), selon la revendication 9, telle qu’une matelassure de dossier ou une matelassure d’assise, en appui sur la structure (3), - a padding (MAT), according to claim 9, such as a back padding or a seat padding, resting on the structure (3),
- éventuellement une coiffe (CF), recouvrant la face frontale (FF) de la matelassure - possibly a cap (CF), covering the front face (FF) of the padding
[Revendication 11] Siège de véhicule selon la revendication 10 dans lequel la face frontale (FF) conformée comprend une partie centrale (PC), et deux boudins latéraux (BL) en saillie destinés à assurer le maintien latéral de l’occupant. [Claim 11] Vehicle seat according to claim 10 in which the shaped front face (FF) comprises a central part (PC), and two projecting side flanges (BL) intended to ensure lateral support of the occupant.
[Revendication 12] Siège selon la revendication 10 ou 11 dans lequel la face dorsale (FD) opposée comprend une portion centrale (PCE), saillante par rapport à deux portions latérales (PL) de la matelassure, et dans lequel : [Claim 12] Seat according to claim 10 or 11 in which the opposite dorsal face (FD) comprises a central portion (PCE), projecting relative to two lateral portions (PL) of the padding, and in which:
- pour une matelassure d’assise, la portion centrale de la face dorsale s’intercale entre deux flaques (31 ) de la structure d’assise (3A) alors que les deux portions latérales (PL) viennent respectivement en appui sur les deux flasques (31 ),- for a seat cushion, the central portion of the back face is inserted between two puddles (31) of the seat structure (3A) while the two lateral portions (PL) come respectively to bear on the two flanges (31),
-- pour une matelassure de dossier, la portion centrale (PCE) de la face dorsale s’intercale entre deux montants (32) de la structure de dossier (3B) alors que les deux portions latérales (PL) viennent respectivement en appui sur les deux montant -- for a back padding, the central portion (PCE) of the dorsal face is inserted between two uprights (32) of the back structure (3B) while the two lateral portions (PL) come respectively to bear on the two amount
PCT/FR2023/051255 2022-08-31 2023-08-08 Method for manufacturing seat padding and padding associated therewith WO2024047304A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2784049A1 (en) * 1998-10-05 2000-04-07 Faure Bertrand Equipements Sa Producing foam for vehicle seat upholstery, comprises spraying composition onto covering in mold, injecting more foam and closing mold
US20070257393A1 (en) * 2006-05-02 2007-11-08 Wei-Sung Chen Manufacturing method of an artificial strip for imitated rattan/willow furniture and a device system thereof
DE102010009127A1 (en) * 2009-02-23 2010-09-09 Faurecia Sièges d'Automobile S.A. Multi-density padding for a motor vehicle seat
US20160075073A1 (en) * 2014-09-11 2016-03-17 T.W. Womer & Associates, Llc Flow controlled strand die
EP3542990A1 (en) * 2018-03-22 2019-09-25 ALBA Tooling & Engineering GmbH Method for manufacturing a mould

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2784049A1 (en) * 1998-10-05 2000-04-07 Faure Bertrand Equipements Sa Producing foam for vehicle seat upholstery, comprises spraying composition onto covering in mold, injecting more foam and closing mold
US20070257393A1 (en) * 2006-05-02 2007-11-08 Wei-Sung Chen Manufacturing method of an artificial strip for imitated rattan/willow furniture and a device system thereof
DE102010009127A1 (en) * 2009-02-23 2010-09-09 Faurecia Sièges d'Automobile S.A. Multi-density padding for a motor vehicle seat
US20160075073A1 (en) * 2014-09-11 2016-03-17 T.W. Womer & Associates, Llc Flow controlled strand die
EP3542990A1 (en) * 2018-03-22 2019-09-25 ALBA Tooling & Engineering GmbH Method for manufacturing a mould

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