DE102018207936B4 - Vehicle seat with a rear wall element and a hinge formed by a cover layer, and manufacturing method - Google Patents

Abstract

Vehicle seat (F) with a backrest (R) which has a flat rear wall element (1) with at least one cover layer (12) for a back (1A) of the backrest (R), characterized in that on one of the back (1A) the inside (1B) of the rear wall element (1) facing away from the backrest (R), a hinge point (103) for a hinge (120) is defined, which is formed by a section (12a) of the cover layer (12), the hinge (120 ) forming section (12a) of the cover layer (12) encompasses an edge section (1C) of at least one structural layer (10, 11) of the rear wall element (1) and at the hinge point (103) the encompassing section (12a) forming the hinge (120) of the cover layer (12), and wherein the section (12a) of the cover layer (12) surrounding the edge section (1C) is provided at the hinge point (103) on the inside (1B) of the backrest (R) facing away from the back (1A). Rear wall element (1) is fixed, so that the top layer (12) with a rear side (1A) of the backrest (R) can be folded relative to a core (10, 11) of the rear wall element (1) formed with the at least one structural layer, or the section (12a) surrounding the edge section (1C) the cover layer (12) is fixed at the hinge point (103) on a backrest frame (LR) of the backrest (R), so that the rear wall element (1) together with a folding section (12b) visible on the back (1A) of the backrest (R) the top layer (12) can be folded relative to the backrest frame (LR).

Description

The proposed solution relates to a vehicle seat with a backrest, which has a flat rear wall element, and a method for producing a backrest.

the JP 2016-215996 A describes such a vehicle seat with a backrest which has a flat rear wall element.

Other vehicle seats are in the documents US 2011/0 248 523 A1 , FR 2 962 056 A1 , U.S. 6,406,085 B1 , US 2014/0 103 692 A1 , DE 10 2014 112 858 A1 , U.S. 5,188,416 A , WO 2003/016 091 A1 , US 2016/ 0 046 220 A1 , U.S. 6,918,625 B2 , DE 101 51 166 B4 , U.S. 6,390,553 B1 and DD 14 211 A5 described.

In the case of backrests for vehicle seats that are customary in practice, in particular vehicle seats for a rear, e.g. second or third row of seats in a vehicle, a flat rear wall element made of thin-walled sheet steel is typically welded onto a backrest frame. A carpet is then glued as a cover layer to the side of the rear wall element that is visible and thus facing away from a backrest cushion, in order to cover any embossing, holes or deformations on the rear wall element and, if the backrest can be folded forward into a loading space position, to create a flat loading surface provided at the back of the backrest. However, the hitherto customary construction of a vehicle seat with such a flat rear wall element leads to a comparatively high weight and is also complex to manufacture in individual cases. It is also difficult to integrate additional functions into the steel sheet of the rear wall element or the top layer, in particular not without significantly impairing the assembly process for producing the backrest.

There is therefore a need for a vehicle seat which is improved in this respect, as well as a method for the production of a backrest for a vehicle seat which is improved in this respect.

Against this background, a vehicle seat according to claim 1 with a backrest is proposed, which has a flat rear wall element with at least one cover layer for a rear side of the backrest, with a hinge point for a hinge, in particular a film hinge, on an inner side of the rear wall element facing away from the rear side of the backrest , which is defined by a portion of the topsheet.

On the back of the backrest, the rear wall element itself can be completely foldable and/or at least one cover layer provided on this rear wall element can be foldable. For example, a cover for a gap or for a storage compartment can be implemented via the foldable rear wall element and/or the at least one foldable top layer. A foldable section of the cover layer is a section of the cover layer that is visible on the back of the backrest or a section of the (first) cover layer that is at least partially covered by a further (second) cover layer.

The hinge is formed by a (hinge) section of the cover layer, which encompasses an edge section of at least one structural layer of the flat rear wall element. The top layer provided for this purpose is then, for example, sufficiently flexible and/or correspondingly thin-walled, at least in the region of this section, in order to specify a film hinge and thus a defined folding axis via the (hinge) section. A hinge (a) for the rear wall element or (b) optionally also only the top layer or several top layers can be formed in a simple manner via the edge-side wraparound of the rigid or possibly flexible and/or carpet-like top layer.

The (hinge) section of the cover layer surrounding the edge section is fixed to an inside of the rear wall element facing away from the back of the backrest and/or to a backrest frame of the backrest to which the flat rear wall element is fixed. If a hinge is formed for the entire rear wall element via the section of the cover layer that encompasses the edge, for example an area of the encompassing section of the cover layer provided on an inside of the rear wall element is (additionally) attached to a backrest frame of the backrest and/or an additional stiffening element and provided on the backrest frame Additional rear wall element fixed. If only at least one cover layer is intended to be foldable relative to the rear wall element via the hinge, fixing the section of the cover layer forming the hinge to the rear wall element is sufficient.

In one possible development, in which the hinge is formed by a (hinge) section of the top layer, this section of the top layer encompasses, for example, an edge section of one of at least two different structural layers of the rear wall element connected to one another in a sandwich construction.

A (hinge) section of the top layer is provided in one embodiment variant in the area of a local reduction in a wall thickness of the rear wall element, in particular formed by such a local reduction in the wall thickness. This includes, in particular, design variants in which the section of the top layer that (also) forms the hinge does not encompass an edge section of at least one structural layer of the flat rear wall element.

The hinge point, which is defined on the rear wall element, can be formed, for example, by an embossing or punching on the rear wall element. If the rear wall element has a honeycomb structure, this honeycomb structure can be embossed and/or interrupted to form the hinge point. An interruption of the honeycomb structure includes in particular the provision of an unstructured planar section or recess (through a material of the rear wall element that forms the honeycomb structure).

The flexural rigidity of the section of the top layer that forms the hinge can be locally reduced in a targeted manner by means of perforations. Alternatively or additionally, a wall thickness of the cover layer can be reduced locally in order to define a hinge axis of the hinge. A bending point and thus the hinge axis can be specified via such a local reduction in the wall thickness—just as via one or more perforations. In addition, not only the flexural rigidity, but also the bending radius can be influenced here - as well as via one or more perforations.

In principle, at least two different cover layers can be provided on an outer surface of the rear wall element. The different cover layers can overlap one another at least partially or over the entire surface. The use of two different top layers can be used here, for example, to form different surfaces on the visible back of the backrest and/or to form different functional layers for the back of the backrest. For example, a first water-repellent layer is provided from a first cover layer and on this in turn a second, concealing (decorative) layer, for example with a carpet-like surface, which is formed by a second cover layer. The first cover layer is at least partially arranged between a core of the rear wall element and the second cover layer. For example, the material forming the rear wall element can form a (sandwich) core with at least two structural layers connected to one another in a sandwich construction, to which a multi-layer composite cover layer is attached on the back. At least two cover layers of a cover layer composite can of course also be connected to one another in a sandwich construction.

In one embodiment variant, at least the foldable section of the cover layer provided on the rear wall element is held in a first position on the backrest with the aid of at least one magnet, from which at least the cover layer can be folded via the hinge (about a hinge axis defined thereby) into a second, folded-down position can be. A closure with at least one magnet can thus be provided in order to hold at least the cover layer in the (first) position from which at least the cover layer can be folded into a further (second) position. The cover layer, which e.g. forms a visible and/or carpet-like surface on the back of the backrest for a loading floor when the backrest is folded down, can thus be secured, e.g be folded down relative to the outer surface after releasing the corresponding magnetic closure, e.g. to make a gap or a storage compartment accessible.

In one embodiment variant, the flat rear wall element is made from a material having at least two different structural layers connected to one another in a sandwich construction. The rear wall element made from such a (sandwich) material enables in particular a lightweight construction that cannot be achieved with the hitherto customary use of a thin-walled sheet steel for a rear wall element. In addition, the rear wall element can be easily adapted to different installation space conditions and design requirements due to the structural layers connected to one another in a sandwich construction. For example, the necessary structural geometry for functional components of the backrest can be formed on one side via at least a first structural layer, for example cable ducts, clips or embossing. A planar and optionally concealing surface can be provided via a second structural layer that faces the rear side of the backrest and is optionally visible thereon. The second structural layer can, for example, facilitate the attachment of the at least one cover layer, at least via a planar configuration. The at least two structural layers of the rear wall element, which form the rear wall element in a sandwich construction and are thus stacked on top of one another in a mold in order to form the rear wall element with the desired contour, can thus be used to integrate different functions into the rear wall element, which is then constructed in multiple layers. In this case, it is not mandatory that the different structural layers consist of different materials. Although this can be provided, the different structural layers can basically also consist of identical materials.

In one exemplary embodiment, it is provided, for example, that a first structural layer of the material in the rear wall element forms an inside of the rear wall element. Such an inner side faces a backrest cushion of the backrest that serves to support a seat occupant. In this case, the first structural layer can then form a flat inner side of the rear wall element with at least one structural element that projects or is set back in relation to a reference plane. Such a structural element includes, for example, a clip, a fastening profile, in particular a piping profile, a honeycomb structure, an embossing or a channel. Such a structural element formed by the first structural layer is then used, for example, to fasten and/or guide functional components of the vehicle seat arranged on or in the backrest and/or to connect to other elements of the backrest, such as spars of a backrest frame. Due to a multi-layer construction of the rear wall element, such a structural element that protrudes or is recessed on the inside is not necessarily connected to a corresponding counter-contour on the side of the rear wall element that faces the back of the backrest. A flat surface can easily be formed here by means of a second structural layer.

For example, in one embodiment variant it is provided that a second structural layer of the material in the rear wall element at least partially forms a visible rear side of the backrest and at least one cover layer is provided on the second structural layer to form at least one (further) part of a visible rear side of the backrest. The second structural layer and/or the top layer provided thereon thus form part of the visible rear side of the backrest. The second structural layer and/or the cover layer provided thereon can, for example, form the carpet-like surface customary for a loading floor, on which objects can be arranged when the backrest of the vehicle seat has been folded forward into a loading space position.

The second structural layer of the rear wall element can, for example, form a flat outer surface which faces away from an inner side of the rear wall element which faces a backrest cushion of the backrest. According to the variants explained above, the flat outer surface then forms, for example, part of the back of the backrest and/or the at least one cover layer is provided on this flat outer surface, so that the outer surface of the second structural layer is at least partially covered by the at least one cover layer.

By providing the at least one cover layer, a visible rear side of the backrest is at most partially formed by a (second) structural layer of the sandwich material of the rear wall element. However, the attachment of the at least one cover layer can be facilitated by the at least two-layer sandwich structure of the rear wall element. Since any structural elements and thus, for example, embossing, channels or deformations on an inside of the rear wall element are already laminated by the at least one second structural layer of the rear wall element, the at least one cover layer can be thin-walled and in particular thinner-walled than has been customary in practice up to now.

In one embodiment variant, a recess with at least one slot through which an anchoring element protrudes into the recess is formed on an outer surface of the rear wall element, which faces away from an inner side of the rear wall element facing a backrest cushion of the backrest. In this context, an anchoring element is understood to mean, in particular, an element that defines an attachment point on the rear side of the backrest. This includes an attachment point for a child seat attachment, e.g. for an Isofix strap, on the back of the backrest. For example, an anchoring element consequently provides a possibility for an (additional) intended fastening or anchoring of a child seat and forms an anchoring point, referred to as a “top tether”, for a child seat on the back of the backrest. In the case of previously customary backrests, such anchoring elements are covered by a separate panel, which must be subsequently installed, for example clipped, to a rear wall element as an additional component. Since a recess with a slot is formed, for example, in the rear wall element formed from a sandwich material, a corresponding panel is not necessary. Rather, a screen for the anchoring element is already integrated into the rear wall element.

In this context, it can also be provided, for example, that the inner walls of the depression facing the anchoring element are formed by at least one structural layer of the rear wall element, so that at least the one structure forming the walls turlage forms a screen for the anchoring element on the back side of the backrest.

The slot formed in the recess, through which the anchoring element protrudes, can be produced, for example, by stamping. The anchoring element can, for example, comprise an anchoring bracket or an anchoring eyelet.

As already mentioned above, in principle at least one cover layer can be provided on an outer surface of the rear wall element, which at least partially forms a visible rear side of the backrest. In one embodiment variant it can additionally be provided that a recess is formed in the rear wall element, which is covered by the at least one cover layer. For example, holes in the rear wall element can be covered over the at least one cover layer. Here, for example, the structural layers of the rear wall element, which are connected to one another in a sandwich construction, are pressed together on one side to a minimum and the cutouts that occur on a visible side of the rear wall element are covered with a cover layer, in particular with a cover layer with a carpet-like surface and/or a decorative layer. There is no need for an additional screen or an additional cover, as has been used in practice to date to cover a cutout in a thin-walled sheet steel of a rear wall element.

In principle, at least one of the structural layers of the rear wall element can comprise a fiber composite material. For example, one of the structural layers can comprise a plastic, in particular a glass fiber reinforced plastic, and/or a fleece, in particular a glass fiber reinforced fleece. In one embodiment variant, one of the structural layers is formed by a glass fiber reinforced plastic fleece, e.g. by a glass fiber reinforced polypropylene fleece. Alternatively or additionally, one of the structural layers can be formed with a honeycomb structure made of paper or cardboard. In one embodiment variant, a structural layer of paper or cardboard provided with a honeycomb structure is arranged between two structural layers of a plastic fleece, e.g. a polypropylene fleece. The rear wall element is consequently produced here from a material which, in a sandwich construction, comprises two glass fiber reinforced plastic fleeces with a structural layer of paper or cardboard lying in between. At least one additional cover layer can optionally be attached to a structural layer made of fiberglass-reinforced plastic fleece facing the back of the backrest, which at least partially forms a visible back of the backrest with its one surface.

In one embodiment variant, at least one insert is integrated into a material of the rear wall element that has at least two structural layers. Such an insert formed by a separate component and then embedded in the sandwich material, for example, forms a clip or a fastening profile, in particular a piping profile, on the rear wall element in order to integrate additional functions into the rear wall element.

In one embodiment variant, the rear wall element forms a honeycomb structure. This includes not only that the rear wall element has an internal structural layer provided with a honeycomb structure, which, for example, is arranged between two further structural layers and/or is made of paper or cardboard. Rather, this includes in particular that a first structural layer defining an inside of the rear wall element forms the honeycomb structure and this honeycomb structure is visible on the inside of the rear wall element.

In principle, the backrest can be pivoted from a position of use, in which the back of a seat occupant can be supported by the backrest, into a loading space position, in which a rear side of the backrest defines a loading area on which objects can be placed. By folding the backrest, for example, an enlarged loading floor is made available in a vehicle in which the vehicle seat is installed as intended.

A further aspect of the proposed solution relates to a method according to claim 14 9 for producing a backrest of a vehicle seat, in which a flat rear wall element is mounted on a backrest frame of the backrest. It is provided that a hinge point for a hinge is defined on an inside of the rear wall element facing away from the back of the backrest, the hinge being formed by a section of the cover layer, with the section of the cover layer having an edge section of at least one structural layer of the rear wall element to form the hinge encompasses and the encompassing of the hinge-forming section of the top layer is provided at the hinge point. The section of the cover layer that encompasses the edge section is fixed at the hinge point on the inside of the rear wall element facing away from the back of the backrest, so that the cover layer can be folded with a folding section that is visible on the back of the backrest relative to a core of the rear wall element formed with the at least one structural layer , Or the edge portion encompassing portion of the top layer is at the hinge point on a backrest frame Backrest fixed, so that the rear wall element is foldable relative to the backrest frame together with a visible on the back of the backrest folding portion of the top layer.

A backrest of an embodiment variant of a proposed vehicle seat can thus be produced in particular within the scope of an embodiment variant of a proposed manufacturing method. Advantages and features specified above and below for embodiment variants of a proposed vehicle seat therefore also apply to embodiment variants of a proposed manufacturing method and vice versa.

In one embodiment variant, the rear wall element can accordingly be made of a material, for example, which has at least two structural layers connected to one another in a sandwich construction, and/or a honeycomb structure is formed in the rear wall element, which is embossed and/or interrupted to form the hinge point.

The rear wall element can be fixed to the backrest frame, for example, by gluing and/or using at least one friction connector, in particular a plastic friction connector. Adhesive bonding of the rear wall element to the backrest frame of the backrest and the use of friction connectors enable comparatively fast cycle times in industrial production. Moreover, both of the aforementioned fixing methods offer weight advantages compared to fixing using screws and/or bolts.

The attached figures illustrate exemplary possible embodiment variants of the proposed solution.

• 1 ausschnittsweise mit Blick auf eine Innenseite eine Ausführungsvariante eines in Sandwichbauweise hergestellten flächigen Rückwandelements;
• 2 eine weitere Ausführungsvariante eines in Sandwichbauweise hergestellten flächigen Rückwandelements in perspektivischer Ansicht mit einer zusätzlich hieran angebrachten Decklage, die mit einem randseitig umgreifenden Abschnitt ein Filmscharnier ausgebildet;
• 2A einen vergrößerten Ausschnitt der 2 mit Blick auf das Filmscharnier;
• 3 in perspektivischer Ansicht einen Fahrzeugsitz mit schwenkbarer Rückenlehne, an der ein flächiges Rückwandelement gemäß den 1 und 2 vorgesehen werden kann;
• 4 und 4A in unterschiedlichen Ansichten ein aus dem Stand der Technik bekanntes Rückwandelement, das durch ein dünnwandiges Stahlblech mit einem kaschierendem, vergleichsweise dickwandigen Teppich an einer Rückseite überdeckt ist;
• 5 eine Flussdiagramm zu einer Ausführungsvariante eines vorgeschlagenen Herstellungsverfahrens;
• 6 ausschnittsweise und in Seitenansicht eine Ausführungsvariante eines Fahrzeugsitzes mit abgeklapptem Abschnitt eines Rückwandelements;
• 6A einen vergrößerten Ausschnitt des Fahrzeugsitzes der 6.

Here show:

• 1 a detail of an embodiment of a flat rear wall element produced in a sandwich construction with a view of an inside;
• 2 a further embodiment variant of a flat rear wall element produced in a sandwich construction in a perspective view with an additional cover layer attached thereto, which forms a film hinge with a section encompassing the edge;
• 2A an enlarged section of the 2 facing the film hinge;
• 3 in a perspective view of a vehicle seat with a swiveling backrest on which a flat rear wall element according to the 1 and 2 can be provided;
• 4 and 4A in different views, a rear wall element known from the prior art, which is covered by a thin-walled sheet steel with a concealing, comparatively thick-walled carpet on a rear side;
• 5 a flowchart for an embodiment variant of a proposed manufacturing method;
• 6 detail and side view of an embodiment variant of a vehicle seat with a folded-down section of a rear wall element;
• 6A an enlarged section of the vehicle seat 6 .

the 3 FIG. 1 shows a vehicle seat F, which includes a seat base G that is longitudinally displaceable along a longitudinal direction L via a rail arrangement SA, and a backrest R that can be pivoted about a pivot axis A on the seat base G. The seat base G has two opposite side parts S1 and S2. A seat pan W is displaceably arranged on these side parts S1 and S2 via a plurality of pivoting levers H1, H2, H3. The backrest R is provided above a transverse tube Q that connects the two side parts S1 and S2 to one another in a rear area of the vehicle seat F. The backrest R can be adjustable in its inclination with respect to the seat pan W about the pivot axis A. Furthermore, the backrest R, for example likewise about the pivot axis A or about an axis running parallel thereto, can be folded onto the seat pan W into a loading space position. In the cargo space position, a rear side 1A of the backrest R can provide an additional cargo area in a vehicle in which the vehicle seat F is mounted as part of a second or third row of seats.

The backrest R has a backrest frame LR. Such a backrest frame LR is formed, for example, from two opposite, longitudinally running (left and right) bars and two (upper and lower) cross members connecting the two bars to each other. At least one flat rear wall element 1 is fixed to the backrest frame LR.

In a vehicle seat known from the prior art, such a rear wall element is, for example, according to the 4 and 4A formed as a rear wall element 1' with a sheet steel 10'. Structural elements in the form of stampings 101 and holes 104 are formed on this comparatively thin-walled but heavy steel sheet 10'. These embossings 101 and the holes 104 serve as an example On an inner side 1B of the rear wall element 1' facing a backrest cushion, functional components are fixed and/or guided within the backrest R. In order to cover the embossings 101 and holes 104 on a visible side of the steel sheet 10', a comparatively thick-walled cover layer 12' is provided in the form of a carpet. This carpet 12' partially defines a visible rear surface 1A of the backrest R.

The production of the known from the prior art rear wall element 1 'according to 4 and 4A is comparatively expensive. Incidentally, the sheet steel 10' in particular is comparatively heavy and the carpet 12' cannot extend on or over an edge section 1C of the rear wall element 1 on the visible side, in particular due to its necessary thickness for concealing the embossings 101 and holes 104, over which a fixation of the rear wall element 1' on the backrest frame LR of the backrest R takes place.

In contrast, a rear wall element 1 according to the 1 formed in a sandwich construction by at least two structural layers 10 and 11. The flat rear wall element 1 of 1 is consequently formed from a material having two structural layers 10 and 11 . In this case, a first structural layer 10 defines the inner side 1B facing the backrest cushion. On this inner side 1B, embossings 101 and channels 102 are formed as structural elements via the first structural layer 10, as are any possible holes. A second structural layer 11 connected to this first structural layer 10 in a sandwich construction method covers the visible side of the rear wall element 1 and thus defines a flat outer surface on which at least one thin-walled cover layer 12 (cf. 2 and 2A ) can be easily attached.

Protruding and/or recessed structural elements 101, 102 that are necessary on the inside can already be formed during the molding and thus the shaping of the rear wall element 1 by producing the rear wall element 1 from a sandwich material or in a sandwich construction with two structural layers 10 and 11 that fulfill different functions. The two structural layers 10 and 11 also extend in particular together over a raised edge section 1C (which protrudes substantially perpendicularly compared to the inside 1B) of the rear wall element 1, via which it is fixed to the backrest frame LR by means of adhesive bonding and/or friction connectors.

Basically, a structural layer 10 or 11 of the 1 Rear wall element 1 shown consist of a fiber composite material, for example of a glass fiber reinforced thermoplastic material and in particular of a glass fiber reinforced plastic fleece, such as a polypropylene fleece. In principle, more than two structural layers 10, 11 can also be provided. For example, a development provides a rear wall element 1 which is formed in a sandwich construction with two (first and second) structural layers of a glass fiber reinforced plastic fleece and a (third) structural layer of paper or cardboard lying between them with a honeycomb structure.

In the variant of the 2 and 2A is a flat rear wall element 1, which is attached to the backrest frame LR of the backrest R 3 is to be fixed, is formed with a core which is produced in a sandwich construction and has at least two structural layers 10 and 11, although this is not mandatory for the solution proposed here. An (additional) thin-walled cover layer 12, for example with a carpet-like surface, is attached to this core 10, 11 on the visible side facing the back 1A of the backrest R.

The top layer 12 forms in the rear wall element 1 of 2 and 2A at least part of a rear side 1A of the backrest R and encompasses both sides (left and right in the 2 ) with two sections opposing areas of the peripheral edge section 1C. Here forms a first in which 2 right-lying encompassing (hinge) section 12a of the cover layer 12 has a hinge 120 . The rear wall element 1 attached to the backrest frame LR with the cover layer 12 (relative to the backrest frame LR) or only a section 12b of the cover layer 12 visible on the back 1A of the backrest R (relative to the backrest frame LR and the core 10 , 11 of the rear wall element 1) be foldable. The encompassing hinge section 12a of the cover layer 12 is—at least locally—sufficiently flexible or elastic in bending to define a hinge axis at an edge of the encompassed edge section 1C. The flexural rigidity of the hinge section 12a surrounding the edge section 1C can be reduced by perforations 120a.

To the illustrated embodiment 2 and 2A For example, to make the cover layer 12 foldable relative to the sandwich-construction core 10, 11 of the rear wall element 1, a hinged edge 121 is formed by the cover layer 12 in a region of the edge section 1C that is spaced apart from the hinge 120, which is detachably attached to the core 10, 11 of the rear wall element 1 is held. With this folding edge 121 the cover layer 12 surrounds the edge of the core 10, 11 of the rear wall element 1 opposite the hinge 120. The cover layer 12 can be releasably held in the position shown, in which the cover layer 12 rests with the folding section 12b on an outer surface of the core 10, 11 of the rear wall element 1. Here, the magnets 13 act together with a metallic counterpart on the rear wall element 1 or--in the assembled state of the backrest R--the backrest frame LR. The folding edge 121 can then be detached manually from the rear wall element 1 and/or the backrest frame LR against the applied magnetic force and the cover layer 12 can thus be folded about the hinge axis provided by the hinge 120 .

Deviating from the in 2 In a variant of the selected representation, it can be provided that the folding edge 121 does not extend by 180° around the edge section 1C (as is also provided for the hinge section 12a of the top layer 12 for the formation of the hinge 120). Alternatively, the folding edge 121 can also extend only partially and, for example, in an L-shaped cross section around the edge section 1C. A tab-shaped or web-shaped section of the folding edge 121 can already be grasped by a user in the area of a lateral edge of the rear wall element 1 . Consequently, the folding edge 121 does not have to be grasped and released on the inner side 1B of the rear wall element 1 facing the backrest cushion and thus difficult to access from the rear side of the backrest R.

At the in the 2 In the configuration shown, the planar folding section 12b of the cover layer 12 can be folded relative to the core 10, 11 of the rear wall element 1, which is produced in a sandwich construction, before the rear wall element 1 is mounted on the backrest frame LR. In an alternative embodiment variant, however, after the rear wall element 1 (with the cover layer 12) has been installed as intended on the backrest frame LR, a hinge axis can also be defined via the hinge 120, around which the rear wall element 1 together with the cover layer 12 can be folded on the backrest frame LR. In this case, not (only) a fixing of an area of the encompassing hinge section 12a of the cover layer 12 on the inside 1B is provided on the core 10, 11 of the rear wall element 1. Rather, an (additional) fixation of this area on the backrest frame LR is provided, so that part of the hinge section 12a is fixed directly on the backrest frame LR, relative to which the rear wall element 1 can be folded.

The cover layer 12, which can be folded in sections using the at least one hinge 120, or the rear wall element 1 that can be folded over it together with the cover layer 12, can be used, for example, for an integrated gap cover, a cover for storage compartments and/or a cover for a gap to a roller blind box on the back 1A of the backrest R be realizable. In this case, the respective cover can be removed manually by folding it about the hinge axis provided via the hinge 120 . After the vehicle seat F has been installed as intended, the cover layer 12 or the rear wall element 1 with the cover layer 12 can be folded via the (film) hinge 120 relative to the backrest frame LR between two positions, a first, closed position on the one hand and a second, open position on the other .

That in the 2 and 2A In the present case, the rear wall element 1 illustrated forms a honeycomb structure 100 visible on the inside 1B with the structural layers 10 and 11 connected in a sandwich construction. This honeycomb structure 100 is specifically embossed and/or interrupted for the definition of a hinge point 103, at which the gripping of the hinge section 12a of the cover layer 12 is provided. In this way, apart from the originally formed honeycomb structure 100, a defined reduction in thickness is made, interrupting the honeycomb structure 100, in order to form the hinge 120 here with the aid of an encompassing section of the cover layer 12.

In addition to the illustrated variants of the 1 and 2 until 2A In particular, a slotted depression can also be formed on the rear wall element 1 via the structural layers 10 and 11 on the rear wall element 1, into which an anchoring element protrudes. An anchoring point for a child seat called a “top tether” is provided on the back 1A of the backrest R via the anchoring element, for example in the form of an anchoring bracket or an anchoring eyelet. In this case, an additional covering of the anchoring element is not necessary, since the second structural layer 11 provided on the outside, with which the depression is formed, already forms a corresponding covering.

In one embodiment of a proposed manufacturing method, for example, according to the flow chart 5 First, in a method step A1, the rear wall element 1 is formed with the multi-layer sandwich material. Here, for example, according to the 1 illustrated embodiment, the rear wall element 1 formed with the multi-layer, the structural layers 10 and 11 having core, in which the structure layer 11 forms a flat outer surface which - the back 1A of the backrest R faces - when the vehicle seat F is installed as intended.

In a subsequent process step A2, the intended embossing and punchings are provided on the inside 1B of the rear wall element 1 and the single-layer or multi-layer cover layer 12 corresponding to that in FIGS 2 and 2A illustrated embodiment, separately attached to form the hinge 120.

Subsequently, in a method step A3, the rear wall element 1 prefabricated in this way with a concealing structural layer 11 or a separately attached cover layer 12 is fixed to the backrest frame LR of the backrest R, in particular in the case of a non-folding core 10, 11 by means of adhesives and/or friction connectors.

Deviating from the representation in the 2A the hinge 120 can also be designed without perforations 120a. For example, the encompassing (hinge) section 12a of the cover layer 12 can already be designed with sufficient flexibility. Alternatively or additionally, a wall thickness of the cover layer 12 can be reduced locally in that area of the encompassing hinge section 12a via which the hinge axis of the hinge 120 is to be defined. A bending point and thus the hinge axis can be specified via such a local reduction in the wall thickness--just as via the perforation 120a. In addition, not only the flexural rigidity, but also the bending radius can be influenced here--as well as via the perforations 120a.

the 6 shows a detail and side view of an embodiment variant of a vehicle seat F with a folded-down section 12b of a rear wall element 1. The folding section 12b is provided here by way of example in a lower region of the backrest R and is used as a cover, in particular as a cover between the body and the vehicle seat F, for example. The hinge 120 is formed here via perforations 120a and/or a local reduction in the wall thickness of the flat rear wall element 1, so that folding at a hinge section 12a of the top layer 12 about a hinge axis formed thereby is made possible.

In order to hold the folding section 12b in a closed position, in which the folding section 12b is flush with the other sections of the rear wall element 1 and defines a flat rear side 1A of the backrest R, a lock is provided. In the present example, this closure is designed with at least one magnet 13 .

the 6A shows an enlarged detail of the vehicle seat F of 6 in the area of the hinge 120. Based on the enlarged view of 6A it is illustrated in particular that the folding section 12b can be folded over the film hinge 120 by more than 60° from the closed position into an open position.

Deviating from or supplementing the embodiment variants shown in the figures, it can also be provided that at least one structural element in the form of a clip or a piping profile is formed over at least one of the structural layers 10, 11 on the rear wall element 1 or is provided via an insert that is the sandwich material having the structural layers 10 and 11 is integrated.

Reference List

1.1'

rear wall element

10

First structural layer

10'

sheet steel

100

honeycomb structure

101, 102

embossing / channel (structural element)

103

hinge point

104

(through) hole

11

Second layer of structure

12, 12'

cover layer

12a

(Hinge) section of the top layer

12b

(Folding) section of the top layer

120

hinge

120a

perforations

121

folding edge

13

magnet

1A

back

1B

inside

1C

edge section

A

pivot axis

A1, A2, A3

process steps

f

vehicle seat

G

seat frame

H1, H2, H3

swing lever

L

longitudinal direction

LR

backrest frame

Q

cross tube

R

backrest

S1, S2

side panel

SA

rail arrangement

W

seat pan

Claims (15)

Vehicle seat (F) with a backrest (R) which has a flat rear wall element (1) with at least one cover layer (12) for a rear side (1A) of the backrest (R), characterized in that on one of the rear side (1A) the inside (1B) of the rear wall element (1) facing away from the backrest (R), a hinge point (103) for a hinge (120) is defined, which is formed by a section (12a) of the cover layer (12), the hinge (120 ) forming section (12a) of the cover layer (12) encompasses an edge section (1C) of at least one structural layer (10, 11) of the rear wall element (1) and at the hinge point (103) the encompassing section (12a) forming the hinge (120) of the cover layer (12), and wherein - the section (12a) of the cover layer (12) surrounding the edge section (1C) at the hinge point (103) on the inside (1B) of the backrest (R) facing away from the rear side (1A). Rear wall element (1) is fixed, so that the top layer (12) with a Rü Rear side (1A) of the backrest (R) visible folding section (12b) can be folded relative to a core (10, 11) of the rear wall element (1) formed with the at least one structural layer, or - the section (12a) surrounding the edge section (1C) the cover layer (12) is fixed at the hinge point (103) on a backrest frame (LR) of the backrest (R), so that the rear wall element (1) together with a folding section (12b) visible on the back (1A) of the backrest (R) the top layer (12) can be folded relative to the backrest frame (LR). Vehicle seat (F) to claim 1 , characterized in that a perforation (120a) is provided on the section (12a) of the cover layer (12) forming the hinge (120). Vehicle seat (F) according to one of the preceding claims, characterized in that the rear wall element (1) forms a honeycomb structure (100). Vehicle seat (F) to claim 3 , characterized in that the honeycomb structure (100) is embossed and/or interrupted to form the hinge point (103). Vehicle seat (F) according to one of the preceding claims, characterized in that a plurality of cover layers (12) which at least partially overlap one another are provided on the rear wall element (1). Vehicle seat (F) according to one of the preceding claims, characterized in that a cover is formed on the vehicle seat (F) at least over the folding section (12b) of the cover layer (12) visible and foldable on the rear side (1A) of the backrest (R). . Vehicle seat (F) to claim 6 , characterized in that the cover at least partially covers a gap or a storage compartment. Vehicle seat (F) according to one of the preceding claims, characterized in that at least the foldable section (12b) of the cover layer (12) provided on the rear wall element (1) can be fixed in a first position on the backrest (R ) is held, from which at least the folding section (12b) of the cover layer (12) can be folded into a second, folded-down position via the hinge (120). Vehicle seat (F) according to one of the preceding claims, characterized in that the rear wall element (1) is produced from a material having at least two different structural layers (10, 11) connected to one another in a sandwich construction. Vehicle seat (F) to claim 9 , characterized in that a first structural layer (10) of the material forms an inner side (1B) of the rear wall element (1) facing away from the rear side (1A) of the backrest (1B). Vehicle seat (F) to claim 9 or 10 , characterized in that on the second structural layer (11) the cover layer (12) for the formation of at least part of a visible rear side (1A) of the backrest (R) is provided. Vehicle seat (F) according to one of the preceding claims, characterized in that at least two different cover layers (12) are provided on an outer surface of the rear wall element (1) facing the rear (1A) of the backrest (R). Vehicle seat (F) according to one of the preceding claims, characterized in that the backrest (R) can be pivoted from a position of use, in which the back of a seat occupant can be supported by the backrest (R), into a loading space position, in which a rear side (1A ) the backrest (R) defines a loading area on which objects can be parked. Method for producing a backrest (R) of a vehicle seat (F), in which a flat rear wall element (1) is mounted on a backrest frame (LR) of the backrest (R), characterized in that on one of the rear sides (1A) of the backrest ( R) a hinge point (103) for a hinge (120) is defined on the inner side (1B) of the rear wall element (1) facing away, which is formed by a section (12a) of the cover layer (12), wherein for the formation of the hinge (120) the section (12a) of the cover layer (12) embraces an edge section (1C) of at least one structural layer (10, 11) of the rear wall element (1) and the embrace of the section (12a) of the cover layer (12) forming the hinge (120) at the Hinge point (103) is provided, and - the section (12a) of the cover layer (12) surrounding the edge section (1C) at the hinge point (103) on the inside (1B) of the backrest (R) facing away from the rear (1A). Rear wall element (1) is fixed so that the cover layer (1 2) with a visible folding section (12b) on the back (1A) of the backrest (R) that can be folded relative to a core (10, 11) of the rear wall element (1) formed with the at least one structural layer, or - which closes the edge section (1C ) encompassing section (12a) of the cover layer (12) is fixed at the hinge point (103) on a backrest frame (LR) of the backrest (R), so that the rear wall element (1) together with a backrest (1A) on the backrest (R ) Visible folding section (12b) of the top layer (12) relative to the backrest frame (LR) can be folded. procedure after Claim 14 , characterized in that a honeycomb structure (100) is formed on the rear wall element (1) and the honeycomb structure (100) is embossed and/or interrupted to form the hinge point (103).

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