DE2362521A1 - Upholstered article esp. for automobiles - having external layer of perme-able fabric with impermeable backing and elastic foam body behind backing - Google Patents

Abstract

Upholstered article, esp. for automobiles e.g. seats, roof linings and arm supports, is made by providing an external layer of flemeable fabric with an impermable backing, and forming a body of flexible, elastic foam behind the backing. One surface of the fabric is free to undergo sideways displacement relative to the body of foam material, this surface extending over at least a part of the entire surface of the fabric.

Description

Upholstery and method of making the same. The invention relates to on an upholstery of the type specified in the preamble of the main claim, which can be used in particular in motor vehicles, for example as a seat or backrests of motor vehicle seats, for roof and door panels, as inside Armrests attachable to the doors and to surround the dashboard.

A padding is known which consists of a body made of flexible, consists of elastic and foamed material as well as different material layers, which are bound or glued to each other and to the foam body ears for the production of such upholstery are known (DT-OS 2 301 505) Are the usual upholstery exposed to frequent deformation in use, then tend they often to throw creases along the same lines or to biladen tricks, If the outer material layer or blanket is a woven or knitted fabric or some other permeable material, then this has repeated folding or deicing along the same lines often result in the ceiling along these lines receives a permanent marking, so that the respective upholstery is permanently disfigured. This can happen in particular with seats that are in Use0 often become considerably deformed. However, it is also used in other upholstery instead, for example those for armrests, if there is only frequent deformation that doesn't even have to be particularly strong.

Two basic types of wrinkles or creases can be observed are, namely so-called "star folds or pinches" and so-called 'tWeradfalten or -'rniffe ". The former extend radially from a central region largest Deformation away, while the latter extend in directions, which in general next to and parallel to the pre-formed lines of the respective upholstery, like for example the edges or grooves, seams and the like depressions or elevations, which extend over the surface of the padding.

In the known proposal (DD-OS 2 301- a fold or Kink formation can be avoided in that a layer of preformed foam material between the outer layer or blanket and the foam body, which should preferably be relatively thick and / or white. This will be true has had a favorable effect, but the distortion of the outer ceiling is through repeated folding or pinching of the foam body underneath is not perfect avoided.

The invention is therefore based on the object in a different way and ways to avoid that the outer ceiling moves back and forth along exactly the same Lines fold, i.e.

Wrinkles or wrinkles when the upholstery is in use is repeatedly deformed.

This task is solved by the in the characterizing part of the Features specified in the main claim. Advantageous developments of the invention Upholstery are characterized in claims 2 to 12-e.

In the case of the upholstery according to the invention, no intermediate layer or -Layer of preformed or prefabricated foam material between the outer Blanket and the foam body may be provided, but this can be done. Here can this intermediate layer or layer according to the earlier proposal (DT-Oo 2.301 505) be trained.

If the padding according to the invention is elastically deformed during use, then the outer cover can laterally opposite the foam body located underneath slide. It has been found that such lateral movement is no longer an option at least diminishes the blanket from being repeatedly folded in exactly the same place or pinched if the upholstery is deformed several times. The ceiling will thus less severely or less quickly disfigured than in the case in which the Cover cannot move sideways with respect to the foam body.

In the case of the upholstery according to the invention, the lateral mobility either between the outer ceiling and the associated base or base and foam body or both between the ceiling and the base. as well as between the base and the foam body be provided. Especially when the ceiling adheres to the base while the latter is laterally movable with respect to the show body, the pad can as Be formed composite element and made of a film or a layer of flexible, impermeable material as well as an intermediate layer made of flexible, elastic and peeled material between the ceiling and the said layer exist, In the Intermediate layer it can be pre-formed or pre-made Trade component.

The invention also provides a method for production upholstery characterized in claims 1 to 12. This procedure is through the features specified in claims 13 to 20 characterized.

When making upholstery with mutual mobility between the outer ceiling and the associated base can be done in such a way that the ceiling and that of a film, sheet or sheet of impermeable Material formed underlay only in certain places by an adhesive connected to one another or welded to one another under the action of heat. The foam body can be on the side facing away from the blanket in front of or be filled with foam after the ceiling has been attached to the base.

When producing upholstery with open-sided mobility of the base and the foam body can be proceeded in various ways. For example, an advantageously powdery release agent can be applied to the base, possibly at certain points of the same, before the chemicals are applied be abandoned to form the foam body. Instead, a leaf, foil or film-shaped separator made of flexible, impermeable material the entire surface of the base or on certain areas of it are placed, on which the foam-forming chemicals are then applied.

The foam normally adheres to the beparator as it is formed. The separator can cover the entire area of the mutual contact surface be detached from the adjacent pad, but is preferably at intervals associated with it. Furthermore, the separator kPnnd the entire neighboring Area of. Cover the substrate or only part of this area.

The upholstery according to the invention can have a flat ceiling, the base and the adjacent surface of the foam body are also flat. Instead, however, the surfaces provided with the ceiling cannot be level, d. H. be curved. When making such upholstery, the ceiling and the associated support, if desired also the separator or separators preferably formed into the desired shape and placed in a mold around this to undress. The foam-forming chemicals are then added to the mold. Has the foaming has ceased and the foam is cured or allowed to cure then the whole thing is removed from the mold.

The show body can be self-adhesive, i.e. when it is formed connect to the base and / or the separator or separators. Instead of pouring however, it can also be glued to it.

The invention can advantageously be used in combination with the Proposal according to DT-OS 2 301 505 can be implemented.

Below are embodiments of the invention based on the drawing for example described. These schematically show: FIGS. 1 to 6 each one Cross-section through another form of casting of the upholstery according to the invention; Fig. 7 shows the vertical cross-section, parallel to the backrest, through an inventive Seat padding of a motor vehicle seat; and FIG. 8 shows a part of the cross section according to FIG. 7 on a larger scale.

In the schematic representations of the drawing are the strengths some layers of the upholstery shown enlarged for better clarity reproduced. The foam bodies can also have other strengths and shapes.

The upholstery according to FIG. 1 has a permeable cover 1, an impermeable one Base 2 and a body 3 made of flexible and elastic, foamed llmaterial on, which is made behind the pad 2. In the middle area is the Cover 1 is freely movable with respect to the base 2, which is indicated by the gap 4 in Fig. 1 is indicated. The ceiling 1 is permanently connected to the base 2 at the edges. The body 3 is with the base 2 in the entire area of the mutual contact surface tied together.

The blanket 1 can be made of a woven, knitted or non-woven fabric exist. In many cases, a warp knitted fabric made of brushed nylon is of, for example 70 denier suitable.

The impermeable base 2 preferably consists of a thin, flexible plastic film such as polyurethane.

The ceiling 1 can at the edge areas with the base 2 by means of be connected by an adhesive. Instead, however, this connection can also go through mutual welding - if the material covers the ceiling 1 or the underlay 2 is suitable for this. Ceiling 1 and the underlay connected to it 2 are placed in a suitable shape, not shown, -, - wörauf the chemicals required to produce the foam body 3 are entered. Foam then forms, which is allowed to solidify. The underlay 2 prevents the foam-forming chemicals from coming into contact with the blanket 1. In particular, it is excluded that a penetration into or penetration through the permeable blanket 1 takes place, so that this deformed or in terms of the handle changed, i.e. would become too stiff.

The foam is preferably such that it attaches itself to the support 2 is liable. If this is not the case, however, then the foam body 3 can also use An adhesive can be connected to the base 2 after the ceiling 1 is attached to it Pad 2 and the foam body 3 are removed from the mold.

The body 3 is preferably made of polyurethane foam, in particular one in which the cells communicate with one another. The foam is both flexible as well as elastic. The foam can be relatively soft, in particular when the upholstery is intended for a seat. It can be stiffer, for example then when the upholstery for an armrest or as a covering for a dashboard is used. In any case, the foam has the appropriate for the use of the padding suitable softness or

Stiffness on, does not collapse and is not constantly bulged, when he is deformed.

If a pressure is exerted on the upholstery according to FIG. 1, and although in the middle area of the ceiling 1, so that the underlying body 3 deformed, then the ceiling 1 can slide laterally on the adjoining base 2. It can happen that the body 3 after several deformations in certain, defined Areas becomes weaker and is particularly clearly deformed in these areas, even if in any of several closely spaced locations the blanket 1 a pressure is exerted. Since the ceiling 1 is related to the base 2 and the body 3 can move freely, the folds formed in the blanket 1 vary with the point at which pressure is applied, even if the foam body 3 is always deformed along the same inner plane of greater weakness. Through this it is avoided that permanent wrinkles form in the ceiling 1, which then happens would if the blanket 1 firmly connected to the base 2 and the foam body 3 would be to follow the deformations of the surface of the upholstery so precisely.

The upholstery according to FIG. 2 is similar to that according to FIG. 1 in that as also an outer cover 5 with an impermeable base 6 as well a body / 7 made of flexible and elastic, foamed material are provided. However, the blanket 5 and the base 6 are mutually exclusive over the entire area Contact surface connected to one another, while the pad 6 in the central area is freely movable with respect to the body 7, as indicated by the gap 8 in FIG.

As in the production of the upholstery according to FIG. 1, the base 6 produced separately from the ceiling 5 and then with this by an adhesive or welding. Preferably, however, the base 6 is as impermeable film made by applying a liquid to the ceiling 5, which are left to cure - or cured will, with the rest the base 6 is connected to the ceiling 5. The film-forming liquid can be applied after the blowing process, whereby the liquid through a narrow Slot is extruded and immediately next to the ceiling 5 forms a film which settles on the cover 5, still sticky to harden or solidify to adhere firmly to the ceiling 5 This procedure is similar to that which for the formation of films from PVC sheets or plates is applied to this to give a so-called "wet" appearance. The film has only one strength of a few thousandths of a millimeter, for example a thickness of about 2 or about 5 / u.

The blanket 5 provided with the base 6 is placed in a form, so that this is lined by it, and the chemicals used to make the foam are given into the mold. The foam then forms and is solidified or allowed to solidify, i.e. cured or allowed to harden. As in the embodiment of FIG. 1 can be taken to ensure that the Foam does not adhere to the base 6. The ceiling connected to the pad 6 5 is then after their and the removal of the foam body 7 from the mold in the edge area connected to the foam body 7.

Preferably, however, a foam is generated which when solidifying or hardening adheres to the base 6.

A release agent, such as dalk powder, is used in the middle Area applied to the base 6 after the provided with this base 6 Cover 5 has been inserted into the mold. After that, the foam-forming chemicals entered. The forming sound body 7 adheres to the base 6 in the edge areas, which are not provided with release agent, but not in the one with release agent coated middle area.

The places of mutual connection or mobility between Ceiling 1 or 5 and show body 3 or 7 can also be made according to a different pattern be distributed.

The embodiment according to FIG. 3 corresponds to that according to FIG. 2 insofar as an outer cover 9, an impermeable film 10 and a body 11 made of flexible, elastic and peeled material are provided. The underlay however, additionally has a layer 12 made of flexible, elastic and shaved Material which is provided between the ceiling 9 and the film 10. The intermediate layer 12 is preferably at most 12 or 15 mm thick. One strength is particularly troubled between 1 and 10 mm.

The intermediate layer 12 is preformed or prefabricated.

It can be cut from a block of foam material and with the ceiling 9 can be connected in any suitable manner, for example by means of an adhesive or by welding, the surface of the intermediate layer 12 is heated so that it temporarily melts or softens, whereupon the intermediate layer 12 is printed on the ceiling 9 and allowed to solidify.

The foam material of the intermediate layer 12 is preferably such that the cells communicate with one another so that the intermediate layer 12 and the ceiling 9 are each permeable.

The intermediate layer 12 preferably consists of polyurethane foam. In a typical upholstery according to the invention, the thickness of the intermediate layer lies 12 between 2 and 5 mm. The density can be about 37 kgm-) b, the penetration hardness index between about 25 and 27 kg, which is based on the British Standard B.ß. 3667, part I, described way is determined.

The film 10 is either prefabricated and comes with the intermediate layer 12 glued, or it is applied according to the illustrated blow molding process, like in the embodiment according to FIG. 2, the film 10 is in the central region with respect to of the foam body 11 is freely movable, as indicated by the gap 13 in FIG. 3.

This is done in the manner outlined in connection with FIG achieved.

A typical upholstery according to the invention has the density of the foam body 11 at about 40 kgm-3, the penetration hardness index between about 27 and 33 kg. The fact that the intermediate layer 12 is less hard and dense than the body 11 further favors that there are no permanent ones in the ceiling 9 Form folds or creases. The embodiment according to FIG. 4 is that according to FIG. 1 and 2 similar. There are a blanket 14, an impermeable pad 15 made of one flexible film and a foam body 16 is provided. There are ceilings in the peripheral areas 14 and base 15 are connected to one another and to the foam body 16. In the middle Areas are ceiling 14 and base 15 with respect to each other and with respect to the body 16 movable, as indicated by the columns 17 and 18 in FIG. In the preparation of can be taken care that the ceiling 14 and base 15 in the edge areas with each other glued --and then placed in a form, whereupon the base 15 in the -mediate Area coated with a powdery release agent and the foam body 16 is formed in the mold, with the foam in the edge areas on the base 15 adheres, but is movable in the central area with respect to the base 15.

In Fig. 5 is another technique Dargest.ellt to the mutual Mobility of foam body and more permeable, film-shaped To reach the document. The embodiment according to FIG. 5 is similar to that according to FIG Fig. 3.

There are an outer cover 19, an impermeable base consisting of a permeable intermediate layer 20 made of foamed material and an impermeable Film 21 and a flexible and elastic show body 22 are provided.

Parts of the film 21 are freely movable with respect to the body 22, such as indicated by column 23. To ensure that film 21 is free to move, a separator 24 is provided between this and the body 22.

Separator 24 and film 21 form two layers of preformed tube or sack. The one-piece mountain between these two layers is on the linear Side of Fig.

5 can be seen. A piece of hose is used during manufacture made of polyethylene film laid flat so that the two flat layers 21 and 24 lie against one another. The two layers 21 and 24 are applied along predetermined longitudinal lines 25 connected by heat and pressure. The two layers 21 and 24 for example between heated rollers or the electrodes of a high-frequency heater be passed through.

never layer 21 is then glued to the back of the intermediate layer 20, to form the impermeable element of the base. On the other position or the separator 24 foaming chemicals are applied so that a forms flexible and elastic foam that adheres to the separator 24.

This procedure is particularly suitable for the production of Seat surfaces of motor vehicle seats. For example, a polyethylene tube can be used can be used to form the film 21 and the separator 24, the two Tubular flaps are connected to one another along two longitudinal lines 25, which extend from the Front edge to the rear edge of the seat extend and its surface in three share equal areas.

The embodiment according to FIG. 6 differs only in this respect from that of FIG. 5, that the intermediate layer 20 is made of foamed material is missing. The film 21 thus alone forms the impermeable base for the ceiling 19 and is glued to the back.

Each of the described embodiments can be modified in this way be that the ceiling 1 or 5 or 9 or 14 or

19 and the base 2 or 6 or 10, 12 or 15 or 20, 21 or 21 and optionally the separator 24; are shaped into a non-planar shape, before the body 3 or 7 or

11 or 16 or 22 is formed from foamed material behind it. Cover and base and optionally separator are first connected to one another and then brought into the desired shape before the foam-forming chemicals to be posted on the back. Cover and pad and, if necessary, separator can simply be placed in a curved shape to adapt to its shape, or they can be softened and permanently deformed by the action of heat. in the The latter case requires that at least some of the layers be thermoplastic are. If not all layers are thermoplastic, the remaining layers must be stretchable be.

If the ceiling is 1 or 5 or 9 or 14 or 19, respectively a knitted fabric, then it is easier to stretch than a woven blanket. Is the ceiling made of thermoplastic yarn, such as nylon yarn, then can they are also permanently deformed by heating. The combination of these properties so makes it appear advantageous than Cover in the invention Upholstery in particular a knitted fabric made of nylon thread or -> yarn should be used.

It is not absolutely necessary that all layers be in & the desired shape can be brought. For example, the with a layer of foamed material provided ceiling in the desired shape be brought, whereupon an impermeable film on the back of the molded Interlayer is applied, for example by the blowing method mentioned.

In Fig. 7 the seat of an Era, vehicle seat is shown, which is designed according to the invention.

There is a blanket 26, an intermediate layer 27 made of foamed material, an impermeable film 28 and a foam body 33 are provided.

During production, the intermediate layer 27 is exposed to heat softens, whereupon the cover 26 is pressed on, so that the two layers are together associate. Then the film 28 is on the back of the intermediate layer 27 after geschilder.ten blow molding applied.

The three layers, of which two are adjacent over the entire mutual contact surface are connected to each other are heated between Forins brought and permanently deformed so that they are the ones in Fi. 7 reproduced Have shape. The intermediate layer 27 is for the most part not compressed, however, there are two parallel gluten 29, which extend from the front edge extend to the rear edge of the seat, and in which area the intermediate layer 27 is compressed. One of these mares 29 is shown in detail in FIG.

About the formation of constant straight folds or twists in the ceiling 26 in and next to the grooves 29 are polyethylene sheet or film strips 30 are provided, each extending along one side of each groove 29 and only at the longitudinal edges at 31 with the film 28 on the intermediate layer 27 facing away from the rear side are connected by gluing or welding. In the middle Area, each strip 30 can be bent laterally with respect to the film 28, as indicated by column 32 in FIG.

Cover 26, intermediate layer 27 and film 28 are created after the design and after applying the strips 30 placed in a mold in which foam-forming Chemicals are entered. From these the show body 33 results, which adheres to the film 28, apart from those points which are from the strip 30 are covered, to which the body 33 also adheres. It has shown, that in use the seat according to FIGS. 7 and 3 not to form permanent Straight folds or kinks in the ceiling 26 tends to.

In an embodiment of the invention, not shown, the ceiling, optionally provided with an attached, prefabricated or preformed intermediate layer made of Deschäuntem Itlaterial, under the action of heat in brought the desired shape to be then placed in a mold, whereupon a Sheet or film of impermeable material such as polyethylene, which also to the desired shape. can be preformed, also into the shape is laid to cover the back of the ceiling or the intermediate layer. That Sheet or the film is only at certain points with the cover or the Glued intermediate layer. Then foaming chemicals are added to the mold, so that a show body forms on the impermeable sheet or the impermeable Foil sticks.

In use, the blanket, possibly together with the intermediate layer, move around the shell in the few areas where the impermeable Sheet or

the impermeable film not with the cover or the intermediate layer is glued.

The intermediate layer present in some of the described embodiments, which is a component of the pad can be made of polyurethane foam or a other foam. For example, PVC foam can be used, but is this foam is usually less satisfactory than polyurethane foam because it is more expensive and contains plasticizers, which tend to evaporate with prolonged use or to hike. Likewise, the show body does not necessarily have to be made of a polyurethane foam exist. Another foam can be used. Advantageously -is the foam of the body is thermosetting. However, cold-curing polyurethane foams can also be used can be used, especially when increased density is desired.

Claims (20)

Expectations (I) padding with an outer, permeable cover of an impermeable one Underlay behind and a body made of flexible, elastic, foamed material behind the base, characterized in that the ceiling (1; 5; 9; 14; 19; 26) at least in one area (4; 8; 13; 17, 18; 23; 32) opposite the covered surface the foam body (-3; 7; 11; 16; 22; 33) is arranged to be laterally movable. 2. Upholstery according to claim 1, characterized in that the ceiling (1) relative to the base (2) is movable, the foam body (3) over the entire area of the mutual contact surface adheres to the base (2). 3. Padding according to claim 1, characterized in that the ceiling (5; 9; 19; 26) over the entire area of the mutual contact surface on the Base (6; 10, 12; 20, 21; 27, 28) adheres, the foam body (7; 11; 22; 33) is movable with respect to the base (6; 10, 12; 20, 21; 27, 28). 4. upholstery according to claim 1> characterized in that the Cover (14) opposite the base (15) and the base (15) opposite the foam body (16) is movable. 5. Upholstery according to claim 4, characterized in that the areas (17 and 18) mutual mobility between ceiling (14) and base (15) or Base (15) and foam body (16) lie one above the other. 6. upholstery according to one of claims 2, 4 and 5, characterized in that that the ceiling (1; 14) apart from the or each area (4; 17) mutual Mobility on the base (2; 15) adheres. 7. Upholstery according to one of claims 3 to 5, characterized in that that the foam body (7; 11; 16) apart from the or each area (8; 13; 18) mutual mobility on the base (6; 10, 12; 15) adheres. 8. Upholstery according to claim 1, characterized by a sheet, foil-shaped or film-shaped separator (24; 30) made of flexible, impermeable material between foam body (22; 33) and base (20, 21; 27, 28), which under training at least one area (23; 32) of mutual mobility with the base (20, 21; 27, 28) is connected, and on which the foam body (22; 33) via the adheres to the entire area of mutual contact. 9. Padding according to claim 8, characterized in that the separator (24) and base (21) formed by a single tube, sack or the like are. 10. Upholstery according to one of the preceding claims, characterized in that that the base consists of a layer (10; 21; 28) made of flexible, impermeable material and an intermediate layer (12; 20; 27) made of flexible, elastic and foamed There is material between the cover (9; 19; 26) and the layer (10; 21; 28). 11. Padding according to claim 9 and 10, characterized in that the layer (21) made of flexible, impermeable material and the separator (24) of a single tube, sack or the like are formed. 12. Upholstery according to Änsrruch 8, characterized in that the ceiling (26) and the base (27, 28) are provided with grooves (29), and that two separator strips (30) on both sides of each groove (29> are provided, which in each case along the both longitudinal edges are connected to the base (27, 28), the foam body (33) 'on the separator strips (30) and the uncovered areas of the substrate (27, 28) is liable. 13. A method for producing the upholstery according to any one of the preceding Claims, characterized in that the cover (1; 5; 9; 14; 19; 26) and the base (2, 6; 10, 12; 15; 20, 21; 27, 28) are glued or welded together. 14. The method of claim 13, wherein the blanket over the entire Area of mutual contact surface is connected to the base, thereby characterized in that the base (6) is extruded as a film onto the ceiling (5) and is cured or allowed to cure. 15. The method according to claim 13 or 14, characterized in that Blanket (1; 5; 9; 14; 19; 26) and base (2; 6; 10, 12; 15; 20, 21; 27, 28) as well if necessary, the separator (24) or the separators (30) are placed in a mold are, whereupon foam-forming chemicals entered and the foam body (3; 7; 11; 16; 22; 33) is foamed and cured or left to cure. 16. The method according to claim 15, wherein the foam body on the base itself adheres and over at least one area of the mutual contact surface relative to the base is movable, characterized in that the in the Form inserted underlay (6; 10, .12; 15) a powdery release agent in the or each area (8; 13; -18) of mutual mobility is broken up. 17. The method according to claim 15, characterized in that the formed Foam body (3; 7; 11; 16; 22; 33) glued to the base (2; 6; 10, 12; 15) will. 18. The method according to any one of claims 13 to 17, wherein a separator is provided, characterized in that the separator (24; 30) with the base (20, 21; 27, 28) is glued or welded in places. 19. The method according to any one of claims 13 to 18, characterized in, that in the ceiling (26) and the base (27, 28) grooves (29) are pressed before the separators (30) are applied and the foam body (33) is filled with foam. 20. The method according to any one of claims 13 to 19, characterized in that that the ceiling and / or the base or a component thereof and / or the Separator is or are preformed, whereupon the foam body is foamed. L e r s e i t e