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DE-112024003079-T5 - METHOD FOR USING EXCESS SUBSTRATE FROM ONE VEHICLE SEAT COMFORT SYSTEM IN ANOTHER VEHICLE SEAT COMFORT SYSTEM

DE112024003079T5DE 112024003079 T5DE112024003079 T5DE 112024003079T5DE-112024003079-T5

Abstract

A method for manufacturing a comfort system for a vehicle seat, comprising providing a substrate for manufacturing a first comfort system; separating the substrate into a usable substrate and an excess substrate; using at least a portion of the usable substrate to manufacture the first comfort system for the vehicle seat; and using at least a portion of the excess substrate to manufacture a second comfort system for the vehicle seat or for another vehicle seat.

Inventors

  • Andrew Charles White
  • Randy Kent Lewis
  • Luke Andrew Boeve
  • Ricardo Edmundo Flores GONZALEZ
  • Joseph Krzemien
  • Igor Spasojevic
  • William Hardin Goodman

Assignees

  • Gentherm Incorporated

Dates

Publication Date
20260513
Application Date
20240724
Priority Date
20230725

Claims (17)

  1. A method for manufacturing a comfort system for a vehicle seat, comprising: separating a substrate into a usable substrate and an excess substrate; using at least a portion of the usable substrate to manufacture a first comfort system for the vehicle seat; and using at least a portion of the excess substrate to manufacture a second comfort system for the vehicle seat or for another vehicle seat.
  2. The procedure according Claim 1 , where the first comfort system is a thermal system and the second comfort system is a pneumatic system.
  3. The procedure according Claim 1 or 2 , wherein the process includes a shaping step in which one or more elements of the second comfort system are attached to the excess substrate.
  4. The method according to one of the preceding claims, wherein the method comprises a shaping step in which the excess substrate is attached to the usable substrate to connect the first comfort system and the second comfort system.
  5. The method according to any of the preceding claims, wherein the separation step comprises cutting or punching the substrate.
  6. The method according to one of the preceding claims, wherein the substrate is a nonwoven fabric.
  7. The method according to one of the preceding claims, wherein the substrate is first provided as a roll and is unrolled from the roll before the separation step.
  8. The method according to one of the preceding claims, wherein the substrate is initially provided in individual pieces.
  9. The procedure according Claim 3 or one of the preceding claims, wherein one or more elements of the second comfort system, which are attached to the excess substrate, comprise one or more bubbles, cells and/or tubes.
  10. The procedure according Claim 1 or one of the preceding claims, wherein at least a portion of the excess substrate remains adhered to the usable substrate after the separation step.
  11. The procedure according Claim 1 or one of the preceding claims, wherein the method comprises adding a cushioning or spacer layer between the first comfort system and the second comfort system.
  12. A comfort arrangement for a vehicle seat, comprising: a first comfort system comprising a first substrate; and a second comfort system comprising a second substrate; wherein the second substrate is a repurposed surplus substrate generated during the manufacture or assembly of the first comfort system.
  13. The comfort arrangement according to Claim 12 , where the first comfort system is a thermal system and the second comfort system is a pneumatic system.
  14. The comfort arrangement according to one of the Claims 12 or 13 , wherein the second substrate is attached to the first substrate and the second substrate is configured to hold or support one or more elements of the second comfort system.
  15. The comfort assembly according to one of the Claims 12 - 14 , where the first substrate is a non-woven or fabric material.
  16. The comfort arrangement according to one of the Claims 12 - 15 , wherein the first substrate undergoes a separation step configured to separate the second substrate from the first substrate.
  17. The comfort arrangement according to one of the Claims 12 - 16 , wherein a padding or spacer layer is arranged between the first comfort system and the second comfort system.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS This application claims priority over the application filed on July 25, 2023. US 63/528,676 , which are hereby incorporated in their entirety by reference for all purposes. AREA This teaching relates to a method for using, repurposing, or recovering excess substrate from one vehicle seat comfort system in another vehicle seat comfort system. This teaching also relates to a vehicle seat comfort system that is at least partially manufactured from excess substrate from another vehicle seat comfort system. BACKGROUND Some vehicle seats incorporate one or more systems to enhance occupant comfort. For example, some vehicle seats include one or more thermal systems to provide heating and/or cooling functions to the occupant. Some vehicle seats include one or more pneumatic systems to provide massage and/or lumbar support functions. While such systems are generally appreciated by consumers, conventional manufacturing methods can generate excess material or waste, which can undesirably increase material costs and negatively impact the environment. Therefore, it may be desirable to improve upon the current state of the art. SUMMARY The present teaching relates to a comfort system for a vehicle seat and to a method for manufacturing one or more comfort systems. These teachings generally relate to collecting, saving, or otherwise recovering excess material from the manufacture or assembly of a comfort system and to reusing, repurposing, or recovering the same for another comfort system for a vehicle seat. These teachings also relate to a comfort system for a vehicle seat manufactured from excess materials collected or recovered during the manufacture or assembly of another comfort system for a vehicle seat. These tools provide a method for collecting or recovering excess materials from the manufacture or assembly of a vehicle seat comfort system that would otherwise end up as waste, and reusing them in the manufacture or assembly of another vehicle seat comfort system. Advantageously, these tools can result in significant cost savings for the comfort system manufacturer, which can be passed on to the consumer. Furthermore, these tools can lead to a substantial reduction in waste, which benefits the environment. BRIEF DESCRIPTION OF THE FIGURES 1 This is a side view of a vehicle and a vehicle seat.2 This is a perspective view of the upholstery of a vehicle seat.3 This is a front view of a raw or bulk substrate for a comfort system.4A is a front view of a substrate for a comfort system with schematically represented cut lines defining usable substrate and excess substrate.4B is a front view of the usable substrate made of 4A , whereby the excess substrate was removed.4C is a front view of the usable excess substrate, which consists of 4A was removed.4D is a front view of the usable excess substrate made of 4C , which is used or repurposed for a different comfort system for a vehicle seat.5A is a front view of a substrate for a comfort system with schematically represented cut lines defining usable substrate and excess substrate.5B This is a front view of the usable substrate and the usable excess substrate.5C This is a front view of the usable excess substrate that is used or repurposed for another comfort system.5D This is a front view of the usable excess substrate that is used or repurposed for another comfort system.6 shows a flowchart of the procedure of this teaching.7A is a front view of a substrate for a comfort system with a schematic representation They established cutting lines that define usable substrate and usable excess substrate.7B This is a front view of the usable excess substrate that is being used or repurposed.7C is a side view of 7B . DETAILED DESCRIPTION 1 Figure 1 shows a vehicle 10. The vehicle 10 comprises one or more vehicle seats 12. The vehicle seat 12 consists of a seat section 14 and a backrest section 16. The seat section 14 and/or the backrest section 16 may contain a cushion 18. The cushion 18 may be a single cushion for both sections 14 and 16, or the cushion 18 may consist of two (or more) separate parts for one or both sections 14 and 16. The vehicle seat 12, the seat section 14, and/or the backrest section 16 can comprise one or more comfort systems 100, 200. In the example shown, the vehicle seat 12 comprises two comfort systems (i.e., 100 and 200), which can be referred to as a comfort assembly. It is understood that these teachings can provide for any number of comfort systems and assemblies, including only one comfort system or comfort assembly, or any number of comfort systems or assemblies. 2 Figure 18 shows a cushion 18 and a comfort system 100 (and/or 200). Although the cushion 18 is shown configured for the backrest section 16 of a vehicle seat, its features can also be used for the seat section of the vehicle seat without restriction. Therefore, the description of the cushion 18 is not limited to the backrest section 16 unless explic