Automotive seat based on 3d printed foam

Abstract

The application discloses a kind of based on 3d printing foam automobile seat, including seat frame assembly and rotating installation in the backrest framework assembly rear end, the seat frame assembly is equipped with seat cushion foam, the seat cushion foam is made of 3d printing, its lower side circumferential edge is equipped with first wrapping structure, the first wrapping structure is connected on the edge of seat frame assembly;Backrest framework assembly front side is equipped with backrest foam, the backrest foam is made of 3d printing, its back side circumferential edge is equipped with second wrapping structure, the second wrapping structure is connected on the edge of backrest framework assembly.The beneficial effects of the present application are: 3d printing method directly forms the wrapping structure of foam body and back side, can realize quickly foam assembly on corresponding framework structure, improve the convenience and stability of assembly, and help to realize seat lightweight design.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile seats, in particular to an automobile seat based on 3D printed foam. BACKGROUND

[0002] With the pursuit of energy saving and emission reduction and fuel efficiency in the automobile industry, the lightweight design of automobile seats has become a key link. In the prior art, a seat is composed of a seat frame, a backrest skeleton, foam and a face cover, wherein the seat frame and the support skeleton of the backrest are usually a rectangular metal skeleton, and the foam body is completely wrapped on the support skeleton. However, the foam body on the traditional automobile seat skeleton has many problems. In terms of structure, the foam body has the defects of large volume, heavy weight, inconvenient installation, large space occupation and influence on vehicle performance. In terms of manufacturing, the traditional manufacturing process cannot accurately control the internal pore structure of the foam, so that the physical properties of the foam product are unstable. In terms of installation, the installation method of the foam body and the skeleton is rough, and simple glue is usually used for pasting. This method not only consumes manpower but also cannot guarantee the installation accuracy, resulting in uneven quality of the seat.

[0003] Therefore, as an important part of automobile interiors, the lightweight design of the seat becomes particularly important. SUMMARY

[0004] Therefore, the present application provides an automobile seat based on 3D printed foam, which realizes the lightweight design of the seat and has the advantage of convenient installation.

[0005] To achieve the above-mentioned purpose, the technical scheme of the present application is as follows:

[0006] An automobile seat based on 3D printed foam, the key of which is that it comprises a seat frame assembly and a backrest skeleton assembly rotatably installed at the rear end of the seat frame assembly, a seat cushion foam is arranged on the seat frame assembly, the seat cushion foam is made of 3D printing, a first wrapping structure is arranged on the lower side circumferential edge of the seat cushion foam, and the first wrapping structure is connected to the edge of the seat frame assembly.

[0007] A backrest foam is arranged on the front side of the backrest skeleton assembly, the backrest foam is made of 3D printing, a second wrapping structure is arranged on the back side circumferential edge of the backrest foam, and the second wrapping structure is connected to the edge of the backrest skeleton assembly.

[0008] With the above structure, the design of the first wrapping structure and the second wrapping structure can facilitate the assembly of the foam body on the corresponding skeleton structure, improving the convenience and stability of assembly. Secondly, the 3D printing technology can directly, quickly and accurately manufacture the foam body, accurately control the structure and material distribution of the foam body, and design a lattice structure or a porous structure with lightweight characteristics. Under the premise of ensuring the strength and comfort of the seat, the weight of the automobile seat is effectively reduced.

[0009] As preferred: the first wrapping structure is a downwardly open notch, the notch is buckled on the circumferential edge of the seat frame assembly.

[0010] As preferred: the seat cushion foam and the backrest foam are both made by thermoplastic polyurethane rubber 3d printing.

[0011] As preferred: the middle and / or both side areas of the backrest foam are provided with a first soft support area;

[0012] And / or the middle and / or both side areas of the seat cushion foam are provided with a second soft support area.

[0013] As preferred: the backrest skeleton assembly includes a lower support member for supporting the middle and lower segments of the user's back, the lower ends of the lower support member are both provided with an adapter, the adapter is rotatably installed to the rear end of the seat frame assembly; the top middle position of the lower support member is fixedly connected with an upwardly extending upper support member, the upper support member is used for supporting the middle and upper segments of the user's back.

[0014] As preferred: the lower support member is configured as an arc-shaped arch structure.

[0015] As preferred: the upper support member is a long strip-shaped member, the cross section of the long strip-shaped member has an n-shaped structure and a support flange extending outwardly from the lower ends of both sides of the n-shaped structure.

[0016] As preferred: the front side of the upper support member and the lower support member is fixedly installed with a support plate, the middle and lower part of the support plate is designed as a hollow structure.

[0017] As preferred: the second wrapping structure has a first ring groove arranged on the rear side of the backrest foam, the first ring groove is sleeved on the circumferential edge of the support plate.

[0018] As preferred: the both sides of the seat cushion foam are formed with an upwardly inclined first side support part, and the both sides of the backrest foam are formed with an upwardly inclined second side support part.

[0019] Compared with the prior art, the present application has the following beneficial effects:

[0020] 1. The automobile seat provided by the application can directly form the foam body and the wrapping structure on the rear side of the foam body by 3D printing, so that the foam body can be quickly assembled on the corresponding framework structure, improving the convenience and stability of assembly. Secondly, the 3D printing technology can directly, quickly and accurately manufacture the foam body, ensuring the consistency of the foam body structure, and can easily realize personalized customization production according to the specific needs and requirements of users. On the other hand, 3D printing can accurately control the structure and material distribution of the foam body, and design a lattice structure or a porous structure with lightweight characteristics, effectively reducing the weight of the automobile seat under the premise of ensuring the strength and comfort of the seat, thereby reducing the overall energy consumption of the automobile, improving fuel economy or prolonging the cruising range of the electric automobile.

[0021] 2. The automobile seat provided by the application is made of thermoplastic polyurethane rubber, which has excellent comfort, wear resistance and compressive strength, and has a lighter weight than traditional seats, so that the lightweight design of the automobile seat can be realized.

[0022] 3. The automobile seat provided by the application can enhance the support of the seat and improve the comfort of sitting by setting a soft support area, so that each part of the body can be comfortably supported, avoiding fatigue and discomfort caused by excessive local pressure. Moreover, the 3D printing technology can directly print the soft and hard zones of the foam body, improving the production efficiency and reducing the manufacturing cost.

[0023] 4. The automobile seat provided by the application has an arc-shaped arch structure, which improves the structural strength, enables the lower support member to better disperse the pressure borne by the seat, prevents the framework from deforming, and saves materials and costs, having the technical advantages of simple structure, convenient design and installation.

[0024] 5. By reserving multiple protrusions on the backrest foam, the functional parts can be better embedded in the backrest, without occupying the external space of the seat, having the advantages of high integration, compact structure, neat and beautiful appearance, and convenient installation. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a structural schematic view of an automobile seat (only half of the structure of the backrest foam 4 is shown);

[0026] Figure 2 is another structural schematic view of an automobile seat;

[0027] Figure 3 is a sectional view of an automobile seat;

[0028] Figure 4Structure diagram of the back side of the car seat showing the perspective view (the cover plate 6 has been hidden) ;

[0029] Figure 5 Structure diagram of the seat cushion foam 3 and the backrest foam 4;

[0030] Figure 6 Structure diagram of the internal framework of the car seat showing the perspective view;

[0031] Figure 7 Structure diagram of the backrest framework assembly 2;

[0032] Figure 8 Exploded diagram of the backrest framework assembly 2 and the cover plate 6;

[0033] Figure 9 Right view of the upper support member 23 and the lower support member 21 when connected;

[0034] Figure 10 Structure diagram of the back side of the upper support member 23 showing the perspective view;

[0035] Figure 11 Diagram showing the back side structure of the support plate 24. DETAILED DESCRIPTION

[0036] The present application is further described below in conjunction with the embodiments and the accompanying drawings.

[0037] As shown in Figure 1 , 3 and 6, a car seat based on 3D-printed foam body includes a seat frame assembly 1 and a backrest framework assembly 2 rotatably installed at the rear end of the seat frame assembly 1, wherein the seat frame assembly 1 is provided with a seat cushion foam 3, and the circumferential edge of the lower side of the seat cushion foam 3 is provided with a first wrapping structure 31 connected to the edge of the seat frame assembly 1. The front side of the backrest framework assembly 2 is provided with a backrest foam 4, and the circumferential edge of the back side of the backrest foam 4 is provided with a second wrapping structure 41 connected to the edge of the backrest framework assembly 2. In this embodiment, the seat cushion foam 3 and the backrest foam 4 are both made of 3D printing, and the seat cushion foam 3 and the backrest foam 4 are both covered with a face cover (not shown in the figure).

[0038] Based on the above structural design, the design of the first wrapping structure 31 and the second wrapping structure 41 facilitates the assembly of the foam onto the corresponding skeleton structure, improving the convenience and stability of assembly. Secondly, the use of 3D printing technology allows for the direct, rapid, and precise manufacture of the foam, ensuring the consistency of the foam structure. Furthermore, it enables easy personalized customization based on specific user needs and requirements. On the other hand, 3D printing can precisely control the structure and material distribution of the foam, designing lightweight lattice structures or porous structures, effectively reducing the weight of the car seat while ensuring its strength and comfort.

[0039] In this embodiment, both the seat cushion foam 3 and the backrest foam 4 are made of thermoplastic polyurethane rubber using 3D printing. 3D printing thermoplastic polyurethane rubber foam provides excellent comfort, abrasion resistance, and compressive strength, while also being lighter than traditional seats, enabling lightweight design of automotive seats.

[0040] The first wrapping structure 31 can be connected to the edge of the seat frame assembly 1 by means of looping, embedding, or fastening. In this embodiment, refer to Figure 3 The first wrapping structure 31 is a downward-opening slot that is fastened to the circumferential edge of the seat frame assembly 1.

[0041] like Figure 5 As shown, the seat cushion foam 3 has upwardly inclined first side support portions 3a on both sides, which can support the user's buttocks and outer thighs. The backrest foam 4 has upwardly inclined second side support portions 4a on both sides, which can support the user's arms and outer shoulders.

[0042] Please refer to Figure 5 The backrest foam 4 has a first soft support area a in the middle and / or on both sides, and the hardness of the first soft support area a is less than that of the main body of the backrest foam 4. In this embodiment, the first soft support areas a are distributed on the middle and the second side support portions 4a on both sides of the front surface of the backrest foam 4. The first soft support area a in the middle of the backrest foam 4 corresponds to the area where the user's back rests. Two first soft support areas a are arranged from top to bottom on the second side support portions 4a. The upper first soft support area a is the area where the user's shoulder rests, and the lower first soft support area a is the area where the user's arm rests.

[0043] Revisit Figure 5The second soft support area b is arranged on the middle part and the first side support part 3a on both sides of the upper surface of the seat cushion foam 3. The second soft support area b on the middle part of the seat cushion foam 3 is a surface area contacted by the hips of the user when sitting, and the left and right sides thereof are designed as arc structures curved towards the middle part, thereby ensuring comfort and preventing excessive sinking of the body after long sitting.

[0044] By arranging the soft support areas, the support of the seat is enhanced, and the comfort of sitting is improved, so that each part of the body can be comfortably supported, and fatigue and discomfort caused by excessive local pressure are avoided. Moreover, the foam body and the soft support areas thereon can be directly printed by the 3D printing technology, thereby improving the production efficiency and reducing the manufacturing cost. In actual application, the first soft support area a and the second soft support area b are not limited to the above distribution manner, and the manufacturer can customize the design according to the needs of different customer groups, thereby manufacturing different soft and hard partitions.

[0045] Please refer to Figure 6 The backrest framework assembly 2 comprises a lower support member 21 for supporting the middle and lower part of the back of the user. The lower support member 21 is provided with an adapter 22 at the lower side of each end, and the adapter 22 is rotatably connected to the rear end of the seat frame assembly 1. The upper support member 23 extending upward is fixedly connected to the middle position of the top of the lower support member 21, and the upper support member 23 is used for supporting the middle and upper part of the back of the user. In this embodiment, the middle point of the top of the lower support member 21 and the two end points of the lower side of the lower support member 21 form a triangular structure, which can ensure the structural strength of the lower support member 21. By designing the backrest framework assembly 2 as the upper support member 23 and the lower support member 21 connected in series, the lower support member 21 can provide strong support to the middle and lower part of the back and the waist of the user, and the upper support member 23 can provide strong support to the middle and upper part of the back of the user. Such a structure design can improve the structural strength of the backrest framework assembly 2, and when the backrest foam 4 is installed on the backrest framework assembly 2, the overall stress of the backrest can be balanced, thereby improving the stability of the seat as a whole.

[0046] Further, please refer to Figure 6 The lower support member 21 is designed as an arc-shaped structure. The advantages of such a design are that the structural strength is improved, the lower support member 21 can better disperse the pressure borne by the seat, prevent the framework from deforming, and on the other hand, the material and cost can be saved, and the technical advantages of simple structure, easy design and installation are achieved.

[0047] In the embodiment, the lower support member 21 is made of a bent pipe. In this way, the lower support member 21 has good strength and toughness, and is light in weight, which is beneficial to the lightweight design of the seat. In addition, the lower support member 21 made of a bent pipe can effectively utilize the space, so as to facilitate the installation of other functional components, such as the pipes of the seat heating and ventilation device, the lines of the adjustment structure, and the like, and has the advantages of high integration and compact structure. The upper end of the upper support member 23 is fixedly welded to the middle position of the top of the lower support member 21.

[0048] Referring to Figure 6 and Figure 10 , the upper support member 23 is a long strip-shaped member, and the cross section of the long strip-shaped member has an n-shaped structure and support flanges 231 extending outward from the lower ends of the two sides of the n-shaped structure. The n-shaped cross section of the long strip-shaped member can enhance the compression resistance of the upper support member 23 and maintain the stability of the structure. The support flanges 231 can facilitate the connection with adjacent components during the assembly of the seat, and further strengthen the stability of the connection.

[0049] Referring to Figure 6 and Figure 10 , the lower end surface of the upper support member 23 is provided with an irregular arc-shaped structure 232, which matches the profile of the top of the arc-shaped arch-shaped lower support member 21. Such a structure design can increase the contact area of the upper support member 23 and the lower support member 21, enhance the welding firmness, and improve the welding quality.

[0050] In the embodiment, the upper support member 23 is a sheet metal part, which has the technical advantages of excellent strength and good stability. In addition, referring to Figure 9 , the upper support member 23 is configured to be slightly curved backward, which can better fit the physiological curve of the human spine, so that the seat back is more ergonomic.

[0051] As shown in Figure 7 and 8 , the upper support member 23 and the lower support member 21 are fixedly installed with a support plate 24 at the front side. The support plate 24 can increase the support area of the seat back skeleton assembly 2, and further improve the support strength of the seat back. In the embodiment, the lower part of the support plate 24 is designed to be hollow, which reserves installation space inside the seat back. Without increasing the thickness of the seat back, more functional components can be integrated.

[0052] In the embodiment, the support plate 24 is made of thermoplastic polyurethane rubber. In this way, the support plate 24 has the advantages of light weight, high strength and good toughness, and is not easy to deform when subjected to external force, which can provide reliable support for the seat and ensure the safety of the seat.

[0053] Further, as shown in Figure 7 andFigure 8 As shown, the circumferential edge of the hollowed region in the lower part of the support plate 24 is fixedly connected to the lower support member 21, and the Figure 4 And 11 As shown, a positioning groove 241 is formed on the rear side of the support plate 24, which is adapted to the n-shaped structure. The two side regions of the support plate 24 corresponding to the positioning groove 241 are locked to the support flange 231 by fasteners 7. In this embodiment, the fasteners 7 are bolts. Such a structure design can ensure the stability of the installation of the support plate 24 and will not sway left and right, with high reliability.

[0054] As shown, Figure 11 As shown, the upper end edge of the hollowed region in the lower part of the support plate 24 is provided with a connecting lug 24a, which is fixedly connected to the rear side of the lower support member 21 by bolts. The number of connecting lugs 24a is two. By Figure 4 It can be seen that the two side regions of the support plate 24 corresponding to the positioning groove 241 are fixedly connected to the front side of the support flange 231. Such a design has the advantages of high connection strength and good stability.

[0055] Please refer to Figure 4 A spacer 8 is arranged between the two surfaces contacted by the support plate 24 and the two support flanges 231. The spacer 8 can make the support plate 24 elastic and tight, and can provide better support and stability, prevent the fasteners 7 from loosening, and reduce the wear between the support plate 24 and the upper support member 23.

[0056] Please refer to Figure 8 The circumferential edge of the support plate 24 is provided with a flange side wing 242 protruding forward, and the height of the flange side wing 242 gradually increases from top to bottom. Such a design can effectively support the side wing area on both sides of the backrest.

[0057] As shown, Figure 4 And Figure 5 The second wrapping structure 41 has a first ring groove 411 arranged on the rear side of the backrest foam 4, which is sleeved on the circumferential edge of the support plate 24. Such a structure can further improve the convenience of assembly, and can ensure that the installation of the backrest foam 4 is more firm.

[0058] Please refer to Figure 6 And Figure 8 The adapter 22 between the two ends of the lower support member 21 is connected with a retainer 221. Again by Figure 3 And Figure 4 It can be seen that in this embodiment, the second wrapping structure 41 is a structure folded backward and downward, which is distributed on the upper end and the circumferential edge of the left and right sides of the backrest foam 4, and the first ring groove 411 is adapted to the flange side wing 242 of the support plate 24. As Figure 5As shown, the lower end of the back foam 4 rear side is provided with a third wrapping structure 43 which is bent rearward, and the third wrapping structure 43 has a second ring groove 431 which is sleeved on the holder 221 (not shown in the figure).

[0059] Since the back foam 4 is fixed on the support plate 24 in a ring sleeve manner and does not cover the rear side of the back frame assembly 2 completely, in order to make the overall structure beautiful, the back frame assembly 2 rear side is fixedly provided with a cover plate 6, as shown in Figure 2 and Figure 8 As shown, the back frame assembly 2 rear side is fixedly provided with a cover plate 6. In combination with Figure 4 As shown, in the embodiment, the second wrapping structure 41 circumferential edge is provided with a second connecting structure 44 which is recessed towards the back interior, the recessed depth of the second connecting structure 44 is adapted to the thickness of the cover plate 6, and the second connecting structure 44 is adapted to the upper circumferential contour of the cover plate 6. During installation, the back foam 4 is assembled first, and then the cover plate 6 is assembled, the cover plate 6 can be connected with the back foam 4 back side to form a whole, so as to ensure the beauty of the seat back whole.

[0060] Please refer to Figure 4 The back foam 4 back side is provided with a plurality of protrusions 45, the protrusions 45 are provided with clamping grooves c for installing back functional parts, the functional parts can be ventilation devices and massage devices which need to be arranged in the back, etc. In combination with the structure design of the lower support member 21 and the support plate 24, the lower support member 21 and the support plate 24 do not interfere with the installation of the functional parts, the protrusions 45 can be exposed in the space surrounded by the arc-shaped arch structure, so that the functional parts can be better embedded in the back interior, without occupying the seat external space, having the advantages of high integration, compact structure, neat and beautiful appearance, convenient installation, and being able to select whether to install such functional parts according to the user's needs.

[0061] Finally, it should be noted that the above description is only for the preferred embodiments of the present application, and those skilled in the art can make various similar modifications under the inspiration of the present application without departing from the purpose and scope of the present application. Such modifications fall within the protection scope of the present application.

Claims

1. A car seat based on 3D printed foam, characterized in that: The seat frame assembly includes a seat frame assembly (1) and a backrest frame assembly (2) rotatably mounted on the rear end of the seat frame assembly (1). The seat frame assembly (1) is provided with a seat cushion foam (3). The seat cushion foam (3) is made by 3D printing and has a first wrapping structure (31) on its lower circumferential edge. The first wrapping structure (31) is connected to the edge of the seat frame assembly (1). The backrest frame assembly (2) has a backrest foam (4) on the front side. The backrest foam (4) is made by 3D printing. Its back side circumferential edge has a second wrapping structure (41). The second wrapping structure (41) is connected to the edge of the backrest frame assembly (2). The backrest frame assembly (2) includes a lower support member (21). An upper support member (23) extending upward is fixedly connected to the middle of the top of the lower support member (21). The upper support member (23) is a long strip member with an n-shaped cross section and support flanges (231) extending outward from the lower ends of both sides of the n-shaped structure. A support plate (24) is fixedly installed on the front side of the upper support member (23) and the lower support member (21). The lower part of the support plate (24) is hollowed out. The rear side of the support plate (24) is formed with a positioning groove (241) adapted to the n-shaped structure. The upper edge of the hollowed-out area in the lower part of the support plate (24) is provided with a connecting lug (24a). The connecting lug (24a) is fixed to the rear side of the lower support member (21) by bolts. There are two connecting lugs (24a). The support plate (24) is fixed to the front side of the support flange (231) on both sides of the positioning groove (241).

2. The car seat based on 3D printed foam according to claim 1, characterized in that: The first wrapping structure (31) is a downward-opening slot that is fastened to the circumferential edge of the seat frame assembly (1).

3. The car seat based on 3D printed foam according to claim 1, characterized in that: The seat cushion foam (3) and backrest foam (4) are both made of thermoplastic polyurethane rubber 3D printed.

4. The car seat based on 3D printed foam according to claim 1, characterized in that: The backrest foam (4) has a first soft support area (a) in the middle and / or both sides. And / or the seat cushion foam (3) has a second soft support area (b) in the middle and / or side areas.

5. The car seat based on 3D printed foam according to claim 1, characterized in that: The lower support member (21) has adapters (22) installed on both sides of its lower side. The adapters (22) are rotatably installed to the rear end of the seat frame assembly (1).

6. The car seat based on 3D printed foam according to claim 1, characterized in that: The lower support member (21) is constructed as an arc-shaped arch structure.

7. The car seat based on 3D printed foam according to claim 6, characterized in that: The second wrapping structure (41) has a first annular groove (411) disposed on the rear side of the backrest foam (4), the first annular groove (411) being sleeved on the circumferential edge of the support plate (24).

8. The car seat based on 3D printed foam according to claim 1, characterized in that: The seat cushion foam (3) has an upwardly inclined first side support (3a) formed on both sides, and the backrest foam (4) has an upwardly inclined second side support (4a) formed on both sides.

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