Vehicle seat and preparation method thereof

Abstract

The invention relates to the technical field of seats, in particular to a vehicle seat and a preparation method thereof. The vehicle seat comprises a seat back structure and a seat surface structure, and the seat surface structure is installed at the lower end of the seat back structure; the chair back structure is fixedly mounted and comprises a chair back body and chair back ends, the chair back body is formed by mixing and weaving carbon fibers, and the chair back ends are mounted at the left end and the right end of the chair back body; the chair surface structure comprises a chair surface body and chair surface end heads, the chair surface body is formed by mixing and weaving carbon fibers, the chair surface end heads are mounted at the left end and the right end of the chair surface body, the rear ends of the chair surface end heads are rotationally connected with the lower ends of the chair back end heads, and a leaning and sitting part is arranged at the front end of the bottom side of the chair surface body. The problems that an existing seat structure is large in weight, poor in heat conductivity, single in form and the like are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of seats, and in particular to a vehicle seat and a preparation method thereof. Background Art

[0002] In modern urban transportation systems, subways are a major form of public transportation. The comfort and functionality of their seats have a direct impact on the passenger experience. With technological advancements and developments in materials science, traditional metal or plastic seats are gradually being replaced by lighter, more durable materials. Carbon fiber composites, due to their light weight, high strength, and excellent thermal conductivity, are an ideal material for rail transit seats.

[0003] Currently, urban rail transit seats are generally designed with multiple seats in a row, and generally adopt a fixed structure with a glass fiber composite seat surface and a metal frame. Although this structure has certain strength and durability, it has problems such as heavy weight, poor thermal conductivity, and a single form. The glass fiber composite seat surface requires multiple sets of molds to form, resulting in high mold costs. In addition, the glass fiber composite seat surface is commonly manufactured using HLU and RTM processes. During the manufacturing process, the resin content in the edges and corners is high, which is prone to quality problems such as cracks. Passengers will feel uncomfortable when riding in glass fiber composite seats for a long time due to their low thermal conductivity, and they lack the "cool feeling" of metal seats.

[0004] Therefore, the existing seat structure has the following technical problems:

[0005] 1. The seats are heavy, which increases the energy consumption and operating costs of rail transit vehicles.

[0006] 2. The seats have poor thermal conductivity, making them uncomfortable to sit on for long periods of time, which affects the passenger experience.

[0007] 3. The seat style is single, lacking flexibility and personalization, and cannot meet the needs of different customers.

[0008] 4. The mold cost is high during the seat manufacturing process and quality problems such as cracks are prone to occur. Summary of the Invention

[0009] To address the shortcomings of existing technologies, the present invention aims to provide a vehicle seat and its manufacturing method to address the existing seat structures' issues of heavy weight, poor thermal conductivity, and monotonous design. This seat structure reduces weight, improves thermal conductivity, increases design diversity, and reduces manufacturing costs. By utilizing carbon fiber materials and innovative molding processes, a lighter, more comfortable, and more economical rail transit seating solution is achieved, enhancing passenger comfort and seat performance.

[0010] In order to achieve the above objectives, the embodiments of the present invention provide the following technical solutions:

[0011] A vehicle seat comprises: a backrest structure and a seat surface structure, wherein the seat surface structure is mounted on the lower end of the backrest structure; the backrest structure is fixedly mounted, comprising a backrest body and a backrest end head, wherein the backrest body is formed by a mixed weaving of carbon fibers, and the backrest end heads are mounted on the left and right ends of the backrest body; the seat surface structure comprises a seat surface body and a seat surface end head, wherein the seat surface body is formed by a mixed weaving of carbon fibers, and the seat surface end heads are mounted on the left and right ends of the seat surface body, the rear end of the seat surface end head is rotatably connected to the lower end of the backrest end head, and the front end of the bottom side of the seat surface body has a sitting portion.

[0012] Optionally, a mounting hole is provided on the back side of the chair back body, and the chair back body is fixed to the end wall by connecting the mounting hole with fasteners, and the chair back body is in an upright state.

[0013] Optionally, the chair back body is woven by a mixture of graphene-based carbon fiber and PAN-based carbon fiber, and the chair seat body is woven by a mixture of graphene-based carbon fiber and PAN-based carbon fiber.

[0014] Optionally, the backrest end includes a left backrest end and a right backrest end, and the left backrest end and the right backrest end are respectively plugged into the left end and the right end of the backrest body; the seat surface end includes a left seat surface end and a right seat surface end, and the left seat surface end and the right seat surface end are respectively plugged into the left end and the right end of the seat surface body.

[0015] Optionally, the left end of the chair back and the left end of the seat seat are rotatably connected via a left hinge, and the right end of the chair back and the right end of the seat seat are rotatably connected via a right hinge.

[0016] Optionally, the left end of the chair back, the right end of the chair back, the left end of the seat surface and the right end of the seat surface are all made of aluminum alloy or magnesium alloy.

[0017] Optionally, a backrest is further provided on the front side of the chair back body, the backrest is plugged into the chair back body, and the backrest is made of polyurethane material.

[0018] Optionally, a seat cushion is further provided at the upper end of the chair seat body, the seat cushion is plugged into the chair seat body, and the seat cushion is made of polyurethane material.

[0019] An embodiment of the present invention further provides a method for preparing the vehicle seat as described above, comprising:

[0020] Lead the yarn ball placed on the creel and lead it out from the threading hole at the end;

[0021] The yarn passes through the yarn threading plate in sequence according to the product layer table and is threaded from top to bottom;

[0022] The yarn is drawn out and placed on the edge of the mold;

[0023] The yarn is arranged according to the layup table and then pulled out through the die;

[0024] Epoxy resin with graphene slurry added is injected and cured.

[0025] Optionally, the ply layup is, from inside to outside, an inner layer, a 0° straight yarn, a winding layer, a 0° straight yarn and an outer layer, wherein the outer layer is graphene-based carbon fiber, and the remaining layers are PAN-based carbon fiber mixed weaving.

[0026] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages:

[0027] The load-bearing carbon fiber composite seat structure of this invention eliminates the traditional frame, resulting in a lighter weight and lower operating costs. The use of new materials and a novel structural design reduces the overall weight by 15% compared to existing structures, effectively lowering overall operating costs. Furthermore, the carbon fiber composite seat, with its heat dissipation function, offers high thermal conductivity and a feel comparable to that of a metal seat.

[0028] The use of carbon fiber chair seats reduces product weight and improves thermal conductivity. The pultrusion / braiding process improves production efficiency, simplifies the number of molds, and reduces mold costs. While meeting strength requirements, weight is reduced and production efficiency is improved.

[0029] Additional advantages of the present invention will be given in the description which follows, and in part will be obvious from the description which follows, or may be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] To more clearly illustrate the embodiments of this application or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are only some of the embodiments described in this application. For those skilled in the art, other drawings can be derived from these drawings without inventive effort. In addition, the spacing or size between parts is exaggerated to show the position of each part, and the schematic diagram is for illustrative purposes only.

[0031] Figure 1 is a three-dimensional diagram of a seat provided by an embodiment of the present invention;

[0032] Figure 2 is a schematic diagram of the back side of a seat provided by an embodiment of the present invention;

[0033] Figure 3 is a schematic diagram of the right side of a seat provided by an embodiment of the present invention;

[0034] Figure 4 is a schematic diagram of a seat folded state provided by an embodiment of the present invention;

[0035] Figure 5 Schematic diagram of a production line for a chair back body or a chair seat body according to an embodiment of the present invention;

[0036] Figure: 11, right end of chair back; 12, chair back body; 121, mounting hole; 13, backrest; 14, left end of chair back; 21, right end of seat surface; 22, seat body; 221, seat back; 23, seat cushion; 24, left end of seat surface; 31, right hinge; 32, left hinge; 41, yarn rack; 42, yarn feeder plate; 43, yarn drying oven; 44, preforming tooling; 45, mold and heating plate; 46, post-curing oven; 47, servo pultrusion machine; DETAILED DESCRIPTION

[0037] It should be noted that the following detailed description is illustrative and is intended to further illustrate the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0038] Explanation of terms:

[0039] HLU: In composite manufacturing, HLU stands for "Hand Lay-Up," a method of manual layering. During the Hand Lay-Up process, workers manually lay reinforcements onto a mold and evenly apply the resin system to the reinforcements using a brush or roller to form the composite structure. This method is relatively simple, but requires high worker skill and has low production efficiency. It is typically used for small-batch production or the manufacture of complex-shaped components.

[0040] RTM: RTM stands for "Resin Transfer Molding." It's a closed-mold manufacturing process in which reinforcements are placed in a mold, and then resin is injected into the mold under pressure, causing the resin to flow around the fibers and solidify, forming the composite part. The RTM process can achieve a high fiber volume ratio and more complex part shapes. Compared to hand lay-up, RTM offers higher production efficiency and more precise quality control.

[0041] Example 1

[0042] In order to solve the technical problems mentioned in the background technology, this embodiment proposes a vehicle seat, such as Figure 1As shown, the vehicle seat includes a backrest structure and a seat surface structure, with the seat surface structure being mounted at the lower end of the backrest structure. The backrest structure is fixedly mounted and comprises a backrest body 12 and backrest end caps. The backrest body 12 is formed from a mixed woven carbon fiber structure, with the backrest end caps mounted on the left and right ends of the backrest body 12. The seat surface structure includes a seat surface body 22 and seat surface end caps. The seat surface body 22 is also formed from a mixed woven carbon fiber structure, with the seat surface end caps mounted on the left and right ends of the seat surface body 22. The rear end of the seat surface end caps is rotatably connected to the lower end of the backrest end caps. The bottom front end of the seat surface body 22 has a reclining portion 221.

[0043] The backrest body 12 and the seat body 22 are both made of a mixed weave of carbon fibers. This material selection is intended to reduce the weight of the seat while maintaining structural strength. The backrest end and seat seat end are made of aluminum alloy or magnesium alloy to further reduce weight and maintain durability. The connection between the backrest end and the backrest body 12 is a fixed installation, while the seat seat end and the backrest end are connected by a rotation, allowing the seat seat structure to be flipped relative to the backrest structure to provide different usage modes. The fixedness of the backrest structure provides stable support, while the rotatability of the seat seat structure allows the seat to be adjusted in different usage scenarios to suit the needs of passengers. This design makes the seat light and flexible while maintaining sufficient strength and durability to meet the needs of urban rail transit seats.

[0044] like Figure 2 As shown, a mounting hole 121 is opened on the back side of the chair back body 12, and the chair back body 12 is fixed to the end wall by fasteners connected to the mounting hole 121, and the chair back body 12 is in an upright state.

[0045] Mounting holes 121 on the back of the seatback body 12 are designed to secure it to the end wall. The design of mounting holes 121 allows for securement using fasteners (such as bolts, screws, etc.). The connection between the seatback body 12 and the end wall via mounting holes 121 is rigid, ensuring the stability of the seatback during vehicle operation. Fasteners secure the seatback body 12 to the end wall, ensuring stability and safety during vehicle operation.

[0046] The chair back body 12 is made of a mixed weaving of graphene-based carbon fibers and polyacrylonitrile (PAN)-based carbon fibers, and the chair seat body 22 is made of a mixed weaving of graphene-based carbon fibers and polyacrylonitrile-based carbon fibers.

[0047] Both the backrest 12 and seat 22 are woven from a blend of graphene-based and PAN-based carbon fibers. This hybrid weaving technique improves the material's thermal conductivity and strength. The addition of graphene-based carbon fibers enhances the seat's thermal conductivity, ensuring it maintains a pleasant feel even after extended use. This material combination not only reduces the seat's weight but also improves its thermal conductivity and strength, ensuring a comfortable ride while also extending its service life.

[0048] The pultrusion / stretch-braiding molding process improves preparation efficiency, overall component quality and component thermal conductivity, avoids the uncontrollable resin content and cracking problems of HLU and RTM molding processes, and gives the seat a "cool feel" like a metal seat.

[0049] Polyacrylonitrile is a synthetic material commonly used in the manufacture of carbon fibers. During the carbon fiber production process, PAN-based carbon fibers are obtained by carbonizing polyacrylonitrile fibers at high temperatures and then subjecting them to a series of processing steps. Of course, carbon-glass composites or specialty pitch-based carbon fibers can also be used.

[0050] The backrest end includes a left end 14 and a right end 11, which are respectively plugged into the left and right ends of the backrest body 12; the seat surface end includes a left end 24 and a right end 21, which are respectively plugged into the left and right ends of the seat surface body 22.

[0051] The connection between the end and the seat body is achieved through a plug-in connection, which is simple and secure. This plug-in connection allows for quick assembly and disassembly, facilitating seat maintenance and replacement. This design makes seat assembly and maintenance more convenient while also improving the seat's structural stability.

[0052] In another embodiment, adhesives such as epoxy / acrylic adhesives may be used to bond the components into a whole for support.

[0053] The left end of the chair back 14 and the left end of the seat 24 are connected by a left hinge 32, and the right end of the chair back 11 and the right end of the seat 21 are connected by a right hinge 31, so that the two forms of fixed and flip can be realized. Figure 3 、 Figure 4 shown.

[0054] Hinges are typically made of metal to ensure sufficient strength and durability. This hinge connection allows the seat's seat end to pivot relative to the seatback end, providing a flip-up function. This hinged connection allows the seat to be flipped as needed to accommodate different usage scenarios. This design makes the seat more flexible and adaptable to the passenger's needs, enhancing its practicality.

[0055] The left and right seatback ends 14 and 11, as well as the left and right seatback ends 24 and 21, are all made of aluminum or magnesium alloy. This material is chosen to reduce the overall weight of the seat while maintaining sufficient strength and durability. The use of aluminum or magnesium alloy ensures that the ends retain their shape and function despite the stresses of daily use. This material selection helps reduce the overall weight of the vehicle while ensuring component strength, thereby reducing energy consumption and improving energy efficiency.

[0056] The right end 11 and the left end 14 of the chair back are made of aluminum (magnesium) alloy by die casting, with an overall thickness of 3mm; the right end 21 and the left end 24 of the seat surface are made of aluminum (magnesium) alloy by die casting, with an overall thickness of 4mm.

[0057] A backrest 13 is also provided on the front side of the chair back body 12, and the backrest 13 is plugged into the chair back body 12. The backrest 13 is made of polyurethane material. The backrest 13 is made of polyurethane material, which has good elasticity and comfort. The connection between the backrest 13 and the chair back body 12 is achieved by plugging, which is convenient for disassembly and replacement. The plug-in design of the backrest 13 allows for quick replacement to adapt to different usage requirements or maintenance needs. The backrest 13 made of polyurethane material provides good riding comfort, and the plug-in design makes maintenance and replacement more convenient. The overall thickness and texture effect of the backrest 13 are adjusted according to customer requirements. The backrest 13 is added in cold seasons to avoid direct contact with the chair back.

[0058] A seat cushion 23 is also provided at the upper end of the seat body 22. The seat cushion 23 is plugged into the seat body 22 and is made of polyurethane to provide a comfortable ride. The seat cushion 23 is also connected to the seat body 22 by plugging, making it easy to disassemble and replace. The plug-in design of the seat cushion 23 allows for quick replacement as needed to accommodate different usage scenarios or maintenance requirements. The polyurethane seat cushion 23 provides a good riding experience, and the plug-in design makes maintenance and replacement more convenient. The overall thickness and texture of the seat cushion 23 can be adjusted according to customer requirements.

[0059] This embodiment innovatively utilizes modular components. A single composite mold allows for product length adjustment and conversion between fixed and flip-up configurations. A complete carbon fiber seat is constructed using heat-dissipating carbon fiber profiles as the seat surface, with aluminum (magnesium) alloy ends at each end. This addresses the issues of composite seats, such as heavy weight, low thermal conductivity, and a single form factor. Furthermore, the seat can be configured in various configurations, from fixed to flip-up hinged, to meet the diverse installation needs of different customers.

[0060] Example 2

[0061] This embodiment proposes a method for preparing the vehicle seat in embodiment 1, wherein the molding process of the seat back body 12 and the seat seat body 22 is as follows (refer to Figure 5 ):

[0062] 1) The yarn ball placed on the creel 41 is drawn out from the yarn threading hole at the end;

[0063] 2) The yarns are passed through the yarn threading plate 42 in sequence according to the product layer table and are threaded from top to bottom;

[0064] 3) The yarn is drawn out through the yarn drying oven 43 and pre-forming tooling 44 and then placed on the edge of the mold and heating plate 45;

[0065] 4) The yarn is arranged according to the layup table and passed through the die, and then pulled out using the servo pultruder 47 after passing through the post-curing oven 46;

[0066] 5) injecting epoxy resin added with (10-20)% graphene slurry and curing.

[0067] Product layup table:

[0068]

[0069] As shown in the table above, the layup sequence, from inside to outside, is as follows: inner layer, 0° straight yarn, wound layer, 0° straight yarn, and outer layer. The outer layer is graphene-based carbon fiber, and the remaining layers are a mixed weave of PAN-based carbon fibers. This layup ensures the seat's strength and thermal conductivity. The outer layer's graphene-based carbon fibers provide excellent thermal conductivity, while the inner layer's PAN-based carbon fibers provide the necessary strength. Weaving and curing according to the layup sequence allows for precise control of the final product's physical properties. This layup design ensures the seat maintains a lightweight yet possesses excellent strength and thermal conductivity, enhancing ride comfort and product durability.

[0070] The backrest body is formed by pultrusion / stretching and weaving process and the profile is prepared by cutting. The overall thickness is 3mm, of which the thermal conductive layer (graphene-based carbon fiber) is 1mm and the length can be adjusted according to requirements; the seat body is formed by pultrusion / stretching and weaving process and the profile is prepared by cutting. The overall thickness is 4mm, of which the thermal conductive layer is 1.5mm and the length can be adjusted according to requirements.

[0071] This production method details the entire process from yarn preparation to final curing, including yarn drawing, threading, placement, arrangement, and curing. This method ensures a uniform and strong carbon fiber hybrid weave structure for the back and seat body, while the addition of graphene slurry improves the material's thermal conductivity. By precisely controlling yarn alignment and resin infusion, seat components can be manufactured with specific properties, such as high strength, lightness, and good thermal conductivity, ensuring product performance and efficient production.

[0072] Although the above describes the specific embodiments of the present invention in conjunction with the accompanying drawings, it is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art on the basis of the technical solution of the present invention without creative work are still within the scope of protection of the present invention.

Claims

1. A vehicle seat, characterized in that: include: A seat back structure and a seat surface structure, wherein the seat surface structure is mounted at the lower end of the seat back structure; The chair back structure is fixedly installed, comprising a chair back body and a chair back end, the chair back body is made of mixed weaving of carbon fibers, and the chair back end is installed at the left and right ends of the chair back body; The seat structure includes a seat body and a seat end head. The seat body is made of a mixed weaving of carbon fibers. The seat end heads are installed at the left and right ends of the seat body. The rear end of the seat end head is rotatably connected to the lower end of the backrest end head. The front end of the bottom side of the seat body has a sitting portion.

2. The vehicle seat according to claim 1, characterized in that The back side of the chair back body is provided with a mounting hole, and the chair back body is fixed on the end wall by connecting the mounting hole with a fastener, and the chair back body is in an upright state.

3. The vehicle seat according to claim 1, characterized in that The chair back body is made of a mixed weaving of graphene-based carbon fiber and PAN-based carbon fiber, and the chair seat body is made of a mixed weaving of graphene-based carbon fiber and PAN-based carbon fiber.

4. The vehicle seat according to claim 1, characterized in that The chair back end includes a left end and a right end, and the left end and the right end are respectively plugged into the left end and the right end of the chair back body; the chair surface end includes a left end and a right end, and the left end and the right end are respectively plugged into the left end and the right end of the chair surface body.

5. The vehicle seat according to claim 4, characterized in that The left end of the chair back and the left end of the seat surface are rotatably connected via a left hinge, and the right end of the chair back and the right end of the seat surface are rotatably connected via a right hinge.

6. The vehicle seat according to claim 4, characterized in that The left end of the chair back, the right end of the chair back, the left end of the seat surface and the right end of the seat surface are all made of aluminum alloy or magnesium alloy.

7. The vehicle seat according to claim 1, characterized in that A backrest is also arranged on the front side of the chair back body. The backrest is plugged into the chair back body and is made of polyurethane material.

8. The vehicle seat according to claim 1, characterized in that A seat cushion is also arranged at the upper end of the chair seat body. The seat cushion is plugged into the chair seat body and is made of polyurethane material.

9. A method for preparing a vehicle seat according to any one of claims 1 to 8, characterized in that: include: Lead the yarn ball placed on the yarn rack and lead it out from the yarn threading hole at the end; The yarn passes through the threading plate in sequence according to the product layer table and is threaded from top to bottom; After the yarn is drawn out, it is placed on the edge of the mold; The yarn is drawn out through the die according to the lay-up table; Epoxy resin with graphene slurry added is injected and cured.

10. The preparation method according to claim 9, characterized in that: The ply surface is composed of an inner layer, a 0° straight yarn, a winding layer, a 0° straight yarn and an outer layer from the inside to the outside, wherein the outer layer is graphene-based carbon fiber, and the remaining layers are PAN-based carbon fiber mixed weaving.

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