Seat for a motor vehicle and motor vehicle comprising said seat

Abstract

The invention relates to a seat, a vehicle and a method for manufacturing a seat, in which the seat (10) comprises a cushion (20) and an outer cover (30) covering the cushion (20), said cushion (20) in turn comprising a frame (21) made of a shape memory material and a filler (22), the frame (21) being at least partially embedded in the filler (22), the vehicle of the invention comprising such a seat. The present invention provides a method for manufacturing a seat (10) comprising the steps of: i) manufacturing a skeleton (21) from a shape memory material; ii) at least partially embedding the skeleton (21) in a filler (22) to form a cushion (20); iii) covering the cushion pad (20) with an outer cover (30).

Description

[0001] Cross-reference to related applications

[0002] This patent application claims priority to Italian Patent Application No. 102024000011362, filed on May 20, 2024, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention relates to an improved seat, particularly a seat for automotive applications. The invention also relates to motor vehicles incorporating the improved seat. Background Technology

[0004] Known motor vehicles include seats for the driver and / or possible passengers. These seats typically include:

[0005] - Cushioning pads made of foam, such as polyurethane foam; and

[0006] - An outer covering that surrounds the cushioning pad, which may be made of, for example, leather.

[0007] It has been observed that when occupants of motor vehicles sit down and when they stand up, the external covering is alternately compressed and stretched, subjecting the seat to repetitive stress. These repetitive stresses tend to cause permanent deformation of the cushioning, resulting in wrinkles and other aesthetic defects on the external covering over time, which affect the overall quality of the seat.

[0008] For the reasons mentioned above, there is a need for seats that are less prone to wrinkling than known seats.

[0009] The purpose of this invention is to preferably meet the above-mentioned needs in a simple and reliable manner. Summary of the Invention

[0010] The above objective is achieved by the vehicle seat as defined in claim 1. The dependent claims define specific embodiments of the invention. Attached Figure Description

[0011] In the following description, embodiments of the invention will be illustrated by way of non-limiting examples and with reference to the accompanying drawings, in order to allow for a better understanding of the invention, wherein:

[0012] - Figure 1 This is a perspective view of the seat according to the present invention;

[0013] - Figure 2 This is for clarity and to isolate it from the rest of the seat. Figure 1 A three-dimensional view of a portion of the seat;

[0014] - Figure 3 It shows Figure 2the seat portion shown, from which the outer covering has been removed; and

[0015] - Figure 4 is Figure 2 a partial cross-sectional view of a much larger proportion of the seat portion shown. DETAILED DESCRIPTION

[0016] In Figure 1 , reference 1 is used to indicate a whole motor vehicle comprising a seat 10. The seat 10 is adapted to support a driver or a passenger of the motor vehicle 1 and substantially comprises:

[0017] - a seat cushion 11 extending horizontally or substantially horizontally with respect to the ground level on which the motor vehicle 1 is located;

[0018] - a backrest 12 extending in a vertical or substantially vertical manner from the seat 11; and

[0019] - a headrest 13 arranged on a side of the backrest 12 facing away from the seat cushion 11.

[0020] Figure 2 A portion 15 of the seat 10 is shown. This portion 15 is comprised, for example, in the seat 11, in the backrest 12 and / or in the headrest 13. In particular, the seat 10 comprises a single portion 15 or a plurality of portions 15.

[0021] By way of example, Figure 2 The portion 15 shown has a parallelepiped shape or substantially parallelepiped shape.

[0022] The portion 15 comprises a cushion 20 and an outer covering 30, which covers the cushion 20 and is adapted to come into direct contact with the user. In particular, the outer covering 30 completely covers the entire cushion 20 and / or makes it invisible from the outside.

[0023] By way of example, the outer covering 30 is made of leather or synthetic material.

[0024] The cushion 20 advantageously comprises:

[0025] - a skeleton 21 made of shape memory material; and

[0026] - a filler 22 in which the skeleton 21 is at least partially embedded.

[0027] In detail, the material of the skeleton 21 is a shape memory polymer or a shape memory metal alloy. In addition, the material of the skeleton 21 is super-elastic due to the fact that it is of the shape memory type.

[0028] Furthermore, since the skeleton 21 is covered by the outer covering 30, it can be understood as an internal skeleton of the seat 10.

[0029] As shown in Figure 3 skeleton 21 comprises a reticular structure 23 comprising repeated unit cells 25, 26 each comprising a structural element 24. In the embodiment shown herein, the structural elements 24 are beam-like elements, for example rods.

[0030] Preferably, the reticular structure 23 is a three-dimensional triangular mesh defined, for example, by a Delaunay triangulation algorithm.

[0031] In addition, the reticular structure 23 preferably comprises repeated unit cells 25, 26 which are different from each other in different areas of the cushion 20. In detail, as shown in Figure 4 the reticular structure 23 comprises at least:

[0032] - unit cells 25 of a first type comprising first structural elements 24 having a first size and arranged at a first distance from each other;

[0033] - at least one unit cell 26 of a second type comprising second structural elements 24 having a second size and arranged at a second distance from each other.

[0034] In detail, the second size is different from the first size and / or the second distance is different from the first distance. More in detail, the size of the structural elements 24 means the diameter or the length of the structural elements 24.

[0035] The reticular structure 23 is manufactured by additive manufacturing, for example by FDM (Fused Deposition Modeling) or stereolithography.

[0036] Furthermore, the filler 22 comprises an elastomeric material. In particular, the filler 22 comprises a foam, for example a polyurethane foam.

[0037] In particular, the filler 22 is arranged at the spaces interposed between the structural elements 24 of the reticular structure 23.

[0038] Preferably, the seat 10 comprises a frame in a known manner, the seat 10 being operatively connected to the rest of the motor vehicle 1 in the area of the frame.

[0039] The manufacturing method of the seat 10 will be described below. Said manufacturing method comprises the following steps:

[0040] i) manufacturing the skeleton 21 from a shape memory material, for example by additive manufacturing;

[0041] ii) embedding the skeleton 21 at least partially in the filler 22 to form the cushion 20;

[0042] iii) covering the cushion 20 with the outer covering 30.

[0043] In particular, step ii) can be performed by a process of co-moulding or injection of the foam into or around the volume defined by the skeleton 21.

[0044] Step i) in turn comprises in detail a step iv) of manufacturing a reticular structure 23 having repeated unit cells 25, 26; the unit cells 25, 26 comprise structural elements 24.

[0045] More in detail, step iv) comprises manufacturing a reticular structure 23 comprising:

[0046] at least one unit cell 25 of a first type comprising first structural elements 24 having a first size and arranged at a first distance from each other;

[0047] at least one unit cell 26 of a second type comprising second structural elements 24 having a second size and arranged at a second distance from each other;

[0048] wherein the second size is different from the first size and / or wherein the second distance is different from the first distance.

[0049] The operation of the seat 10 will be described below.

[0050] In use, the seat 10 inside the motor vehicle 1 acts as a support for the driver or for a passenger.

[0051] In particular, when the user sits on the seat 10, the cushion 20 supports the user and deforms; when the user gets up from the seat 10, the cushion 20 recovers its shape before the user sat down, thus limiting the creation of wrinkles on the outer covering 30.

[0052] For the above-mentioned reasons, the advantages of the seat 10 and of the motor vehicle 1 according to the present application are evident.

[0053] Thanks to the fact that the cushion 20 comprises a skeleton 21 made of shape memory material and embedded in the filler 22, the seat 10, and in particular the outer covering 30, is less prone to the creation of wrinkles compared to the known seats discussed in the introduction of the present description. This is possible because the structural characteristics of the filler 22 are significantly improved by the skeleton 21, which makes the cushion 20 able to withstand the repeated stresses to which the seats of motor vehicles are usually subjected.

[0054] Furthermore, thanks to the characteristics of the shape memory material, the seat 10 is also particularly effective in resisting thermal stresses or humidity.

[0055] Since the net structure 23 can comprise different types of unit cells 25, 26, it is possible to obtain specific desired structural behavior in different areas of the seat 10.

[0056] Finally, the seat 10 and the motor vehicle 1 according to the present application can be varied and modified, but these variations and modifications do not go beyond the scope of protection set forth in the attached claims.

[0057] The geometry of the seat 10 can vary with great freedom, to adapt, for example, to aesthetic requirements and / or to ergonomic requirements.

[0058] The seat 10 can not be part of the motor vehicle 1, but can be included in another type of means of transport (for example, a boat) or in a stationary device (for example, a game station or a simulator).

[0059] The motor vehicle 1 can comprise a plurality of seats 10. In particular, for example, the motor vehicle 1 can comprise a seat 10 for the driver and one or more seats 10 for passengers. The motor vehicle 1 can also comprise seats 10 adapted to simultaneously support more than one passenger of the motor vehicle 1.

[0060] The unit cells 25, 26 that make up the net structure 23 can have a geometry different from that shown herein. For example, the unit cells 25, 26 can have a spiral or honeycomb structure.

Claims

1. A seat (10) comprising a cushion (20) and an outer cover (30) covering the cushion (20), characterized in that, The cushion (20) comprises: a skeleton (21) of shape memory material; and a filler (22) in which the skeleton (21) is at least partially embedded.

2. The seat according to claim 1, wherein the shape memory material is superelastic.

3. The seat according to claim 1, wherein the shape memory material comprises a shape memory polymer or a shape memory metal alloy.

4. The seat according to claim 1, wherein the skeleton (21) comprises a lattice structure (23) comprising repeating unit cells (25, 26) comprising structural elements (24).

5. The seat according to claim 4, wherein the lattice structure (23) comprises: at least one first type of unit cell (25) comprising first structural elements (24) having a first size and arranged at a first distance from each other; at least one second type of unit cell (26) comprising second structural elements (24) having a second size and arranged at a second distance from each other; wherein the second size is different from the first size and / or wherein the second distance is different from the first distance.

6. The seat according to claim 4 or 5, wherein the lattice structure (23) is made by additive manufacturing.

7. The seat according to claim 1, wherein the filler (22) comprises a foam.

8. A vehicle (1) comprising at least one seat (10) according to claim 1.

9. A method for manufacturing a seat (10) comprising the steps of: i) manufacturing a skeleton (21) of shape memory material; ii) at least partially embedding the skeleton (21) in a filler (22) to form a cushion (20); iii) covering the cushion (20) with an outer cover (30).

10. The method according to claim 9, wherein the step i) of manufacturing the skeleton (21) comprises a step iv) of manufacturing a lattice structure (23) comprising repeating unit cells (25, 26) comprising structural elements (24).

11. The method according to claim 10, wherein the step iv) comprises manufacturing the lattice structure (23) such that the lattice structure (23) comprises: at least one first type of unit cell (25) comprising first structural elements (24) having a first size and arranged at a first distance from each other; at least one second type of unit cell (26) comprising second structural elements (24) having a second size and arranged at a second distance from each other; wherein the second dimension is different from the first dimension and / or wherein the second distance is different from the first distance.

12. The method according to claim 10 or 11, wherein the mesh structure (23) is manufactured by additive manufacturing.

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