阅读说明：本技术 具有由纤维复合材料制成的管元件的车辆座椅框架 (Vehicle seat frame with tube elements made of fiber composite material ) 是由 安德烈亚·鲍尔扎克斯 约亨·霍夫曼 托马斯·比特曼 雅舍·法伊特 斯文·辛纳 迈克·居德 于 2019-07-25 设计创作，主要内容包括：本发明一种用于制造由纤维复合材料形成的管元件的方法,该方法包括：提供(S1)分别由编织软管形成的第一纤维编织物(M1)和第二纤维编织物(M2),并且加热(S3)纤维编织物(M1、M2)用以在形成管元件(2)的管体(21)的情况下在纤维编织物(M1、M2)之间建立材料锁合的连接,该管体至少具有：具有第一纤维编织物(M1)的第一层(210)和具有第二纤维编织物(M2)的第二层(211)。以这种方式,提供了如下管元件,该管元件能够实现车辆座椅的轻质结构,同时在载荷情况下将力有利且有针对性地导出。(The present invention relates to a method for manufacturing a pipe element formed of a fibre composite material, the method comprising: providing (S1) a first fiber weave (M1) and a second fiber weave (M2) each formed by a braided hose, and heating (S3) the fiber weaves (M1, M2) for establishing a material-bonded connection between the fiber weaves (M1, M2) in a state of forming a tubular body (21) of the tubular element (2) having at least: a first layer (210) having a first fiber weave (M1) and a second layer (211) having a second fiber weave (M2). In this way, a tube element is provided which enables a lightweight construction of the vehicle seat, while at the same time forces are advantageously and specifically conducted away in the case of loading.)

1. Method for manufacturing a pipe element (2) formed of a fibre composite material, the method comprising:

-providing a first fabric of fibres (M1) and a second fabric of fibres (M2) each formed by a braided hose, and

-heating the fiber braid (M1, M2) for establishing a material-locking connection between the fiber braids (M1, M2) in the case of forming a tube body (21) of the tube element (2) having at least: a first layer (210) having a first fiber weave (M1) and a second layer (211) having a second fiber weave (M2).

2. Method according to claim 1, characterized in that one of the fibre mats (M1, M2) is arranged within the other of the fibre mats (M1, M2).

3. The method according to claim 1 or 2, characterized in that the fiber weave (M1, M2) has a fiber composition that is different from each other.

4. The method according to any one of the preceding claims, characterized in that the fiber braids (M1, M2) each comprise a polymer fiber (30).

5. Method according to claim 4, characterized in that the fiber weave (M1, M2) comprises different volume fractions of polymer fibers (30).

6. Method according to any one of the preceding claims, characterized in that at least one of the fibre braids (M1, M2) is mainly or entirely composed of polymer fibres (30).

7. Method according to any one of claims 4 to 6, characterized in that the fibre fabric (M1, M2) is composed of commingled yarns (3) respectively.

8. The method according to any one of claims 4 to 7, characterized in that the fiber braiding (M1, M2) is consolidated in a common consolidation process in a consolidation die (4) while heating to establish an cohesive connection, wherein the polymer fibers (30) form the matrix material of the fiber composite.

9. The method of claim 8, wherein additional components are thermoplastically welded during or after the common consolidation process.

10. Method according to claim 8 or 9, characterized in that at least one fiber formation (26) is provided as a flat woven fabric, non-crimp fabric, weft or needle fabric and is connected in a cohesive manner to the fiber weave (M1, M2) in a common consolidation process.

11. Method according to any of the preceding claims, characterized in that a cut is introduced into at least one of the fibre braids (M1, M2) before heating to establish an adhesive bond.

12. Method according to any of the preceding claims, characterized in that a tongue flap is cut out of at least one of the fibre braids (M1, M2) before heating to establish an adhesive bond.

13. Method for manufacturing a structural assembly of a vehicle seat frame (1), characterized in that a tube element (2) according to one of the preceding claims is manufactured and arranged on a structural section (110) of a seating portion structural assembly (10) for providing a seating surface (100) for a vehicle occupant or on a structural section (110) of a backrest portion structural assembly (11) connected to the seating portion structural assembly (10).

14. A pipe element (2) extending along a longitudinal axis (L) and formed of a fibre composite material,

it is characterized in that

Comprising a tube (21) which at least comprises: a first layer (210) having a first fiber weave (M1) and a second layer (211) having a second fiber weave (M2), wherein the fiber weaves (M1, M2) are each formed by a weaving hose extending [ at least in sections ] circumferentially around a longitudinal axis (L).

15. A pipe element (2) according to claim 14, characterized in that the pipe body (21) is in form-locking engagement with the other parts (24, 27).

16. A pipe element (2) according to claim 14 or 15, characterized in that the pipe element (2) is circumferentially closed and encloses a lumen (20) as seen in a cross-section transverse to the longitudinal axis (L).

17. A pipe element (2) according to any of claims 14-16, characterized in that the pipe element (2) has a substantially cylindrical shape with a right circular cross-section.

18. Pipe element (2) according to any of claims 14-18, characterized in that the pipe element (2) has a shape other than a cylindrical shape.

19. Pipe element (2) according to one of claims 14 to 16 or 18, characterized in that the pipe element (2) has a cross section which is star-shaped and/or is toothed.

20. Pipe element (2) according to any of claims 14 to 19, characterized in that the first layer (210) with the first fiber weave (M1) is arranged radially inside the second layer (211) with the second fiber weave (M2).

21. A pipe element (2) according to any one of claims 14-20, wherein the pipe body (21) has: a third layer (212) having a third fiber weave (M3).

22. A pipe element (2) according to claim 21, wherein the third layer (212) is arranged radially outside the second layer (211).

23. A pipe element (2) according to any of claims 14 to 22, characterized in that the layers (210, 211, 212) of the pipe body (21) are embedded in a thermoplastic plastic material.

24. A tubular element (2) according to any one of claims 14 to 23, characterized in that the fibre braiding (M1, M2, M3) is formed by intersecting fibres (F), respectively.

25. A tubular element (2) according to claim 24, characterized in that the fibres (F) of the fibre braid (M1, M2, M3) are formed by continuous fibres.

26. A tubular element (2) as claimed in any one of claims 14 to 25, characterized in that the fibre braids (M1, M2, M3) of the layers (210, 211, 212) of the tubular body (21) have different axial lengths, measured along the longitudinal axis (L).

27. A tubular element (2) as claimed in any one of claims 14 to 26, characterized in that the fibre braids (M1, M2, M3) of the layers (210, 211, 212) of the tubular body (21) differ in the orientation of the fibres (F) constituting the fibre braids (M1, M2, M3).

28. A tube element (2) according to any one of claims 14-27, characterized in that at least one of the layers (210, 211, 212) of the tube body (21) has longitudinally extending reinforcing fibres (214) in addition to the respective fibre braiding (M1, M2, M3).

29. A tube element (2) according to any of claims 14-28, characterized in that the different layers (210, 211, 212) of the tube body (21) have different arrangements of reinforcing fibers (214) in addition to the respective fiber braids (M1, M2, M3), wherein the arrangements of reinforcing fibers (214) differ in the orientation, density and/or material of the reinforcing fibers (214).

30. A pipe element (2) according to any one of claims 14-29, characterized in that the pipe body (21) has at least one band-like structure (215) on an outwardly facing peripheral side (216) for locally reinforcing the pipe body (21).

31. A pipe element (2) according to claim 30, wherein the at least one band-like structure (215) extends on the peripheral side (216) circumferentially around a longitudinal axis (L) along a circumferential direction (U), on the peripheral side (216) parallel to the longitudinal axis (L) or helically around the peripheral side (216).

32. A tube element (2) according to any one of claims 14-31, characterized in that at least one of the fibre braids (M1, M2) or the fibre formations (25) which are connected thereto in an interlocking manner form loops (250) and/or fibre composite sections (26) project laterally from the tube body (21).

33. Structural component of a vehicle seat frame (1), the structural component having:

-a structural section (110) of a seating portion structural assembly (10) or a structural section (110) of a backrest portion structural assembly (11) connected to the seating portion structural assembly (10) for providing a vehicle occupant with a seating surface (100), and

-a pipe element (2) made of fiber composite material arranged on the structural section (110) extending along a longitudinal axis (L) for reinforcing the structural section (110), characterized in that a pipe element (2) according to any of claims 14 to 32 is constructed.

34. The structural assembly of a vehicle seat frame (1) according to claim 33, characterized in that the tube element (2) extends between frame portions (111, 112) of the structural section (110) extending substantially transversely to the longitudinal axis (L).

35. Vehicle seat frame (1), characterized by having a structural component of the vehicle seat frame (1) according to claim 33 or 34.

Technical Field

The present invention relates to a method for manufacturing a tube element and a method for manufacturing a structural assembly of a vehicle seat frame according to claim 1, and to a tube element and a structural assembly of a vehicle seat frame according to the preamble of claim 14.

Background

In the conventional construction of vehicle seat frames, for example in the construction of the backrest part, tube elements in the form of transverse tubes, which have hitherto generally been made of steel, extend between the frame parts of the backrest part and serve to provide sufficient rigidity and strength on the backrest part, in particular also in view of the strength requirements in the event of a crash. Such steel tubes are generally heavy and add significantly to the overall weight of the vehicle seat.

Under load, torsional moments, bending loads, and tensile and compressive loads occur on the structure of the seat frame. For this purpose, the structural sections must be designed to be able to absorb and conduct these loads. It should be noted here that the load on the seat frame varies strongly locally, so that measures for absorbing and dissipating load forces and load moments must be provided in particular at the location of the load.

DE 102006012699 a1 discloses a three-dimensional structure of a backrest of a motor vehicle, which has regions made of plastic reinforced with long fibers that are not oriented and regions made of plastic reinforced with long fibers that are oriented in multiple dimensions.

DE 102010051180 a1 discloses an outer shell of a seat back made of blow-molded plastic, which is hollow and flat overall and has a tubular reinforcing element, which is preferably made of metal, but possibly also of a composite material.

A transverse support for a vehicle seat, which comprises a tube and is designed as a hollow body, is known from DE 202014004095U 1. The transverse carriers comprise a plastic material.

Disclosure of Invention

The object of the present invention is to provide a tube element which enables a lightweight construction of a vehicle seat and at the same time leads forces out in a favorable and targeted manner under load.

This object is achieved by a method having the features of claim 1.

As such, a method for manufacturing a pipe element formed of a fibre composite material, in particular an organic board material, is described. The method includes providing a first fiber weave and a second fiber weave, optionally each formed from a braided hose. The method also comprises producing a cohesive (stoffschlussig) connection between the fiber mats in the case of forming a tubular body of the tube element, in particular by heating the fiber mats, the tubular body having at least: a first layer having a first weave of fibers and a second layer having a second weave of fibers.

With such a tube element, in particular a vehicle seat can be produced which is particularly lightweight and at the same time enables a targeted force derivation. Optionally, the tube element extends along a longitudinal axis. The pipe elements can have different cross-sectional geometries, in particular over their length, and can also be referred to as hollow profiles.

After providing the fiber mats and before heating, the fiber mats may be fixed to each other. For this purpose, one or more welding points, for example infrared welding points and/or ultrasonic welding points, can be provided, by means of which two or more (previously separate) fiber braids (and optionally further fiber formations) are fastened to one another.

The pipe element produced comprises, for example, continuous fibers embedded in a thermoplastic matrix.

One of the fiber mats can be arranged at least in sections within the other of the fiber mats. Thus, for example, in the finished pipe element, a first layer having a first fiber weave is arranged radially within a second layer having a second fiber weave. Alternatively, more than two fiber mats can be arranged nested within one another in a plurality of layers. In this way, an optimal load-bearing capacity of the pipe element can be adjusted for a specific application in a particularly simple manner.

The fiber mats may have different fiber compositions from one another or alternatively have the same fiber composition.

Alternatively, the fiber mats each comprise polymer fibers, for example made of Polyamide (PA), polypropylene (PP) or polyethylene terephthalate (PET). The polymer fibers can melt when heated and completely or partially form the matrix of the fiber composite, which enables a considerable simplification of the production process and a particularly uniform distribution of the matrix material.

The fiber mats can comprise different weight and/or volume fractions of polymer fibers. For example, the fiber braiding forming the surface of the tubular body has a greater volume fraction of polymer fibers than an adjacent fiber braiding (e.g., surrounded on both sides by the fiber braiding).

At least one of the fiber braids may be composed primarily or entirely of polymer fibers.

Optionally, at least one of the fiber braids or a plurality, in particular all, of the fiber braids is/are each composed of or comprises a commingled yarn. The hybrid yarn includes polymer fibers and reinforcing fibers composed of, for example, glass, Carbon Fiber (CF), basalt, or aramid.

The fiber mats can be consolidated in a consolidation die in a common consolidation process while being heated to establish an interlocking connection. The polymer fibers can form the matrix material of the fiber composite.

Optionally, additional components are thermoplastically welded and/or injection molded during or after the common consolidation process. This enables satisfaction of the additional function. The component is for example made of or comprises a thermoplastic material.

Alternatively or additionally, at least one fiber formation can be provided as a particularly flat knit, woven fabric, non-crimp fabric, weft knit, woven fabric (gestice) or other (particularly flat) textile decoration and can be joined to the fiber knit material in a cohesive manner in a common consolidation process. This makes it possible to achieve a particularly simple manufacture while fulfilling the additional function. In particular, it is possible here, for example, to use a mixed yarn with the same type of polymer or the same polymer, like one or more fiber mats.

Before heating to establish an adhesive bond, a cut may be introduced into at least one of the fiber braids. This enables targeted weakening and, alternatively or additionally, for example, connection to other components.

A flap may be cut from at least one of the fiber braids prior to heating to establish the cohesive connection.

Furthermore, a method for producing a structural assembly of a vehicle seat frame is proposed, wherein the tube element is produced according to any of the embodiments of the method for producing a tube element described herein and is arranged on a structural section of a seat part structural assembly or a structural section of a backrest part structural assembly connected to the seat part structural assembly for providing a seating surface for a vehicle occupant.

The object is also achieved by a tube element, in particular for a structural component of a vehicle seat frame, which extends along a longitudinal axis and is formed, in particular made, of a fiber composite material (in particular of an organic sheet material), and which has a tube body having at least: a first layer having a first weave of fibers and a second layer having a second weave of fibers. Optionally, the fiber mats are each formed by a weaving tube which extends at least in sections circumferentially around the longitudinal axis.

The pipe elements can be made, for example, by the methods described herein.

For example, the fiber braids of the different layers of the tube body are each formed from braided hoses that extend circumferentially about the longitudinal axis. The fiber mats can thus each form a (circumferentially closed) hose structure, wherein the first fiber mat of the first layer is arranged, for example, inwardly on the tube body and is covered by the fiber mat of the second layer. A third layer of fiber fleece can be arranged radially outside the second layer of fiber fleece, which in turn can be surrounded by a fourth layer of fiber fleece. The fiber weave in the form of a woven hose can be designed to withstand specific loads (torsional, bending or tensile/compressive loads), wherein loads from different load directions can be absorbed and captured by superimposing different fiber weaves. The elevated stiffness can be set locally on the pipe element and the reduced stiffness can be set elsewhere via the fiber braid, so that, for example, a targeted flexibility can also be predefined on the pipe element.

Alternatively, the pipe body can be brought into positive engagement with other parts of the pipe element, for example for introducing torques or for sealing.

The pipe element is thus constructed in multiple layers with its pipe body. The first layer has a first weave of fibers and the second layer has a second weave. The fiber braid is formed by, for example, intersecting fibers and superposed to form a tubular body.

The tube elements are for example circumferentially closed and enclose an inner cavity. Thus, the tube element is hollow inside. The tubular body which circumferentially encloses the inner space is produced here by a layer formed from a fiber braid. The fiber mats of the individual layers can be identical or can also be formed differently.

In one embodiment, the pipe elements have a substantially cylindrical shape (in whole or in sections) with a circular cross section. The tube element thus extends longitudinally along the longitudinal axis and is here (cylindrically) shaped.

Alternatively (or in addition in the case of a segmented embodiment), it is also conceivable and possible for the tube element (in whole or in segments) to have a shape other than a cylindrical shape, in particular not to be formed with a circular cross section. The shape of the pipe elements may differ not only in the circumferential direction from a circular shape but also in the longitudinal axis from a cylindrical shape. By shaping in a suitable shaping tool, the pipe elements can in principle be designed in any desired shape for the targeted absorption and removal of forces and moments. Optionally, the pipe element has a star-shaped and/or toothed cross section. It should also be emphasized that the cross-sectional shape may vary in the longitudinal direction. For example, the pipe elements have a right circular cross-section at one location and a non-right circular cross-section at another location, for example a multi-sided cross-section. For example, the pipe element has a right circular cross-section at one location, a quadrangular cross-section at another location and/or a hexagonal cross-section at another location. Alternatively or additionally, the cross-sectional diameter of the pipe elements may differ in sections.

The tubular body of the tubular element is formed from a plurality of layers. The layers are preferably arranged radially one above the other in such a way that the first layer represents the radially innermost layer and the second layer is located radially outside the first layer. The second layer thus covers the first layer at least in sections on the outside of the first layer.

In addition, the tubular body can have a third layer, which is arranged radially outside the second layer, for example. Radially beyond the third layer, further layers may be arranged. The pipe body is thus formed of three (or more) layers arranged one above the other, wherein the number of layers is preferably matched to the strength provided (locally or globally) on the pipe body.

In one embodiment, the tubular body can be formed, for example, from up to ten layers, each layer having a fiber weave. Even more layers are conceivable, if necessary.

The layers each have a fiber weave, wherein the fiber weaves of the layers are arranged one above the other for forming a multi-layered structure. The fiber braiding is thereby formed, for example, from a braided hybrid yarn or embedded in a matrix made of a thermoplastic/thermosetting plastic material, so that a multi-layer structure of the tube element made of a matrix fiber composite is obtained. If the fiber mats consist of warp-knitted mixed threads, the fiber mats can be connected to one another in a cohesive manner, for example by heating, with partial melting. When embedded in the matrix, the fiber mats of the individual layers are arranged, for example, overlapping and then polymerized together and thus embedded in the polymer matrix.

Preferably, the fiber weave is formed by fibers crossing each other in the manner of a fiber woven fabric or a fiber buckling-free fabric, respectively. The differently oriented fibers of each fiber weave extend, for example, obliquely (e.g., at an angle of between 20 ° and 90 °) or approximately perpendicularly to one another. The fiber braid is preferably rolled up in the form of a hose and therefore a braided hose made of intersecting fibers is provided, which is arranged one above the other in multiple layers for forming the tubular body.

In one embodiment, the fibers of the fiber weave are formed from continuous fibers. Continuous fibers are generally understood to be fibers having a great length, for example a length of more than 50 mm. Such continuous fibers contribute to the high strength of the pipe element and may be made of different fiber materials, such as glass, aramid or carbon.

The different layers of the tubular body may differ from each other, in particular with respect to the construction of the fibre braid.

The fiber mats of the different layers can thus be formed in different lengths, measured along the longitudinal axis. In particular, the fiber mats in the hose-shaped configuration are therefore superimposed only in sections (viewed axially along the longitudinal axis), so that the tube body can be constructed, for example, in a length section only in a single layer, in another section in two layers, and in yet another section in three layers. There may be additional layers having other axial lengths or lengths comparable to the axial length of another layer.

Different variations of the arrangement of the layers with respect to one another are conceivable and possible. For example, the first layer with the first fiber braiding may be short in the axial direction and arranged centrally on the tube element, for example in the axial direction, in order to provide increased stiffness centrally on the tube element. In this case, the second and third layers can be longer than the first layer, for example, and surround the first layer in the circumferential direction and project beyond the first layer in the axial direction.

In a further embodiment, it is also conceivable for the first layer to be formed long in the axial direction, while the second layer and optionally the third layer are formed shorter than the first layer. In this case, the third layer may, for example, have the shortest length in the axial direction and may, for example, be arranged centrally on the pipe element, so that, in turn, increased rigidity may be provided centrally on the pipe element.

In a further embodiment, the axially shortest layer (for example the first or third layer) can also be arranged at the end of the pipe element, in order to provide increased rigidity at this end.

In addition or as an alternative to the formation of fiber mats with layers of different axial length, it can also be provided that the fiber mats differ in the orientation of their fibers. The adjacent fiber braids can therefore be arranged relative to one another such that an angle of inclination is obtained between the fibers of the fiber braids, wherein the angle can be selected such that a high load capacity on the tube element is set in one or more preferred load directions. In the production of the tube element, in particular in the case of a change in shape, for example in a blow-molding tool, the angle of the fiber braiding can be maintained in such a way that in the final state, i.e. during the shaping of the tube element, the desired angle is set between the fiber braiding.

The fiber weave may differ in its fiber density, fiber material, and fiber thickness (i.e., diameter).

In addition or alternatively to the respective fiber weave, one or more layers may also have longitudinally extending reinforcing fibers, which additionally reinforce the respective fiber weave in the direction of the longitudinal extension of the reinforcing fibers. The different layers may differ in the arrangement of the reinforcing fibres. For example, different layers may have reinforcing fibers that are oriented differently or arranged in different densities from one another. It is also conceivable and feasible that the reinforcing fibers of different layers differ in their material. For example, the reinforcing fibers may be made of glass, aramid, or carbon.

In addition to the multilayer structure formed by the fiber mats placed on top of one another, additional structures can be installed on the outside of the tube body (or also on the inside if necessary) for locally reinforcing the tube body. The tube body can thus be provided externally, for example, with an additional tape-like structure with longitudinally extending fibers, which is laminated onto or into the tube body. By means of such a strip-like structure, the pipe element can be reinforced, for example at its ends or in its longitudinal extension, in order to be able to achieve a targeted, direction-dependent strength for absorbing forces or moments. For example, it is provided that the tube body has at least one strip-like structure on the outwardly facing peripheral side in addition to the respective fiber weave for locally reinforcing the tube body.

For example, such a tape-like structure may be wound circumferentially about the longitudinal axis and thus extend externally around the peripheral side of the tube body. Additionally or alternatively, the tape-like structure may extend longitudinally on the peripheral side of the tube body. Again, additionally or alternatively, the tape-like structure may have a spiral shape extending helically around the peripheral side of the tube body. The fibers of the ribbon-like structure are each directed along the longitudinal extension of the ribbon-like structure. By means of such a strip-like structure, the pipe elements can be specifically adapted to the particular load type, so that forces and moments can be absorbed on the pipe elements in an advantageous manner.

Additionally or alternatively, the tube element may have a further reinforcing structure, for example in the form of a circumferential land, which is formed from a short braided hose and is shaped centrally, for example on the tube body, or one or more struts arranged inside the tube body, which extend diametrically (transversely to the longitudinal axis) inside the tube body and thus reinforce the tube element internally, in particular against loads transverse to the longitudinal axis.

Furthermore, at least one of the fiber mats or the fiber formation connected to the fiber mat in a material-locking manner forms a loop. In particular, loops (typically fibre composite segments) project laterally from the tube body. The loop may for example constitute a Top strap (Top-other) bow for a children's chair. Alternatively, for example, two such loops may constitute an Isofix (child restraint) holder.

Furthermore, a structural assembly of a vehicle seat frame is provided. Such structural assemblies include structural sections of a seating portion structural assembly or a back portion structural assembly connected to a seating portion structural assembly for providing a seating surface for a vehicle occupant. A pipe element made of a fiber composite material extending along a longitudinal axis is arranged on the structural section for reinforcing the structural section. The pipe element is designed according to any of the embodiments described herein and/or has a pipe body which has at least: a first layer having a first weave of fibers and a second layer having a second weave of fibers.

In one embodiment, the tube element extends transversely over a structural section, which is, for example, an integral part of the backrest part structural assembly. The tube elements are thus, for example, transverse tubes which extend, for example, between frame parts, for example, in the form of longitudinal beams of the structural section which extend transversely to the longitudinal axis. The pipe elements thus connect the different frame parts to each other and reinforce the frame parts relative to each other. The pipe elements may extend between frame portions (e.g. extending substantially transverse to the longitudinal axis) of the structural section. The tube element can generally connect two frame parts of a frame of a vehicle seat, for example a seat frame or a backrest frame, to one another.

Furthermore, a vehicle seat and a vehicle seat frame are provided, each comprising a structural component of a vehicle seat frame according to any of the embodiments described herein.

Drawings

The idea on which the invention is based should be elaborated below with reference to the embodiments shown in the drawings. Wherein:

fig. 1 shows a view of a seat frame of a vehicle seat according to the prior art;

figure 2 shows a view of a seat frame of a vehicle seat with a tube element reinforcing a structural section of the backrest portion structural assembly;

FIG. 3 shows an isolated view of a pipe element;

FIG. 4A shows a view of one embodiment of a tube element having three different layers with different fiber braids;

FIG. 4B shows a longitudinal section through the pipe element according to FIG. 4A;

FIG. 5A shows a view of another embodiment of a tube element having three different layers with different fiber braids;

FIG. 5B shows a longitudinal section through the pipe element according to FIG. 5A;

FIG. 6A shows a view of yet another embodiment of a tube element having three different layers with different fiber braids;

figure 6B shows a longitudinal section through the pipe element according to figure 6A;

FIG. 7A shows a view of yet another embodiment of a pipe element having three different layers with different fiber braids;

figure 7B shows a longitudinal section through the pipe element according to figure 7A;

FIG. 8 shows a view of yet another embodiment of a pipe element having three different layers with different fiber braids;

FIG. 9A shows a view of an embodiment of a pipe element with reinforcement partially formed by a band-like structure;

figure 9B shows a longitudinal section through the pipe element according to figure 9A;

FIG. 10A shows a view of an embodiment of a pipe element having other band-like structures;

figure 10B shows a longitudinal section through the pipe element according to figure 10A;

FIG. 11A shows a view of another embodiment of a pipe element having a band-like structure;

FIG. 11B shows a longitudinal section through the pipe element according to FIG. 11A;

FIG. 12A shows a view of a tube element having a shape other than cylindrical;

FIG. 12B shows a cross-sectional view taken along line A-A of FIG. 12A;

FIG. 12C shows a cross-sectional view taken along line B-B of FIG. 12A;

FIG. 13A shows a view of a hybrid yarn having a circular cross-section;

FIG. 13B shows a view of a hybrid yarn having a rectangular cross-section;

FIG. 14A shows a view of a pipe element with a form-locking structure;

FIG. 14B shows a cross-sectional view of FIG. 14A;

FIG. 15A shows a view of a tubular body having an annular ring;

FIG. 15B shows a view of the wrapped tubular body with the collar;

FIG. 16 shows a view of a tube from which a flat coupling face protrudes; and is

Figure 17 shows a diagram of a method for manufacturing a pipe element.

Detailed Description

The vehicle seat 1 shown by way of example in fig. 1 comprises a seat part structural assembly 10 and a backrest part structural assembly 11, which is arranged via an accessory device 13 in a manner pivotable about a pivot axis D relative to the seat part structural assembly 10. The seating portion structure assembly 10 is configured with a seating surface 100 for a vehicle occupant and is connected with a vehicle floor, for example, via a longitudinal adjustment device 12. The backrest part structure assembly 11 can be adapted by pivoting about the pivot axis D with regard to its inclined position relative to the seat part structure assembly 10 in order to adjust a comfortable seating position for a vehicle occupant or, for example, to place the vehicle seat 1 in a flat position, for example, in order to provide additional storage space in the vehicle.

The vehicle seat 1 may, for example, be a component of a rear seat system of a vehicle (in a second or third row seat of the vehicle). However, it is also conceivable and feasible for such a vehicle seat to constitute a front seat in a vehicle.

In the example shown, the backrest portion structural assembly 11 has a structural section 110, on which a cushion for providing a backrest is typically arranged. Arranged on the structural section 110 are tube elements 2 in the form of transverse tubes which connect the frame parts 111, 112 to one another in the form of longitudinal beams extending substantially perpendicularly to the pivot axis D and reinforce the structural section 110 in such a way that loading forces and loading moments acting on the structural section 110 of the backrest part structural assembly 11 are absorbed and can be conducted out in the direction of the seating part structural assembly 10.

Heretofore, such tube elements 2 in the form of transverse tubes have generally been constructed as steel tubes in order to provide sufficient rigidity on the vehicle seat 1 and in particular on the backrest part structural assembly 11. However, this entails a considerable increase in the weight of the vehicle seat 1 due to the tube element 2.

In the vehicle seat 1 shown in fig. 2, a tube element 2 is therefore provided which is made of a fiber composite material (in particular of an organic sheet material) and is shown in fig. 3 in a separate illustration. The tube element 2 extends longitudinally along a longitudinal axis L and has a tube body 21 which encloses an inner chamber 20 and is therefore of hollow design. Since the tube body 21 is made of a fiber composite material, the tube element 2 can be constructed lightweight, so that the weight of the vehicle seat 1 as a whole can be reduced.

The pipe element 2 is constructed in a multi-layer manner with its pipe body 21. As will be explained below with reference to various exemplary embodiments, the tubular body 21 is formed from different layers having different fiber weaves lying on top of one another. By shaping, arranging and orienting the fiber braiding of the layers, it is possible to set the stiffness (which may be varied locally and direction-dependently) in a targeted manner on the tube element 2 for the targeted absorption of forces and moments.

In the exemplary embodiment shown in fig. 4A and 4B, the tubular body 21 of the tubular element 2 has three layers 210, 211, 212, which have different fiber weaves M1, M2, M3. The fiber mats M1, M2, M3 are each formed from intersecting fibers F and are superimposed on one another in such a way that the innermost first fiber mat M1 of the first layer 210 is arranged radially within the second fiber mat M2 of the second layer 211 and the second fiber mat M2 of the second layer 211 is arranged radially within the third fiber mat M3 of the third layer 212. In the embodiment shown, the axial lengths of the fibre mats M1, M2, M3 are different, so that the outermost third layer 212 is axially shorter than the second layer 211 and the second layer is axially shorter than the first layer 210 again. The third layer 212 is arranged centrally on the tube element 2 with its third fiber braiding M3, and the second layer 111 is aligned centrally with respect to the third layer 212, so that the tube element 2 is reinforced centrally.

In contrast, in the embodiment shown in fig. 5A and 5B, a reinforcement is provided at the end 22 of the pipe element 2. For this purpose, the axially shortest third layer 212 is arranged with its third fiber braiding M3 on the end 22. The second layer 211 also extends as far as the end 22, but here it extends beyond the third layer 212 in the direction of the other end 23 but is axially shorter than the first layer 210 extending as far as the end 23. In the region of the end 22, the tube element 2 is thus reinforced in a targeted manner by the superposition of the fiber mats M1, M2, M3 of the different layers 210, 211, 212. In addition, in this way, it is possible to provide a targeted flexibility in the region of the end 23 for energy management (in the sense of a deformation element) in the event of a crash.

In a further embodiment shown in fig. 6A, 6B, the pipe element 2 is again reinforced centrally, wherein in this case the innermost layer 210 is configured shortest in the axial direction and is arranged centrally. The second layer 211 is axially longer than the first layer 210, but shorter than the third layer 212. Since the layers 210, 211, 212 are superimposed centrally on the pipe element 2, a targeted reinforcement is provided in the middle of the pipe element 2. In addition, in this way, a targeted flexibility can be provided at the ends on both sides for energy management (in the sense of deformation elements) in the event of a crash.

According to the embodiment of fig. 7A, 7B, the layers 210, 211, 212 are arranged in the same way as in the embodiment according to fig. 1. Wherein in this embodiment the inner layer 210 is formed by two braided hoses, which are centrally arranged axially at a distance 213 from each other. In this way, it is made possible to provide flexibility centrally on the tube body 21, if necessary.

The embodiment according to fig. 8 is also similar to the embodiment according to fig. 4A, 4B, wherein in this case additional reinforcing fibers 214 in the form of continuous fibers extending longitudinally along the reinforcing direction V are embedded in the fiber braiding M2 of the second layer 211. Thus, in this embodiment, the second layer 211 is reinforced by additional embedded reinforcing fibers 214, providing additional direction-dependent stiffness on the pipe element 2 along the extension direction V of the reinforcing fibers 214.

In these different embodiments, the fabric braids M1, M2, M3 for constituting the multilayer structure are formed by braided hoses which are superimposed in sections or along the entire length of the tube element 2. The orientation of the fibers F of the different fiber mats M1, M2, M3 can be different, so that the fibers F of the different fiber mats M1, M2, M3 are oriented at an oblique angle to one another, for example. In this way, a predetermined directional dependency for absorbing forces and moments on the pipe element 2 can be adjusted.

The fiber mats M1, M2, M3 may also differ in the density and/or thickness of the fibers F thereof. Additionally or alternatively, the fibers F of the fiber mats M1, M2, M3 can also be made of different materials, for example glass, aramid or carbon.

The fibers F of the fiber mats M1, M2, M3 can be formed, for example, from continuous fibers, that is to say from particularly long fibers, the length of which is preferably (significantly) greater than 50 mm.

The fiber mats M1, M2, M3 are produced, for example, from a mixed yarn, i.e. from a mixture of glass fibers and polymer fibers. For the integral, cohesive connection for the production of the tubular body 21, the overlapping fiber braiding M1, M2, M3 in the form of braided hoses can be heated and thereby partially melted, so that a cohesive connection is obtained between the braided hoses.

Alternatively, the fiber braids M1, M2, M3 may be braided from glass fibers, carbon fibers or aramid fibers, for example. The fabric braids M1, M2, M3 are overlapped to make the tube body 21, and then polymerized together (in situ), thereby obtaining an integral one-piece structural member.

In the embodiment shown in fig. 9A, 9B, on the outside of the outer circumferential side 216 (corresponding to the outside of the third layer 212) additional shapes in the form of strip-like structures 215 are arranged, which circumferentially surround the ends 22, 23 of the pipe element 2 in the circumferential direction U with the fibre structure B and thus provide additional reinforcements on the ends 22, 23. The fibers of the fiber structure B of the belt-like structure 215 run here in the circumferential direction U, so that a particular reinforcement (for example, expansion prevention) is brought about in the circumferential direction U at the ends 22, 23.

In this exemplary embodiment, too, a plurality of layers 210, 211, 212 are superimposed, wherein additional strip-like structures 215 are formed on the outside of the outermost layer 212, for example, laminated to the outer circumferential side 216 or into the fiber matrix structure of the layers 210, 211, 212.

In the exemplary embodiment according to fig. 10A, 10B, a strip-like structure 215 in the form of a strip (Tape) layer is also formed on the outer side of the multilayered tubular body 21. In this embodiment, the tape-like structure 215 extends longitudinally parallel to the longitudinal axis L and is again formed by a longitudinally extending fiber structure B. Thus, in this case, a particular reinforcement is provided on the pipe element 2 along the longitudinal axis L.

In contrast, in the exemplary embodiment according to fig. 11A, 11B, the band-shaped structure 215 extends helically around the outer circumferential side 216 of the tube body 21. The tape-like structure 215 is again formed by a fibre structure B having longitudinally extending fibres following in a spiral.

In the embodiment shown in fig. 4A, 4B to 11A, 11B, the tubular body 21 of the tubular element 2 has a substantially cylindrical shape with a right circular cross-section. In contrast, in the embodiment shown in fig. 12A, 12B, 12C, the outer shape of the tube element 2 differs from a cylindrical shape and varies along the longitudinal axis L and in the circumferential direction around the longitudinal axis L. The shape of the pipe element 2 can thus be adapted in a targeted manner to the mounting on, for example, the structure section 110 of the backrest part structure assembly 11, wherein, via the flattened surface sections, structures can be provided on which accessories (for example, adapters for connection to the fitting 13) can be mounted. In this case, the (direction-dependent) stiffness can also be set by the shaping of the tube element 2, so that torsional moments and bending loads can be absorbed in a targeted manner on the tube element 2.

In each of the embodiments described herein, hybrid yarns 3 may be used for making the tubular body 21. The hybrid yarn 3 comprises thermoplastic polymer fibers 30 and reinforcing fibers 31. The polymer fibers 30 are made of, for example, PA, PP and/or PET. The reinforcing fibers 31 are made of, for example, glass, CF, basalt and/or aramid.

Fig. 13A shows a possible arrangement of polymer fibers 30 and reinforcing fibers 31 in a hybrid yarn 3. The polymer fibers 30 and the reinforcing fibers 31 are substantially uniformly distributed (in cross-section). For example, the distribution may be chaotic.

Fig. 13B shows an alternative arrangement of polymer fibers 30 and reinforcing fibers 31 in hybrid yarn 3. Here, the polymer fibers 30 and the reinforcing fibers 31 are arranged in order. Polymer fibres 30 and reinforcing fibres 31 are provided in a plurality of planar layers. In the present case, the multiple layers of polymer fibers 30 sandwich the multiple layers of reinforcing fibers 31.

The weight fraction of the polymer fibers 30 in the hybrid yarn 3 is between 30% and 70%. The number of polymer fibers 30 in the hybrid yarn may be similar or the same as the number of reinforcement fibers 31. Alternatively or additionally, pure polymer yarns may be used for one or more layers 210, 211, 212 of the tube body 21.

The polymer fibers 30 in the hybrid yarn 3 form the matrix material for impregnating and consolidating the reinforcing fibers 31 and consolidating the tube body 21.

Fig. 14A and 14B show an embodiment of the tube body 21 in which the end of the tube body 21 is provided with a form-locking profile 217 during the consolidation or during a subsequent reshaping. In the present case, the form-locking contour 217 is of star-shaped design. An exemplary cover 24 provided with a suitable form-locking contour 240 is placed on the end 24, for example plugged onto it in a form-locking manner. The cover 24 can seal (on one end) the tube 21, for example, hermetically. Corresponding covers 24 and form-locking contours 217 can be provided on both ends of the tube body 21. The cover 24 is, for example, injection molded or made of a composite material, in particular an organic sheet material, and optionally (in particular in a common curing process) cured to form the shape. A particularly reliable connection can be achieved by means of the form-locking contour 217.

The tubular body 21 comprises at least a fabric weave M1 (in particular made with a hybrid yarn 3) formed by a braided hose, or alternatively at least: a first layer with a first fiber weave M1 and a second layer with a second fiber weave, wherein the fiber weaves can in particular each be formed by a weaving hose extending at least in sections circumferentially around a longitudinal axis.

Fig. 15A shows an embodiment in which one (a plurality of, in particular two) additional fiber formations 25 (alternatively only one fiber formation 25) are connected in a material-locking manner to the tube body 21. In the present case, the fiber formation 25 is arranged in the form of a loop 250. The loop 250 is for example used for fixing a child seat, for example for an Isofix system. Alternatively, one or more loops 250 of this type can be used for belt guidance of the safety belt and/or for belt tensioning force introduction.

The plurality of fiber formations 25 (or one fiber formation 25) may be formed, for example, from a fiber weave, particularly from a woven hose. Alternatively, the fiber formation is produced, for example, from weft-knitted fibers. Alternatively, the fiber formation 25 is connected in a form-fitting manner to the braided tube forming the tube body 21 in a common consolidation process. As a result of the consolidation, the fiber formation 25 is consolidated to form a fiber composite segment. In the present case, the fiber formations 25 each have the shape of a rope, but other shapes are also conceivable.

The fiber-forming objects 25 are illustratively disposed on both ends of the tube body 21.

Fig. 15B shows a modification whereby one or more fibre formations 25 surround the tube body 21 one or more times. In particular, the fiber formation 25 may be wound around the tube body 21 one or more times. This enables a particularly high load capacity.

Fig. 16 shows an embodiment in which additional fiber formations 26 are connected in a material-locking manner to the tube body 21, which additional fiber formations in each case form surface elements by way of example. Upon consolidation, the fiber formation 26 is consolidated into a fiber composite section and may be wrapped around the tubular body 21 in sections, completely, or multiple times. The fiber formation 26 can be connected in a form-fitting and material-fitting manner to the braided tube forming the tube body 21 in a common consolidation process or can be consolidated thereon afterwards. An attachment member may be attached to the fibrous formation 26. The fiber formations 26 may provide an attachment surface for thermoplastic or other types of components, respectively, which may later be introduced during thermoplastic welding. Thus, for example, variants can be formed for different seat arrangements. Furthermore, further hollow profiles can be connected, which are optionally formed by a subsequent process (for example, closing the U-shaped profile by means of a connecting surface).

It is furthermore possible to design the spring element, for example, as a meandering spring and/or spring mat made of fiber composite material (see, for example, fig. 2) and to connect it to the tube body 21 (which, for example, can be the transverse carrier of the seating part structural assembly 10 of the vehicle seat 1 according to fig. 2), in particular in a common consolidation process. The spring element may for example be formed by a hybrid yarn strip. The spring element can also be used as a pelvic support or lumbar support and be arranged accordingly.

In general, in particular in the outer region of the braided tube, flat projecting tongues can be provided, for example cut out.

Fig. 17 shows a method for producing a hollow profile or pipe element formed from a fiber composite material.

The method comprises providing a first fabric of fibres M1 and a second fabric of fibres M2 separate from the first fabric of fibres, each formed from a braided hose. The two fiber braids M1, M2 are provided in the form of a hybrid hose with hybrid yarns.

These braided hoses are then layered, for example, nested into one another. One braided hose is arranged (coaxially) inside the other braided hose. Where a stack of braided hoses is formed. Optionally, one or more additional fiber formations may be positioned and thus added to the stack.

The individual layers of the braided hose can be fixed to one another, for example by local welding, to achieve layer fixing. For this purpose, one or more infrared welding points (IR points) and/or ultrasonic welding points (US points) can be provided.

In addition, a tube 42 or other expansion means is inserted into the braided tube, for example into the innermost braided tube.

The braided hose is placed into the consolidation die 4 together with the hose 42. In the present case, the consolidation die 4 comprises two die halves 40, 41 which can be opened and closed in order to place the braided hose together with the hose 42. The hose 42 is then inflated and the heating 43 is activated on one or both of the mould halves 40, 41. The stack is thereby expanded until it abuts against the shaping contour of the consolidation die 4 (e.g. the variable temperature die of the consolidation die). The hose presses the material outwards.

The heating section 43 heats the stacked fiber mats M1, M2 and optionally one or more additional fiber formations for producing a cohesive connection between the fiber mats M1, M2 when forming the tubular body 21 of the tubular element 2. The fiber mats M1, M2 are pressed together by the pressure exerted by means of the hose 42 (expansion means). The tube 21 is made having at least: a first layer 210 with a first weave of fibers M1 and a second layer 211 with a second weave of fibers M2 (see, e.g., fig. 4A to 9B). In this case, all the braided hoses are consolidated in the same consolidation process, which enables a particularly efficient production.

Alternatively to one of the braided hoses, it is also possible to arrange additional fiber formations 25, 26 and/or a belt structure 215 on or in the braided hose and to connect them in a material-locking manner in the consolidation tool 4. Other tapes and/or inserts may also be connected during the same consolidation process.

Alternatively, a hybrid yarn 3 is used, which provides the entire matrix material. Here, the polymer fibers 30 are melted in the consolidation die 4 so that they impregnate the reinforcing fibers 31. Even if the polymer fibers 30 melt during manufacture, at least the reinforcing fibers 31 remain contained so that the corresponding layers of the fiber weave can be identified both before and after consolidation (except for the pure polymer fiber weave, which can form a continuous matrix coating as adjusted by the consolidation process).

In order to provide additional matrix material, one or more sleeves, films, hoses and/or fiber formations made of polymers, for example, can optionally be arranged on the braided hose stack, for example, within, outside and/or between the braided hoses. In a common consolidation process, a matrix of the composite material, in particular an organic sheet, is thereby at least partially formed.

Since the latter matrix material is already present in the braided hose stack, particularly short cycle times can be achieved, which enables or simplifies mass production.

The finished tubular body 21 shown by way of example in fig. 17 consists of an organic sheet material. According to the method of fig. 17, any hollow profile can be manufactured. As already mentioned, the fibre mats M1, M2 may be of the same type. For example, cutting long fibrous webs into lengthsSegments to provide a plurality of individual fibre braids M1, M2. Alternatively, the fiber weave M1, M2 may be, for example, in its weave type (with regard to the weave angle, additional warp yarnsAnd/or scarfed tapes), differ in their fiber composition (e.g., they have different reinforcing fibers and/or polymer fibers, e.g., different blends of different reinforcing fibers, e.g., of glass, CF, basalt, and aramid) and/or in the volume fraction of polymer fibers.

The finished tube element 2 with the tube body 21 is, for example, incorporated in the vehicle seat 1 and/or forms part of a structural component of a vehicle seat frame.

The idea on which the invention is based is not limited to the embodiments presented above but can in principle also be implemented in completely different types of ways.

A tube element of the type described can be used in particular not only on the backrest part structural assembly but also, for example, on the seating structure assembly of a vehicle seat. In principle, the structural section can be reinforced by a tube element of the type described, wherein the tube element can extend transversely (in the transverse direction of the vehicle) or vertically (in particular transversely to the pivot axis of the backrest part structural assembly).

List of reference numerals

Seat frame for vehicle seat

10 seating portion structural assembly

100 ride surface

11 back rest part assembly

110 structural section

111. 112 frame part (longitudinal beam)

12 longitudinal adjusting device

13 accessory device

2 pipe element

20 inner cavity

21 pipe body

210. 211, 212 layers

213 brace rod element

214 reinforcing fiber

215 ribbon structure

216 peripheral side surface

217 shape locking contour

218 expansion part

22. 23 end of

24 closure

240 form locking profile

25 fiber formation

250 rings

26 fiber formation

3 hybrid yarn

30 Polymer fiber

31 reinforcing fiber

4 consolidation die

40. 41 half mould

42 flexible pipe

43 heating part

B fiber structure

D swing axis

F fiber

L longitudinal axis

M1, M2, M3 fiber braided fabric (braided hose)

U circumferential direction

V direction of reinforcement