# US 9,434,286 B2 · Method for producing a hybrid cushion element, in particular a seat and backrest cushion element for use in a motor vehicle, cushion element and vehicle seat having a cushion element

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- Number: US 9,434,286 B2
- Document ID: US9434286B2
- Status: Granted
- Kind: B2
- Application number: 13/574,832
- Filed: 2010-12-14
- Published: 2013-08-08
- Granted: 2016-09-06
- Earliest claimed: 2010-01-27
- Assignees: Johnson Controls Technology Company
- Applicants: Werner Klusmeier; Michael Janz; Andreas Weingartner
- Inventors: Werner Klusmeier; Michael Janz; Andreas Weingartner
- Web page: https://patentgrep.com/patent/US9434286B2

## CPC

- B60N 2/70: Upholstery springs {; Upholstery}
- B29C 70/088: {and with one or more layers of non-plastics material or non-specified material, e.g. supports}
- B60N 2/5642: {with circulation of air through a layer inside the seat}
- B60N 2/5685: {Resistance}
- B60N 2/7017: {characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for}
- B60N 2/914: {Hydro-pneumatic adjustments of the shape}
- B60N 2/976: {massaging systems}
- B60N: SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

The invention relates to a hybrid cushion element, in particular a seat cushion element for use in a motor vehicle, to a method for producing a cushion element, and to a vehicle seat, wherein the cushion element has a non-woven fabric layer and a fiber composite material, wherein an insert material is arranged between the non-woven fabric layer and the fiber composite material. During the production in a mold, fibers for the fiber composite material wetted with a binder are applied to the insert material, wherein the insert material and the layer of fibers are then pressed to form a complex molded body, wherein the binder can be cured at a temperature less than 120° C.

## Claims

### Claim 1

A cushion element for use in a motor vehicle, the cushion element comprising a fleece layer, an elastic fiber composite material, and an inlay material arranged between the fleece layer and the elastic fiber composite material, wherein the elastic fiber composite material comprises a polyurethane-based or chloroprene-based binder curable at a temperature less than 120° C.;
wherein the elastic fiber composite material comprises tangled fibers wetted with the polyurethane-based or chloroprene-based binder, the polyurethane-based or chloroprene-based binder is curable by removing water without vulcanization, and the tangled fibers are spaced apart from one another by removing the water.

### Claim 2 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 100° C.

### Claim 3 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material has a lower specific weight than the elastic fiber composite material.

### Claim 4 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material comprises a flatly arranged polyurethane material.

### Claim 5 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material comprises a flatly arranged perforated polyurethane material.

### Claim 6 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material comprises an activated carbon mat.

### Claim 7 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material comprises an inflatable air cushion.

### Claim 8 (depends on 1)

The cushion element as claimed in claim 1, wherein the inlay material comprises a heating wire.

### Claim 9 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 5° C.

### Claim 10 (depends on 1)

A vehicle seat comprising a seat part and a backrest part, wherein the seat part and/or the backrest part comprises the cushion element as claimed in claim 1.

### Claim 11 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 80° C.

### Claim 12 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 60° C.

### Claim 13 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 40° C.

### Claim 14 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 30° C.

### Claim 15 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 25° C.

### Claim 16 (depends on 1)

The cushion element as claimed in claim 1, wherein the polyurethane-based or chloroprene-based binder is curable at a temperature less than 15° C.