Upholstered seat element and a method for its manufacture

Abstract

An upholsterd seat element, in particular for vehicle seats, is disclosed along with a method for its manufacture. It comprises a cover ( 10 ) that encloses a layer of padding ( 20 ) on one side and is placed under tension so that it is pulled around the periphery of a cushion carrier ( 30 ). By way of its edge the cover ( 10 ) is directly attached to the periphery ( 32 ) of the cushion carrier ( 30 ), which has been placed on the other side of the layer of padding ( 20 ).

1 . An upholstered seat element, in particular for vehicle seats, with a layer of padding ( 20 ) over which a cover ( 10 ) is disposed, 
 characterized in that the cover ( 10 ) encloses the padding layer ( 20 ) from one side and is placed under tension so that it is pulled around the periphery ( 32 ) of a cushion carrier ( 30 ) that has been disposed on the other side of the padding layer ( 20 ).    
     
     
         2 . The seat element according to  claim 1 , 
 characterized in that the cover ( 10 ) is arranged so that its edge ( 12 ) is folded around the periphery ( 32 ) of the cushion carrier ( 30 ), in particular is folded into a U shape.    
     
     
         3 . The seat element according to  claim 1  or  2 , 
 characterized in that the cover ( 10 ) is fixed in position by a plurality of individual attachment elements ( 40 ), which engage the cushion carrier ( 30 ) at positions that are spaced apart around its periphery.  
 
     
     
         4 . The seat element according to any one of the  claims 1  to  3 , 
 characterized in that the attachment elements ( 40 ) are provided as pins, cotter pins, rivets or clamps.  
 
     
     
         5 . The seat element according to any one of the  claims 1  to  4 , 
 characterized in that the attachment elements ( 40 ) are inserted through the periphery ( 32 ) of the cushion carrier ( 30 ) and the edge ( 12 ) of the cover ( 10 ).  
 
     
     
         6 . The seat element according to any one of the  claims 1  to  4 , 
 characterized in that the attachment elements ( 40 ) are pushed over the edge ( 12 ) of the cover ( 10 ) and the periphery ( 32 ) of the cushion carrrier ( 30 ) and clamp them together.  
 
     
     
         7 . The seat element according to any one of the  claims 1  to  6 , 
 characterized in that the attachment elements are secured against being pulled away from the cover ( 10 ) and the cushion carrier ( 30 ).  
 
     
     
         8 . The seat element according to any one of the  claims 1  to  7 , 
 characterized in that cushion units with separate covers, padding layers and cushion carriers are arranged in pairs next to one another and along the adjacent edges ( 12 ) of their covers ( 10 ) are connected together by shared attachment elements ( 40 ), which simultaneously fix the stretched covers ( 10 ) in position.  
 
     
     
         9 . The seat element according to  claim 8 , 
 characterized in that the cushion carriers ( 30 ) at least in their peripheral region have a degree of elasticity, such that two units that have been connected together can be disposed at an angle to one another.    
     
     
         10 . The seat element according to any one of the  claims 1  to  9 , 
 characterized in that below the cushion carrier ( 30 ) a backing spring arrangement ( 60 ) is inserted, which reinforces or replaces the layer of padding ( 20 ) on its back side.  
 
     
     
         11 . The seat element according to  claim 10 , 
 characterized in that the backing spring arrangement ( 60 ) consists of a plurality of strip-shaped spring elements ( 62 ) that are spaced apart from one another and coupled or fixed to one another near their ends.    
     
     
         12 . The seat element according to  claim 11 , 
 characterized in that the spring elements ( 62 ) have a zig-zag configuration in their longitudinal direction, such that a plurality of mushroom-shaped elevations or projections ( 64 ) are disposed next to one another.    
     
     
         13 . The seat element according to any one of the  claims 1  to  12 , 
 characterized in that the cushion carrier ( 30 ) is a flat, molded piece made of plastic, metal or a plastic-metal composite and at its periphery ( 32 ) comprises a circumferential ridge ( 34 ) over which the edge ( 12 ) of the cover ( 10 ) is folded under tension.  
 
     
     
         14 . The seat element according to  claim 13 , 
 characterized in that the cushion carrier ( 30 ) has a three-dimensional configuration that specifies the shape into which the seat element is to be molded, such that the cushion carrier ( 30 ) can function as a backing spring for a seat back or as a shell to accomodate a seat cushion.    
     
     
         15 . The seat element according to any one of the  claims 1  to  14 , 
 characterized in that the cover ( 10 ) is constructed in one piece and is made of a textile material, plastic, or imitation or genuine leather.  
 
     
     
         16 . The seat element according to any one of the  claims 1  to  15 , 
 characterized in that the layer of padding ( 20 ) consists of plastic foam, a nonwoven woollen or polyester fabric and/or rubberized hair.  
 
     
     
         17 . The seat element according to any one of the  claims 1  to  16 , 
 characterized in that the cover ( 10 ) and the layer of padding ( 20 ) are made of the same or similar plastic materials, and in the region of U-shaped channels ( 14 ) that have the appearance of decorative seams are permanently joined to one another by a thermoforming process, in particular are glued, fused or welded together.  
 
     
     
         18 . A method for manufacturing a seat upholstery element, in which a layer of padding is provided with a cover, 
 characterized by the following process steps: 
 (a) a cover ( 10 ) is laid into a forming tool ( 50 ) with U-shaped cross section and is fixed therein,  
 (b) a layer of padding ( 20 ) is set into the cover ( 10 ),  
 (c) a cushion carrier ( 30 ) is placed onto the layer of padding ( 20 ) and the edge ( 12 ) of the cover ( 10 ) is folded inwardly around the periphery ( 32 ) of the cushion carrier ( 30 ),  
 (d) by moving a plunger into the forming tool so that it presses against the cushion carrier ( 30 ), the layer of padding ( 20 ) is compressed to a specified thickness and simultaneously the tension of the cover ( 10 ) is adjusted, and  
 (e) while the tension produced in step (d) is maintained, the edge ( 12 ) of the cover ( 10 ) is fixed directly to the periphery ( 32 ) of the cushion carrier ( 30 ).  
   
     
     
         19 . The method according to  claim 18 , 
 characterized in that the cover ( 10 ) is fixed to the cushion carrier ( 30 ) by means of a plurality of individual attachment elements ( 40 ) spaced apart from one another.    
     
     
         20 . The method according to  claim 18 , 
 characterized in that the attachment elements ( 40 ) are installed substantially simultaneously.    
     
     
         21 . The method according to any one of the  claims 18  to  20 , 
 characterized in that the attachment elements ( 40 ) are pushed over the edge ( 12 ) of the cover ( 10 ) as well as the periphery ( 32 ) of the cushion carrier ( 30 ) and fixedly clamped there,  
 or in that the attachment elements ( 40 ) are pushed through the edge ( 12 ) of the cover ( 10 ) as well as the periphery ( 32 ) of the cushion carrier ( 30 ) and fixed in that position.  
 
     
     
         22 . The method according to any one of the  claims 18  to  21 , 
 characterized in that after the attachment elements ( 40 ) have been installed, they are secured so that they cannot be accidentally released.  
 
     
     
         23 . The method according to any one of the  claims 18  to  22 , 
 characterized in that cushion units are prepared according to the steps (a) to (d) while arranged in pairs disposed side by side,  
 in that a part ( 56 ) of the forming tool ( 50 ) between the two units is removed and the sides of the two units are brought together,  
 and in that in step (e) the two apposed units are connected to one another by shared attachment elements ( 40 ), which simultaneously fix the stretched covers ( 10 ) in position.  
 
     
     
         24 . The method according to any one of the  claims 18  to  23 , 
 characterized in that a backing spring arrangement ( 60 ) comprising a plurality of strip-shaped spring elements ( 62 ) is inserted under the cushion carrier ( 30 ) and integrated into the seat element.  
 
     
     
         25 . The method according to any one of the  claims 18  to  24 , 
 characterized in that for the cover ( 10 ) and the layer of padding ( 20 ) the same or similar plastic materials are used,  
 and in that by means of a thermoforming process U-shaped channels ( 14 ) are incorporated into the cover ( 10 ) and the layer of padding ( 20 ) to serve as decorative seams, in the region of which the materials are permanently joined to one another.  
 
     
     
         26 . The method according to  claim 25 , 
 characterized in that polyester is used for the cover ( 10 ) and the layer of padding ( 20 ) and in the region of the channels ( 14 ) the two structures are fused or welded together.    
     
     
         27 . The method according to any one of the  claims 18  to  26 , 
 characterized in that for the padding layer ( 20 ) a foam material with uniform thickness is used, in particular a material that is provided in rolls.