FR3037848A1 - REALIZING A THERMAL CABIN FOR A SEAT ELEMENT FOR A MOTOR VEHICLE - Google Patents

Abstract

The invention relates to a method for producing a cap for lining a seat element for a motor vehicle, comprising the following steps: forming, in a mold, a stack of at least one covering material (32) textile, leather, skin or synthetic material, and a foam layer (34) defining, on the back side of the foam layer, a housing (35); and place thermal elements in the housing.

Description

B14197 - 3871 1.EN 1 REALIZATION OF A THERMAL HEAD COVER FOR SEATING ELEMENT FOR MOTOR VEHICLE Field This description relates generally to seats for motor vehicles and, more particularly, to the production of fittings of a seat element (seat , backrest, headrest, armrest). The present description relates more particularly to the production of a cap whose rear face comprises a layer of foam. BACKGROUND OF THE INVENTION Motor vehicle seat upholstery is generally in the form of a quilting coated with a cap. A particular class of gaskets to which the present description applies comprises a foam support block defining the general shape of the seat member and a cover member constituting the cap and defining the apparent face of the trim of the element. seat. The covering element is then at least partly made in the form of a relatively thin foam layer with respect to the thickness of the padding or support element to which it is attached, this layer of mouse being covered with a leather, leather, woven or non-woven fabric covering material of 3037848 B14197 - 3871 1.FR 2 synthetic material, etc., defining the visible face of the seat element lining. Such caps or cover elements are described, for example, in FR-A-2934195 and FR-A-2942423. SUMMARY An embodiment overcomes all or some of the drawbacks of known techniques for producing a cap equipped with a layer of foam on the rear face. One embodiment provides a solution compatible with the incorporation of heat elements into the liner. Thus, an embodiment provides a method of producing a cap for lining a seat element for a motor vehicle, comprising the following steps: forming, in a mold, a stack of at least one textile covering material in leather, in skin or in synthetic material, and a layer of foam defining, on the rear face of the foam layer, a housing; and place thermal elements in the housing. According to one embodiment, a split foam layer is attached to the thermal elements to close the housing. According to one embodiment, the surface of the split foam is flush with the surface of the edges of the housing. According to one embodiment, the thermal elements 25 are flush with the surface of the edges of the housing. According to one embodiment, the thermal elements are heating resistors. According to one embodiment, the thermal elements are Peltier effect elements. According to one embodiment, the foam is sprayed onto a transfer film and is attached to the backside of the cover material. According to one embodiment, a sealing layer is interposed between the cover material and the foam layer. 3037848 B14197 - 3871 1.EN 3 According to one embodiment, the forming is a cold forming. According to one embodiment, the forming is a hot forming. According to one embodiment, the cover material is maintained by suction at least until the closure of the mold. According to one embodiment, the cap comprises foams having different densities and / or hardnesses. One embodiment provides a method of making a lining of a motor vehicle seat member, wherein a cap is attached to a foam support block. One embodiment provides a cap for a motor vehicle seat element comprising: a textile cover material of leather, skin or synthetic material; and a foam layer incorporating thermal elements. According to one embodiment, the cap is obtained by implementing the method described. According to one embodiment, the cap has a non-uniform thickness of between 1 and 50 mm. One embodiment provides a motor vehicle seat member having a cap defining the shape and finish of at least one exposed face of the seat member. One embodiment provides a seat for a motor vehicle comprising at least one seat element. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects, features, and advantages will be set forth in detail in the following non-limiting description of particular embodiments in connection with the accompanying drawings in which: FIG. schematic side view of a seat for a motor vehicle; BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 2A, 2B and 2C are perspective views illustrating one embodiment of a seat member lining; Figures 3A, 3B, 3C and 3D are sectional views illustrating an embodiment of a cap; Figure 4 is a sectional view of the cap resulting from the embodiment illustrated in Figures 3A to 3D; Figure 5 is a sectional view of a completed cap; Figure 6 is a sectional view illustrating an alternative embodiment; and Figure 7 is a sectional view illustrating another alternative embodiment. Detailed Description For the sake of clarity, only the steps and elements useful for understanding the described embodiments have been shown and will be detailed. In particular, the embodiment of the other parts of the seat has not been detailed, the described embodiments being compatible with any customary embodiment of a lining attached to a frame. It should be noted that, in the figures, the structural and / or functional elements common to the various embodiments may have the same references and may have identical structural, dimensional and material properties.

In the description which follows, when reference is made to absolute position qualifiers, such as the terms "before", "backward", "up", "down", "left", "right", etc., or relative, such as the terms "above", "below", "upper", "lower", etc., or with qualifiers for orientation, such as the terms "horizontal", "vertical", etc., it is referred to the orientation of the figures. Unless otherwise specified, the expressions approximately, substantially and, in the order of, signify to within 10%, preferably to within 5%. Figure 1 is a schematic side view of a seat 1 for a motor vehicle. Such a seat has a seat 12 3037848 B14197 - 3871 1.EN 5 on which is articulated a backrest 14, usually surmounted by a headrest 16. The seat 12, the backrest 14 and the headrest 16 each comprise a lining fixed on its frame, generally metallic. The armature of the seat 12 may be connected to the floor P of the vehicle by a slide mechanism 18. The seat 1 may also include one or more armrests (not shown). Figures 2A, 2B and 2C are perspective views illustrating the embodiment of a liner 4 of a seat member 10 (for example, seat 12). A foam support block 2 (Figure 2A) is made without styling reminder (without rib). The difference compared to a usual trim lies in its upper face 22 which does not define the apparent final shape.

A cap 3 (FIG. 2B) or covering element is formed of a stack of a covering material 32, for example textile (woven or not), leather, skin or synthetic material, and a layer The cap 3 is formed separately from the support block 2 and defines the final shape of the apparent face 20 of the lining 4, thus of the seat element. The cap 3 defines, for example, lines 322 style reminder of the seat element. The cap 3 is intended to be reported (Figure 2C) on the block 2 to obtain the lining 4 of the seat member.

The cap 3 may be formed of one or more pieces joined to each other by stitching or heat-sealing. Lateral overlays or skirts (not shown in the figures) may be provided and participate in the holding of the element 3 on the block 2. Such wraps may be sewn to the edges of the cap 3 or be formed of flexible lateral extensions, for example, without foam on the back. The advantages of this technique are, among other things, that a same block of foam support 2 can be used for different families of seats for which reminders of different shapes and styles are desired. Moreover, besides a 3037848 B14197 - 3871 1.FR 6 foam block 2 and a cap 3 of different hardnesses, different hardnesses and / or foam densities can be provided in the cap, for example according to the parts of the element seat. Furthermore, obtaining the final appearance requires no recovery of the support block 2. The cover element or cap 3 therefore defines not only the shape of at least one apparent face (typically the top of the seat or the front of the backrest) of the seat element, but also the finish of at least this apparent face.

The subsequent formation of the cap or cover element 3 is then concerned with defining the final shape and the final appearance of the seat element. The support block 2, made separately, may be made according to various conventional techniques.

Figures 3A, 3B, 3C and 3D are sectional views illustrating one embodiment of a cap 3. Figure 3A shows a step of preparing the cover material 32. Figure 3B shows a preparation step of the foam layer 34. FIG. 3C illustrates the shape of the mold for forming the cap. Figure 3D illustrates the closed mold. Note that the sections of Figures 3C and 3D are in different planes sections of Figures 3A and 3B to illustrate that the front (apparent) of the cap is generally not uniform. In a preparation step (Fig. 3A), a piece of cover material 32 is placed in a frame 42. Then, cover material 32 is placed at the bottom of a die 52 of a mold 5 (Fig. 3C) , or forming press, whose die 52 and a punch 54 define the desired shapes for the cap 3. The die 52 defines the apparent (external) face of the cap 3.

The punch 54 defines the hidden (internal) face of the cap and is therefore a function of the upper face of the support block 2 (FIG. 2A). The cover material 32 is placed face-wise on the die side 52. In another preparation step (FIG. 3B), a transfer film 38, for example made of polyethylene or polypropylene, 3037848 B14197 - 3871 1.EN 7 is stretched on a support frame 44. Then, foam 342 is sprayed, using a spraying tool 46, onto a first face of the transfer film 38. The transfer film 38 is flexible and has a relatively small thickness The foam 342 begins to polymerize in this state on the transfer film. The preparation steps of FIGS. 3A and 3B are carried out separately, in any order. Then (FIG. 3C), the film 38 - foam 342 assembly is attached to the covering material 32, the foam face 342 against the rear face of the covering material 32. The mold 5 is then closed again (FIG. 3D) the time necessary to the complete polymerization of the foam. Figure 4 is a sectional view showing the cap 15 3 obtained from the mold 5. The front face (apparent) of the cap 3 includes the desired styling reminders and more generally the desired shape for the seat member. Due to the thickness of the foam layer 34, the cap 3 retains the shape given by the press.

According to the described embodiments, the punch 54 of the mold comprises a recess 546 for defining a zone 35 (FIG. 4) recessed from the rear face of the cap 3. This zone defines a housing for thermal elements (heating elements). or cooling) to be integrated into the cap 3.

FIG. 5 is a sectional view illustrating the cap 3 obtained after integration of thermal elements. Thermal elements 6, for example a heating and / or cooling mat, are placed in the housing 35 defined on the back side of the foam 34. Preferably, a layer 62 of split foam is attached to the sheet 6 to close the housing. 35. Thus, the completed cap incorporates the thermal elements 6. This cap can then be reported on a support block 2 of the type illustrated in Figure 2A. Preferably, the apparent surface of the layer 62 is flush with the edges of the housing 35 so that the rear of the cap has a flat surface.

Alternatively, the thermal elements themselves are flush with the edges of the housing 35 and the layer 62 is omitted. 3037848 B14197 - 3871 1.GB The thermal elements can be of various natures. For example, heating resistors, coolant circulation lines, Peltier elements, etc. may be provided. The dimensions of the housing 35 are of course adapted to the volume occupied by these thermal elements. Thus, for the same support block 2, it is possible to provide seat inserts with or without thermal elements, the latter being present or not in the cover 3. In addition, for the same apparent surface of the cover 3, therefore the same matrix 52 of the mold 5, it is possible to provide embodiments with or without thermal elements and with thermal elements of different types. Just change the punch 54.

In a variant, thermal elements are placed on the support block 2 (FIG. 2A) before mounting the cap on this support block. In the example of FIG. 3C, a cold forming is envisaged and it is then advantageous to take advantage of the fact that the foam has begun to polymerize on the transfer film 38. Moreover, the presence of the transfer film 38 avoids the need to envisage , punch side 54, a release agent, the transfer film preventing the foam from adhering to the punch 54. The transfer film 38 may or may not be retained during assembly of the cap 3 to the support block 2.

Figure 6 is a sectional view illustrating another embodiment, more particularly for the case where the cover material 32 is not or not sufficiently impermeable. Figure 6 is closer to Figure 3C. According to this embodiment, the rear face of the cover material 32, to which the foam 342 is attached, is coated with a sealing layer 36, for example a plastic film, a thin thickness (between 1 and 5 mm) of slit foam or varnish or the like. The material 32 - seal 36 can be made out of the matrix and then placed at the bottom of the matrix 52, cover material 32 on the die side 3037848 B14197 - 3871 1.EN 9 52, so that the sealing layer 36 is related. It is also possible for the sealing layer 36 to be attached to the rear face of the covering material 32 while the latter is placed against the matrix 52. The film 38-foam assembly 342, resulting from FIG. 3B, is then attached to the material assembly 32 - sealing 36, foam face 342 against sealing layer 36. The mold 5 is then closed the time required for the complete polymerization of the foam. Figure 7 is a sectional view, closer to Figure 3C, illustrating another alternative embodiment. According to this variant, a hot forming is carried out. For example, the mold 5 and, more particularly, the punch 54 of the mold is heated (heating symbolized by heating elements 58). The hot forming is preferably carried out at a temperature between 40 and 80 degrees. According to another variant embodiment, not shown, applied to hot forming, the foam 342 is sprayed directly on the rear face of the covering material 32. According to another variant not shown, the die 52 of the forming mold 5 comprises suction channels. Thus, when positioning the cover material 32, it is pressed against the die 52 by suction. This facilitates the realization and improves the accuracy of the distribution of the foam 342. In particular, it is then not necessary to use a frame (42, 3A, 3C, 5 and 6) for holding and tensioning the foam. Cover material 32. If present, the seal layer 36, reported on the back side of the cover material 32, facilitates placement by suction. The suction is either maintained throughout the forming, or cut once the mold is closed. The resulting cap 3 has, for example, a non-uniform thickness of between 1 and 50 millimeters, preferably between 10 and 35 millimeters. The thickness may further vary according to the areas of the cap.

Embodiments have been described. Various variations and modifications will be apparent to those skilled in the art. In particular, although the embodiments have been described in connection with an exemplary seat cushion trim, they are more generally applicable to any seat element. In addition, the distribution between the thickness imparted to the support foam block 2 and the cap 3 may vary according to the seat ranges. In addition, the practical implementation of the described embodiments is within the abilities of those skilled in the art from the functional indications given above.

Claims (18)

REVENDICATIONS1. Process for producing a cap (3) for lining a seat element (4) for a motor vehicle, comprising the following steps: forming, in a mold (5), a stack of at least one 5 covering material (32) textile, leather, skin or synthetic material, and a layer of foam (34) defining, on the rear face of the foam layer, a housing (35). ; and placing thermal elements (6) in the housing. The method of claim 1, wherein a slit foam layer (62) is attached to the thermal elements (6) to close the housing (35). 3. Method according to claim 2, wherein the surface of the slit foam is flush with the surface of the edges of the housing. 15 4. The method of claim 1, wherein the thermal elements are flush with the surface of the edges of the housing. 5. Method according to any one of claims 1 to 4, wherein the thermal elements (6) are heating resistors. 20 6. Method according to any one of claims 1 to 4, wherein the thermal elements (6) are peltier effect elements. The method of any one of claims 1 to 6, wherein the foam is sprayed onto a transfer film (38) and is attached to the backside of the cover material (32). The method of any one of claims 1 to 7, wherein a sealing layer (36) is interposed between the cover material (32) and the foam layer (34). 30 The method of any one of claims 1 to 8, wherein the forming is cold forming. The method of any one of claims 1 to 8, wherein the forming is hot forming. 3037848 B14197 - 3871 1.EN 12 11. A method according to any one of claims 1 to 10, wherein the cover material (32) is maintained by suction at least until the closure of the mold (5). 12. A method according to any one of claims 1 to 11, wherein the cap (3) comprises foams having different densities and / or hardnesses. 13. A method of producing a lining (4) of a seat element (1) for a motor vehicle, wherein a cap (3) made by carrying out the method according to any one of claims 1 to 12 is reported on a foam support block (2). 14. Headgear (3) for a seat element for a motor vehicle comprising: a cover material (32) textile, leather, skin or synthetic material; and a foam layer (34) incorporating thermal elements (6). 15. Cap, obtained by the implementation of the method according to any one of claims 1 to 12. 20 16. The cap of claim 14 or 15, having a non-uniform thickness of between 1 and 50 μm. A seat member for a motor vehicle, comprising a cap (3) according to any one of claims 14 to 16, defining the shape and finish of at least one apparent face of the seat member. 18. Seat for a motor vehicle comprising at least one seat element according to claim 17.