A seat cushion processing technology

Abstract

The application discloses a seat cushion processing technology, which can arrange gel on a surface layer, is convenient to process, and has better decompression effect after processing, and has the technical scheme that the seat cushion processing technology comprises the following steps: step 1, a bottom layer and a surface layer are prepared, the bottom layer and the surface layer are both sponge materials, the surface layer is used for contacting a rider, and one side of the surface layer is provided with a groove; step 2, gel is filled in the groove; the groove can be arranged according to actual requirements, and the gel is arranged at a specific position; and step 3, the bottom layer and the surface layer are adhered together to form a cushion body, and the bottom layer seals the groove, so that the gel is prevented from leaking from the groove, and belongs to the technical field of cushions.

Description

Technical Field

[0001] This invention belongs to the field of seat cushion technology, and more specifically, relates to a seat cushion processing technology. Background Technology

[0002] Seats are typically equipped with a series of padding such as backrests and seat cushions, the main purpose of which is to enhance the comfort of sitting and effectively improve the support performance of the body.

[0003] However, most common pads on the market are made of sponge material. This material often cannot fully conform to the body curves of the rider when under pressure, resulting in uneven pressure distribution and difficulty in achieving the ideal pressure relief effect. Summary of the Invention

[0004] The main objective of this invention is to provide a processing technology for seat cushions, which allows the gel to be applied to the surface layer, making the processing convenient and resulting in a better pressure-reducing effect for the processed cushions.

[0005] According to a first aspect of the present invention, a process for manufacturing a seat cushion is provided, comprising the following steps:

[0006] Step 1: Make the bottom layer and the top layer. Both the bottom layer and the top layer are made of sponge material. The top layer is used to contact the occupant and has a groove on one side.

[0007] Step 2: Fill the grooves with gel; the grooves can be arranged according to actual needs, and the gel can be placed at specific locations;

[0008] Step 3: Adhere the bottom layer and the top layer together to form the pad body. The bottom layer seals the groove to prevent gel from leaking out of the groove.

[0009] In the above-mentioned seat cushion processing technology, the bottom layer and the top layer are formed by hot pressing.

[0010] In the above-mentioned seat cushion processing technology, the depth of the groove is 1 / 4 to 3 / 4 of the thickness of the surface layer.

[0011] In the above-mentioned seat cushion processing technology, the hardness of the bottom layer is greater than that of the top layer.

[0012] In the above-mentioned seat cushion processing technology, the bottom layer rests against the waist and buttocks from top to bottom, and the sides of the buttocks support bend and extend along the sides of the waist to form a side support area, so that the front of the bottom layer forms a curved surface that is concave from the left and right sides to the middle.

[0013] The surface layer is attached to the front side of the bottom layer, and the groove includes a first groove and a second groove. The first groove is opposite to the waist support, and the second groove is opposite to the side support area.

[0014] In the above-mentioned seat cushion processing technology, the bottom layer includes a support layer and a base, both of which are formed by hot pressing.

[0015] One side of the support layer forms the front side of the bottom layer, and a reinforcing part is provided on the side of the support layer facing away from the front side of the bottom layer. The lower end of the reinforcing part is adhered and fixed to the upper end of the base.

[0016] In the above-mentioned seat cushion processing technology, the upper middle part of the base is recessed downward to form a first recessed part, and the lower middle part of the reinforcing part protrudes downward to form a first protruding part, and the first protruding part matches the first recessed part.

[0017] In the above-described seat cushion manufacturing process, the bottom surface of the first recessed portion is inclined upward along the direction close to the support layer.

[0018] In the above-mentioned seat cushion processing technology, in step 1, after the bottom layer is made, ventilation holes are processed on the bottom layer, and the diameter of the ventilation holes is 3~6mm.

[0019] In the above-mentioned seat cushion processing technology, step 4: wrap a layer of fabric around the outer surface of the cushion body.

[0020] One of the above-described technical solutions of the present invention has at least one of the following advantages or beneficial effects:

[0021] In this invention, a bottom layer and a top layer are first prepared separately. Specific grooves are pre-designed on the top layer, and the position, shape, and size of these grooves can be flexibly designed and adjusted according to actual application requirements. Then, gel is filled into the formed grooves, ensuring gel is present in specific preset areas. After filling, the bottom layer and top layer are firmly bonded together using an adhesive process, ultimately forming the pad body. Thus, the pad body can precisely contain gel in the required locations. When a passenger uses the pad body and comes into contact with the top layer, body pressure acts on the top layer, squeezing the gel underneath. Utilizing the gel's excellent fluidity and deformability, the pad body can more flexibly adapt to the passenger's body curves, achieving a closer fit. This design effectively disperses pressure on specific stress points, significantly reducing localized pressure concentration and helping to alleviate fatigue from prolonged sitting. From a manufacturing perspective, this method is simpler and more efficient, especially in the gel placement stage, where operation is more convenient. Because the gel filling position can be specifically set, pressure dispersion is more precise and personalized. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0023] Figure 1 This is a flowchart of the processing technology of the present invention;

[0024] Figure 2 This is a schematic diagram of the lumbar support cushion manufactured using the processing technology of this invention;

[0025] Figure 3 This is a front view of the lumbar support cushion manufactured using the processing technology of this invention;

[0026] Figure 4 The lumbar support cushion is manufactured using the processing technology of this invention. Figure 3 AA section view;

[0027] Figure 5 This is an exploded view of the lumbar support cushion manufactured using the processing technology of this invention;

[0028] Figure 6 This is a schematic diagram of the surface layer of the lumbar support cushion processed by the processing technology of the present invention;

[0029] Figure 7 This is an exploded view of the bottom layer of the lumbar support cushion processed by the processing technology of this invention;

[0030] Figure 8 This is a schematic diagram of the structure of the support layer of the lumbar support cushion processed by the processing technology of the present invention;

[0031] Figure 9 This is a schematic diagram of the structure of the seat cushion processed by the processing technology of this invention;

[0032] Figure 10 This is a top view of the seat cushion manufactured using the processing technology of this invention;

[0033] Figure 11 The seat cushion is manufactured using the processing technology of this invention. Figure 10 BB cross-sectional view.

[0034] The figure labels for each figure are as follows:

[0035] 1. Bottom layer; 11. Waist area; 12. Hip area; 13. Side support area; 14. Support layer; 141. Reinforcement part; 142. First protrusion; 15. Base; 151. First recess; 16. Ventilation hole; 2. Top layer; 21. Groove; 211. First groove; 212. Second groove; 3. Gel; 4. Protrusion. Detailed Implementation

[0036] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0037] The following disclosure provides many different implementations or examples for different ways of implementing the present invention.

[0038] Example 1

[0039] Reference Figures 1 to 8 As shown, a seat cushion processing technology, specifically involving the processing of lumbar support cushions, includes the following steps:

[0040] Step 1: Make the bottom layer 1 and the top layer 2. Both the bottom layer 1 and the top layer 2 are made of sponge material. The top layer 2 is used to contact the rider. One side of the top layer 2 has a groove 21.

[0041] The bottom layer 1 is divided into the waist 11 and the buttocks 12 from top to bottom. The two sides of the buttocks 12 curve and extend along the two sides of the waist to form the side support area 13, so that the front of the bottom layer 1 forms a curved surface that is concave from the left and right sides to the middle.

[0042] The position, shape and size of the groove 21 can be flexibly designed and adjusted according to actual application requirements. In this embodiment, the groove 21 includes a first groove 211 and a second groove 212. The first groove 211 is opposite to the waist part 11, and the second groove 212 is opposite to the side support area 13.

[0043] Step 2: Fill the groove 21 with gel 3, so that gel 3 is present in a specific preset area;

[0044] Step 3: Adhere the bottom layer 1 and the top layer 2 together to form the pad body. The top layer 2 will adhere to the front of the bottom layer 1. The waist 11 will seal the first groove 211, and the buttocks 12 will seal the second groove 212, thereby preventing the gel 3 from leaking from the groove 21.

[0045] The pad body can precisely contain gel 3 in the required position. When the rider uses the pad body and comes into contact with the surface layer 2, the body pressure will act on the surface layer 2, which will then squeeze the gel 3 underneath. With the good fluidity and deformation properties of the gel 3 itself, the pad body can more flexibly adapt to the rider's body curves and achieve a closer fit. This design can effectively distribute pressure on the specific pressure points of the rider, thereby significantly reducing local pressure concentration and helping to relieve fatigue caused by long-term riding.

[0046] Specifically, the pad body has a semi-circular design, which provides better coverage and restricts the range of motion of the buttocks and waist. The three-point support lifts the buttocks to reduce and distribute the pressure from the body's weight. The lumbar support 11 supports the sacrum, and the side support area 13 is arc-shaped, which can fit on both sides of the sitter's waist. The sides of the waist refer to the hip bone. The buttock support 12 can support the hip bone and buttocks, holding the sitter's buttocks. This supports the sacrum, hip bone and buttocks, allowing the lumbar spine to naturally maintain its physiological curvature. The waist and back are naturally straight, thereby reducing the load on the lumbar muscles and lumbar spine and preventing lower back pain.

[0047] When a passenger leans against the backrest, they are definitely leaning against the surface layer 2. Therefore, there is gel 3 in the lumbar support 11 and the side support area 13. The lumbar support 11 can support the sacrum of the passenger, and the side support area 13, together with the buttock support 12, can support the buttocks of the passenger. The sacrum and buttocks of the passenger can be squeezed by the gel 3. This layout can better distribute the pressure on the lumbar spine and buttocks of the passenger.

[0048] All nerves and the spinal cord run along the vertebral canal inside the spine to the sacrum at the tailbone. The sacrum, commonly known as the coccyx, is an inverted triangle shape. The sacral canal connects to the vertebral canal at the bottom of the sacrum. There are two rows of eight foramina on the surface of the sacrum, four on each side, which are called sacral foramina. Nerves flow out from the sacral canal below the sacrum along the eight sacral foramina, running down to the buttocks, thighs, calves, pelvis, and perineum. Lower back pain, lower abdominal distension, prostatitis, and leg pain after prolonged sitting are mostly due to poor nerve flow. Sitting on hard materials for a long time, gravity presses down, and the pressure is reversed to the sacrum, compressing the sacral foramina and narrowing them, thus hindering nerve flow. The three-point support of the lumbar support not only restricts the radius of lumbar movement but also lifts the body upward, thus reducing pressure. The gel at position 33 on the back is located directly above the sacrum, protecting the sacrum and sacral foramina from compression and ensuring smooth nerve flow from the sacral foramina.

[0049] Step 4: Wrap a layer of fabric around the outer surface of the panty liner; the fabric can make the panty liner more beautiful and more comfortable to touch, and the fabric is breathable and thin so as not to affect the shape of the panty liner. The fabric can be cotton, polyester fiber, etc.

[0050] The entire processing method is simpler and more efficient, especially the gel 3 placement step, which is more convenient to operate. Because the filling position of gel 3 can be set in a targeted manner, the pressure dispersion is more precise and personalized.

[0051] In this embodiment, the bottom layer 1 and the top layer 2 are formed by hot pressing. Hot pressing can directly form a specific shape, which is convenient and quick.

[0052] Preferably, the bottom layer 1 includes a support layer 14 and a base 15. Both the support layer 14 and the base 15 are thermoformed and then glued together by an adhesive process to form the bottom layer 1.

[0053] One side of the support layer 14 forms the front side of the bottom layer 1, and a reinforcing part 141 is provided on the side of the support layer 14 facing away from the front side of the bottom layer 1. The lower end of the reinforcing part 141 is adhered and fixed to the upper end of the base 15.

[0054] The base 15 is harder than the support layer 14, and the support layer 14 is harder than the surface layer 2. The surface layer 2 is softer, making it more comfortable for the rider to lean against. The bottom layer 1 is harder and provides better support. Therefore, the bottom layer 1 and the surface layer 2 work together to provide good support for the rider's sacrum and buttocks, while also providing a comfortable feel.

[0055] The base 15 is in contact with the seat. The base 15 has the highest rigidity and can serve as a support for the entire pad body, maintaining the posture of the entire pad body. It does not deform after sitting for a long time and better supports the gravity from the downward pressure of the body's center of gravity. At the same time, the base 15 corresponds to the back of the side support area 13, which can provide strong support for the side support area 13 and play a key role in supporting the hip bones and buttocks, lifting the body upward and dispersing the downward pressure of the buttocks.

[0056] The reinforcement part 141 mainly supports the sacrum. The greater thickness can improve the support performance. The lower end of the reinforcement part 141 is connected to the upper end of the base 15. The side of the reinforcement part 141 away from the surface layer 2 is smoothly connected to the side of the base 15 away from the surface layer 2, making the back of the pad body neater and easier to press against the seat back.

[0057] In practice, the upper part of the pad body is thinner than the lower part, so the pad body is more stable when placed on the seat. Also, the lower part of the pad body is closer to the occupant's buttocks, which can fill the gap between the buttocks and the seat corner.

[0058] In this embodiment, the middle part of the upper end of the base 15 is recessed downward to form a first recessed part 151, and the middle part of the lower end of the reinforcing part 141 protrudes downward to form a first protruding part 142. The first protruding part 142 matches the first recessed part 151, and the bottom surface of the first recessed part 151 is inclined upward along the direction close to the support layer 14.

[0059] The cooperation between the first protrusion 142 and the first recess 151 can position the base 15, which facilitates the fixing between the base 15 and the support layer 14. Since the bottom surface of the first recess 151 is inclined, the first protrusion 142 will not easily shift its position after it is inserted into the first recess 151.

[0060] In this embodiment, the depth of the groove 21 is 1 / 4 to 3 / 4 of the thickness of the surface layer 2; preferably, the depth of the groove 21 is 1 / 2 of the thickness of the surface layer 2.

[0061] The thickness of gel 3 can be controlled by adjusting the depth of groove 21, making the operation more convenient and easier to control.

[0062] In this embodiment, after the bottom layer 1 is made in step 1, ventilation holes 16 are machined on the bottom layer 1, and the diameter of the ventilation holes 16 is 3~6mm.

[0063] The vent 16 extends from the back of the bottom layer 1 to the front, or from the bottom of the bottom layer 1 to the front, to facilitate ventilation. Since the gel 3 is blocky, the parts are pulled against each other. The diameter of the vent 16 is relatively small. Even if some of it is squeezed into the vent 16, it will return to its original shape due to the tension of the gel 3 itself. Therefore, the gel 3 will not leak from the vent 16.

[0064] Example 2

[0065] Reference Figures 9 to 11 As shown, a seat cushion processing technology, specifically involving the processing of seat cushions, includes the following steps:

[0066] Step 1: Make the bottom layer 1 and the top layer 2. Both the bottom layer 1 and the top layer 2 are made of sponge material. The top layer 2 is used to contact the rider. One side of the top layer 2 has a groove 21.

[0067] Step 2: Fill the groove 21 with gel 3, so that gel 3 is present in a specific preset area;

[0068] Step 3: Adhere the bottom layer 1 and the top layer 2 together to form the pad body. The top layer 2 will adhere to the front side of the bottom layer 1, and the bottom layer 1 will seal the groove 21 to prevent the gel 3 in the groove 21 from leaking.

[0069] The groove 21 creates a corresponding protrusion 4 on the side of the surface layer 2 facing away from the bottom layer 1. When the passenger sits down and comes into contact with the surface layer 2, the protrusion 4 will be naturally squeezed. Since the protrusion 4 is filled with gel 3, it can adapt to the specific body shape and sitting posture of the passenger, thereby achieving precise fit and support. This design not only enhances the support performance of the seat cushion and provides a more stable and reliable support effect, but also effectively disperses the pressure on the buttocks, reduces the concentration of local pressure, and thus reduces the discomfort caused by long-term sitting, which helps to relieve physical fatigue.

[0070] Furthermore, in this embodiment, the depth of the groove 21 gradually increases along the first direction, and correspondingly, the thickness of the gel 3 also gradually increases along the same direction, so that the protrusion height of the protrusion 4 also gradually increases along the first direction, thereby forming an inclined shape that is low in the front and high in the back. When the passenger sits on the seat cushion, this protrusion structure that is low in the front and high in the back can moderately raise the body, so that the body's center of gravity naturally moves backward. In this way, the buttocks can make contact with the protrusion 4 over a larger area, and the body's center of gravity will fall on the thicker area of ​​the gel 3, thereby more effectively dispersing pressure and improving the comfort and rationality of the support.

[0071] Based on the processing method used in this embodiment, the thickness of the gel 3 can be adjusted accordingly by precisely controlling the depth of the groove 21. Since the depth of the groove 21 is a gradient design, the thickness of the gel 3 can also achieve a smooth transition. This gradient structure is easier to operate in actual processing.

[0072] In this embodiment, both the bottom layer 1 and the top layer 2 are thermoformed. Thus, after the top layer 2 is formed, it has a groove 21 and a protrusion 4, and the depth of the groove 21 is gradually changing, requiring no additional processing.

[0073] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A process for processing seat cushions, characterized in that, Includes the following steps: Step 1: Make the bottom layer and the top layer. Both the bottom layer and the top layer are made of sponge material. The top layer is used to contact the occupant and has a groove on one side. Step 2: Fill the groove with gel; Step 3: Adhere the bottom layer and the top layer together to form the pad body, with the bottom layer sealing the groove.

2. The seat cushion processing technology according to claim 1, characterized in that, The bottom layer and the top layer are formed by hot pressing.

3. The seat cushion processing technology according to claim 1, characterized in that, The depth of the groove is 1 / 4 to 3 / 4 of the thickness of the surface layer.

4. The seat cushion processing technology according to claim 1, characterized in that, The hardness of the bottom layer is greater than that of the top layer.

5. The seat cushion processing technology according to claim 1, characterized in that, The bottom layer extends from top to bottom towards the waist and buttocks. The sides of the bottom layer curve and extend along the sides of the waist to form a side support area, so that the front of the bottom layer forms a curved surface that is concave from the left and right sides towards the middle. The surface layer is attached to the front side of the bottom layer, and the groove includes a first groove and a second groove. The first groove is opposite to the waist support, and the second groove is opposite to the side support area.

6. The seat cushion processing technology according to claim 2, characterized in that, The bottom layer includes a support layer and a base, both of which are formed by hot pressing. One side of the support layer forms the front side of the bottom layer, and a reinforcing part is provided on the side of the support layer facing away from the front side of the bottom layer. The lower end of the reinforcing part is adhered and fixed to the upper end of the base.

7. The seat cushion processing technology according to claim 6, characterized in that, The upper middle part of the base is recessed downward to form a first recessed part, and the lower middle part of the reinforcing part protrudes downward to form a first protruding part, and the first protruding part matches the first recessed part.

8. The seat cushion processing technology according to claim 7, characterized in that, The bottom surface of the first recess slopes upward along the direction close to the support layer.

9. The seat cushion processing technology according to claim 1, characterized in that, In step 1, after the bottom layer is formed, ventilation holes are machined on the bottom layer, and the diameter of the ventilation holes is 3~6mm.

10. The seat cushion processing technology according to claim 1, characterized in that, Step 4: Wrap a layer of fabric around the outer surface of the pad body.

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