Method for producing an element having a cover, and such an element

Abstract

A method produces an element (3), in particular a vehicle seat, having a seamless cover (2). The seamless cover (2) is optionally provided with a lamination (1). A molding (1.2) is applied and fastened to a surface side (1.1) of the lamination (1) facing away from the cover (2) or to a surface side (2.2) of the cover (2) that is not visible. The fastened molding (1.2) is connected to the cover (2) by bonding.

Claims

1. A method for producing a vehicle seat element provided with a cover, the method comprising the steps of: applying a molding to a carrier; applying and securing the carrier to a non-visible surface side facing away from a visible surface side of the cover; and connecting the carrier to the cover by a material bond; sewing the molding to the carrier before the carrier is connected to the cover by material bond.

2. The method as claimed in claim 1, wherein a tab, pocket or loop is introduced into or applied to a lining of the cover as the molding.

3. The method as claimed in claim 1, wherein the cover being provided with a lining, the molding is applied and secured to a surface side of the lining that faces away from the cover.

4. The method as claimed in claim 1, wherein the molding is applied to a carrier and the carrier is connected to the cover or to a lining of the cover by the material bond.

5. The method as claimed in claim 1, wherein a support element, comprising a looped tape or wire, is introduced into a cavity in the molding.

6. The method as claimed in claim 1, wherein at least one impression, piece of embroidery, screen print, inkjet print or offset print is introduced into the cover at least in the region of the molding.

7. The method as claimed in claim 1, wherein a film, a foam, a nonwoven or a thermoplastic film is used as the lining.

8. The method as claimed in claim 1, wherein a reinforcing element is applied to the non-visible surface side of the cover.

9. The method as claimed in claim 8, wherein: the molding is applied to a carrier and the carrier is connected to the cover or to a lining of the cover by the material bond; and the carrier provided with the molding is applied to the reinforcing element with the surface side that faces away from the molding.

10. A vehicle seat element provided with a cover arranged on a lining, the element comprising: a molding applied to a carrier, the carrier applied and secured to a non-visible surface side facing away from a visible surface side of the cover; and a material bond connecting the carrier to the cover, wherein the molding is sewn to the carrier before the carrier is connected to the cover by the material bond.

11. The element as claimed in claim 10, wherein a tab, pocket or loop is introduced into or applied to the lining of the cover as the molding.

12. The element as claimed in claim 10, wherein the molding is secured to a carrier and the carrier is connected to the cover or to the lining by the material bond.

13. The element as claimed in claim 12, wherein the carrier is formed from a cloth material, a textile, a woven fabric, a knit or a warp-knit.

14. The element as claimed in claim 10, wherein the lining of the cover is formed from a synthetic film, a foam, a nonwoven film or a thermoplastic film.

15. The element as claimed in claim 10, wherein a reinforcing element and/or a carrier is/are arranged between the lining of the cover and molding or between the cover and molding.

16. A method for producing a vehicle seat element, the method comprising the steps of: providing a molding, a carrier and a cover, the cover having a visible surface which is visible when mounted on a vehicle seat, the cover having a non-visible surface diametrically opposite the visible surface; sewing the molding to the carrier; applying and securing the carrier to the non-visible surface of the cover by a material bond; said sewing of the molding to the carrier being performed before the carrier is connected to the cover by the material bond.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1A is a schematic perspective view showing an enlarged detail of one of different exemplary embodiments of a lining and of a cover for an element upholstered in particular in a seam-free manner;

(3) FIG. 1B is a schematic view showing an enlarged detail of another of different exemplary embodiments of a lining and of a cover for an element upholstered in particular in a seam-free manner;

(4) FIG. 1C is a schematic view showing an enlarged detail of another of different exemplary embodiments of a lining and of a cover for an element upholstered in particular in a seam-free manner;

(5) FIG. 1D is a schematic view showing an enlarged detail of an exemplary embodiment of a seamless cover without a lining for an element upholstered in a seam-free manner,

(6) FIG. 2A is a schematic perspective view showing an element upholstered in a seam-free manner;

(7) FIG. 2B is a schematic front view showing the element upholstered in a seam-free manner;

(8) FIG. 2C is a schematic cross sectional view showing the element upholstered in a seam-free manner;

(9) FIG. 2D is a schematic cross sectional view showing the element upholstered in a seam-free manner;

(10) FIG. 2E is a schematic cross sectional view showing the element upholstered in a seam-free manner; and

(11) FIG. 3 is a schematic side perspective view showing a further exemplary embodiment of an element upholstered in a seam-free manner.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(12) Referring to the drawings, FIGS. 1A to 1C show an exploded illustration and sectional illustrations of an enlarged detail of different exemplary embodiments of a lining 1 and of a seamless cover 2 for an element 3, in particular an upholstered element 3, illustrated in FIGS. 2A, 2B and 3.

(13) The element 3 can be a vehicle seat, a seat part, a backrest or some other upholstered part. The cover 2 can be formed in particular from a textile, a leather or some other natural material or natural woven fabric. To form a desired outer contour, in particular of optically visible upholstered zones, the element 3 comprises the lining 1, which is provided, at least on one surface side 1.1, with a molding 1.2 corresponding to a desired bulge-free outer contour, and a carrier unit 7, in particular a foam cushion, to form lateral bolsters 3.1 and transverse bolsters 3.2, as illustrated for example in FIGS. 2A to 2D.

(14) The molding 1.2 in the lining 1 can have been introduced or applied for example as a tab, pocket or loop. In the exemplary embodiment according to FIG. 1A, the molding 1.2 is formed on that surface side 1.1 of the lining 1 that faces away from the cover 2.

(15) Alternatively, the molding can be formed on the surface side 1.3 facing the cover 2 or on both surface sides 1.1 and 1.3 in a manner which is not illustrated in more detail.

(16) Two lateral moldings 1.2 have been introduced into the lining 1 according to FIG. 1A, these forming bulge-free lateral bolsters 3.1 for example in the case of an element 3 configured as a vehicle seat or seat part, as illustrated in FIGS. 2A to 3. Alternatively or in addition, bulge-free transverse bolsters 3.2 can be formed, by means of further moldings 1.2 that are not illustrated, in particular on a front edge and/or a rear edge of an element 3 configured as a seat element.

(17) In this case, the element 3 comprises the inner carrier unit 7, which forms the outer contours with lateral bolsters 3.1 and transverse bolsters 3.2 and to which the various outer composites illustrated in FIGS. 1A to 1C are applied.

(18) In the simplest embodiment according to FIG. 1A, an outer composite that is able to be applied to the carrier unit 7 comprises the cover 2 laminated with the lining 1, wherein the lining 1 comprises moldings 1.2 on the surface side 1.1 facing away from the cover 2, at least in sections, in particular in the region of lateral bolsters 3.1 and/or transverse bolsters 3.2. In this exemplary embodiment, the moldings 1.2 are secured directly to the lining 1, for example by means of a seam 1.4. In addition, each particular, for example tab-like molding 1.2 can be provided with a support element 1.5, in particular a wire, a rod or a clip.

(19) In an alternative embodiment according to FIG. 1B, an outer composite that is able to be applied to the carrier unit 7 comprises the cover 2 laminated with the lining 1. In this exemplary embodiment, the moldings 1.2 are secured to a carrier 5 which is in turn applied to the lining 1 with the surface side facing away from the molding 1.2 and is connected to the lining 1 by a material bond. The cover 2 is for example a leather. In the case of leather as the cover 2, the lining 1, for example a nonwoven or a warp-knit, is or has been connected to the cover 2 by a material bond by means of an adhesive 4.

(20) In a further alternative embodiment according to FIG. 1C, an outer composite that is able to be applied to the carrier unit 7 comprises the cover 2 laminated with the lining 1. In this case, the lining 1, for example a thermoplastic material such as a foam film or a textile, is or has been applied directly to the cover 2 formed from a woven fabric by fusing (=flame lamination). The moldings 1.2 are secured to the carrier 5 in this exemplary embodiment. A reinforcing element 6 is additionally arranged on the lining 1 and connected thereto by a material bond. The carrier 5 having the secured moldings 1.2 is applied to the reinforcing element 6 with the surface side facing away from the molding(s) 1.2 and connected to the reinforcing element 6 by a material bond.

(21) According to the different embodiments, the moldings 1.2 are introduced into or applied to the lining 1 or introduced into or applied to the carrier 5 before the lining 1 is connected to the cover 2 or to the carrier 5. The molding 1.2, configured for example as a tab, loop or pocket, can additionally be secured to the lining 1 or carrier 5 by means of a seam 1.4. Alternatively, the molding 1.2 can be adhesively bonded or tacked.

(22) FIG. 1D schematically shows an enlarged detail of a further exemplary embodiment of a seamless cover 2 without a lining for an element 3 upholstered in a seam-free manner. The cover 2 has a surface side 2.1 that forms a seat face and a non-visible surface side 2.2 facing away therefrom. The molding 1.2 can be connected directly or indirectly to the cover 2 by a material bond on the non-visible surface side 2.2 in this exemplary embodiment.

(23) In FIG. 1D, the molding 1.2 is optionally secured to the carrier 5, which is in turn connected to the cover 2 on the non-visible surface side 2.2 thereof by a material bond, in particular adhesively bonded thereto.

(24) In addition, a support element 1.5, in particular a looped tape, a rod, a clip or a wire, can have been introduced into a cavity in the molding 1.2.

(25) In one possible embodiment, the lining 1 is formed from a thermoplastic film. Alternatively, the lining 1 can be formed from a spacer warp-knit, in particular a 3D spacer warp-knit, a nonwoven, a plastics material, a hybrid material, in particular a synthetic fabric, or some other woven or nonwoven material.

(26) The lining 1 with the applied or introduced and optionally additionally secured, in particular sewn, adhesively bonded, tacked or clipped, moldings 1.2 is connected to the cover 2 by a material bond. To this end, an adhesive 4, in particular a laminating adhesive, can have been introduced between the lining 1 and the cover 2. The lining 1 and the cover 2 are subsequently connected together by a material bond in an in particular combined pressing and drying operation under a predetermined pressure and/or at a predetermined temperature. In this case, the adhesive 4 is applied to a rear side 2.1 of the cover 2, in particular the surface side facing the lining 1 and/or to a surface side 1.3, facing the cover 2, of the lining 1.

(27) Subsequently, the cover 2 provided with the lining 1 can have been additionally applied to the carrier unit 7, in particular a cushion carrier or cushion body, of the element 3, in a manner not illustrated, with the outer contour formed for example in a convex and/or concave manner, as a result of the moldings 1.2 of the lining 1 or the moldings 1.2 of the carrier 5, and fastened thereto, for example tacked, stapled or clipped or adhesively bonded. The carrier unit 7 is formed for example from a synthetic molded body or a natural molded body.

(28) FIG. 1B shows the exemplary embodiment with the indirect application of the molding 1.2 to a separate carrier 5. In this case, the molding 1.2 has been secured to the separate carrier 5, in particular secured by means of seams 1.4. The carrier 5 is formed in particular from a cloth material, for example a textile, a woven fabric, a knit or a warp-knit.

(29) In this exemplary embodiment, the cover 2 is prefabricated with the lining 1 and cut to size. Subsequently, the carrier 5 having the secured molding 1.2 is connected to the lining 1, in particular by a material bond, for example adhesively bonded thereto, with the surface side facing away from the molding 1.2.

(30) To this end, the carrier 5 is for example provided with an adhesive. Alternatively, the carrier 5 can have been impregnated with an adhesive.

(31) FIG. 1C shows a further exemplary embodiment with the indirect application of the molding 1.2 to a separate carrier 5, wherein the lining 1 is and has been provided optionally with a reinforcing element 6 on that surface side 1.1 of the lining 1 that faces away from the cover 2. The reinforcing element 6 is configured in particular as a reinforcing fabric, for example a warp-knit, a nonwoven or a knit, and connected to the lining 1 by a material bond, in particular adhesively bonded thereto.

(32) The method for producing the element 3 provided with the seamless cover 2 without a lining 1 to form a concave and/or convex outer contour in this case comprises the following steps in a simple embodiment:

(33) introduction or application of at least one molding 1.2, in particular a textile tab, loop or pocket, into or to the non-visible surface side 2.2 of the cover 2, and

(34) securing of the molding 1.2 to the cover 2, and also

(35) connection of the secured molding 1.2 to the cover 2 by a material bond.

(36) A further alternative method for producing the element 3 provided with the seamless cover 2 and the lining 1 to form a concave and/or convex outer contour in this case comprises the following steps in a simple embodiment:

(37) connection of a seamless cover 2 to a lining 1;

(38) introduction or application of at least one molding 1.2, in particular a textile tab, loop or pocket, into or to a surface side 1.1, facing away from the cover 2, of the lining 1, and

(39) securing of the molding 1.2 to that surface side 1.1 of the lining 1 that faces away from the cover 2, and also

(40) connection of the secured molding 1.2 to the cover 2 by a material bond.

(41) Furthermore, in the case of indirect application of the molding 1.2 to the lining 1 of the already laminated cover 2 or to the cover 2 itself, the molding 1.2 can first of all be applied to the carrier 5 and secured, for example sewn or tacked. Subsequently, the carrier 5 having the secured molding 1.2 is applied to the lining 1 of the already laminated cover 2 or to the cover 2 with the surface side facing away from the molding 1.2 and is connected thereto by a material bond, in particular adhesively bonded.

(42) In a further option, the reinforcing element 6 is arranged on that surface side 1.1 of the lining 1 that faces away from the cover 2 or on the non-visible surface side 2.2 of the cover 2 and secured, in particular adhesively bonded. The reinforcing element 6 is for example a knit, a warp-knit or a nonwoven and is adhesively connected to the lining 1.

(43) In the case of a reinforcing element 6, the carrier 5 is then applied to the reinforcing element 6 on the surface side thereof that faces away from the lining 1 or on the non-visible surface side 2.2 of the cover 2.

(44) The lining 1 has in particular a thickness of 1 mm to 10 mm, in particular of more than 3 mm. The optional reinforcing element 6 or the lower material of the lining 1 has a thickness of 0.5 mm to 1.5 mm, in particular of about 1 mm. The carrier 5 has in particular a thickness of 0.5 mm to 1.5 mm, in particular of about 1 mm.

(45) A further embodiment of the production method provides the following steps:

(46) introduction or application of at least one molding 1.2, in particular a textile tab, loop or pocket, into or to a surface side 1.1, facing away from the cover 2, of the lining 1 or into or to the non-visible surface side 2.2 of the cover 2,

(47) optional introduction of at least one support element 1.5, in particular a wire, looped tape, limiting band and/or a partition wall into the molding 1.2, in particular into a cavity formed by the molding 1.2,

(48) securing of the molding 1.2 to the lining 1 or to the cover 2 for example by means of at least one seam 1.4 or a clip,

(49) optionally separately introducing design elements, in particular patterns, decorative stitching, pieces of embroidery, impressions, screen prints, inkjet prints, offset prints, into the cover 2 before the lining 1 and the cover 2 are secured, in particular connected by a material bond,

(50) cutting the lining 1 and/or the cover 2 to size, and

(51) connecting the cut-to-size lining 1 to the cut-to-size cover 2 with a material bond, with forming of the cover 2 in a true-to-contour and seam-free manner on the shaped, in particular convexly and/or concavely shaped lining 1.

(52) As a result of the separate introduction of design elements into the cover 2 before the laminating operation, the number of cuttings and of manual sewing operations is greatly reduced compared with conventional mechanical securing methods. In addition, patterns can be introduced into the cover 2 beforehand without any misalignment.

(53) In one possible development, at least one impression, a piece of embroidery, a screen print, an inkjet print or an offset print is introduced into the cover 2 at least in the region of the molding 1.2. This introduction of design elements into the cover 2 takes place before the laminating operation.

(54) FIGS. 2A to 2D schematically show perspective illustrations, from the front and in cross section, of an exemplary embodiment of an element 3 upholstered in a seam-free manner, with lateral bolsters 3.1 shaped by correspondingly formed moldings 1.2 in the lining 1. Alternatively or in addition, further moldings 1.2 can have been introduced into the lining 1, which form for example a transverse bolster 3.2 in the outer contour at the front edge or rear edge of the element 3.

(55) As FIG. 2C shows, the molding(s) 1.2 has or have in this case been arranged on and secured to the lining 1 directly or by means of the carrier 5 only in sections, in particular in concavely shaped regions of the element 3. In the exemplary embodiment according to FIG. 2C, two moldings 1.2 are provided in the transition region to the lateral bolsters 3.1. Furthermore, further moldings 1.2 can be arranged in the central seat-surface region (as illustrated in FIG. 2D) and/or in the region of the transverse bolsters 3.2 (not illustrated). The moldings 1.2 are illustrated by way of example for an element 3 configured as a seat part; however, they can also be provided in corresponding regions in an element 3 configured as a backrest.

(56) FIG. 2D shows an element 3 configured as a seat part having a concavely shaped seat surface. In this case, the molding(s) 1.2 are arranged on and secured to the lining 1 directly or by means of the carrier 5 in sections in the concavely shaped seat region of the element 3. In particular, the moldings 1.2 are arranged at the lowest point of the concavely shaped region.

(57) FIG. 2E schematically shows a perspective illustration of an element 3 configured as a seat part, wherein the cover 2 has been formed without a lining. In this exemplary embodiment, the molding(s) 1.2 has or have been secured to the cover 2 in sections on the non-visible surface side 2.2 in the concavely shaped seat regions of the element 3, and connected to the cover 2 by a material bond there. Optionally, the carrier 5 can be arranged between the cover 2 and the molding 1.2. In this case, the molding 1.2 is first of all secured to the carrier 5 and the latter is subsequently connected to the cover 2 by a material bond.

(58) FIG. 3 schematically shows a perspective illustration in side view of a further exemplary embodiment of an element 3 upholstered in a seam-free manner, said element 3 forming a seat part with lateral bolsters 3.1.

(59) While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.