Foam structure with support and resilience properties and resistance to surface deformation and cushion

Abstract

The utility model relates to a kind of foam structure with supporting resilience and surface deformation resistance and cushion;Foam structure includes the base body foamed layer in bottom layer, middle foamed layer and the soft sponge layer in top layer, and the filling layer of high resilience and surface deformation resistance is equipped in base body foamed layer and / or middle foamed layer, and filling layer is by reticular gap structure and fills in the gap of reticular gap structure, and the filling foam of upper surface and / or lower surface and the foamed material of base body foamed layer or middle foamed layer are integrated;The thickness of the reticular gap structure is controlled at 5-30mm, and is made of upper knitted elastic net, lower knitted elastic net and the rebounding rope between upper knitted elastic net and lower knitted elastic net.This kind of foam structure not only has supporting resilience, but also can disperse the surface pressure of human hip and cushion, and stress is more balanced, avoid the deformation of cushion surface for long sitting.

Description

Technical Field

[0001] This utility model belongs to the field of automotive seats, specifically relating to a foam structure with supportive and resilient properties and resistance to surface deformation, commonly used in seat cushion foam. Background Technology

[0002] Superior seat comfort has become a core competitive advantage for automobiles. However, current car seats integrate many functional components, which take up space in terms of foam thickness. For example, when the seat cushion integrates massage, ventilation, and softness / firmness adjustment functions, the foam thickness is only 40mm. It is currently quite difficult to achieve the comfort goals of support, rebound, and surface stress balance by simply improving the performance of the foam itself.

[0003] Chinese patent CN207955414U discloses "an embedded polyurethane foam interior component polyurethane foam seat cushion". The seat cushion includes a biodegradable fiber mesh and a high-resilience polyurethane foam from the outside to the inside. The high-resilience polyurethane foam includes a body and side wings. The side wings of the high-resilience polyurethane foam of the seat cushion are provided with embedded polyurethane foam interior components. Although this design can enhance the overall comfort of the seat cushion foam, it can only improve the resilience and cannot evenly distribute the surface pressure.

[0004] Chinese patent CN 215244476U discloses a "high-resilience foam seat cushion," which enhances the cushion's resilience by incorporating high-resilience polyurethane foam within the cushion's resilience layer. However, this design offers only a small increase in resilience and fails to evenly distribute surface pressure. Therefore, it is necessary to provide a foam structure that can significantly improve the cushion's support and resilience while also distributing the surface pressure between the buttocks and the cushion, resulting in more balanced force distribution and preventing surface deformation. Summary of the Invention

[0005] In view of the shortcomings and deficiencies of the existing technology, the purpose of this utility model is to provide a foam structure with supporting and resilient performance and resistance to surface deformation. This foam structure is achieved by placing a highly resilient and surface-deformation-resistant mesh-like void structure within the foamed matrix layer and / or intermediate layer. The polyurethane foam material flows into the mesh-like void structure, filling the gaps in the mesh-like void structure, so that the mesh-like void structure and the foam material are integrated. The mesh-like void structure acts as an internal support structure, providing auxiliary support for the foam and improving the supporting and resilient performance of the foam. Test results show that the supporting and resilient performance is improved by more than 40%. In addition, the design of the mesh-like void structure can also distribute the surface pressure of the human buttocks and the cushion, resulting in more balanced force distribution and preventing the surface of the cushion from deforming after prolonged sitting.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A foam structure with supporting resilience and resistance to surface deformation includes a base foam layer at the bottom, an intermediate foam layer, and a soft sponge layer at the top. The improvement is that the base foam layer and / or the intermediate foam layer are provided with a highly resilient and surface-deformation-resistant filling layer. The filling layer consists of a mesh-like void structure and filling foam material that is integrated with the foam material of the base foam layer or the intermediate foam layer, with the upper and / or lower surfaces of the mesh-like void structure being connected to the foam material of the base foam layer or the intermediate foam layer. The thickness of the mesh-like void structure is controlled between 5-30 mm and consists of an upper woven elastic net, a lower woven elastic net, and a rebound rope disposed between the upper woven elastic net and the lower woven elastic net.

[0008] As a preferred embodiment of this invention, the high-resilience and surface-deformation-resistant filling layer is disposed at the upper, middle, or bottom position of the matrix foam layer or intermediate foam layer.

[0009] As a preferred embodiment of this utility model, the mesh on the upper and lower woven elastic nets is a rhomboid, rectangular, square, or polygonal grid. Multiple rebound ropes are spaced apart around the perimeter of the two opposing grids. One end of the rebound rope is connected to the upper woven elastic net, and the other end is connected to the lower woven elastic net.

[0010] As a preferred embodiment of this utility model, the intermediate foaming layer consists of, from top to bottom, a first foaming layer, a high-resilience and surface-deformation-resistant filling layer, and a second foaming layer; the upper surface of the filling foam in the filling layer is integrated with the foaming material of the first foaming layer, and the lower surface is integrated with the foaming material of the second foaming layer.

[0011] As a preferred embodiment of this invention, the size of the rhombus grid is controlled at 8mm*6mm.

[0012] As a preferred embodiment of this invention, the soft sponge layer and the intermediate foam layer are connected by double-sided adhesive or spray adhesive, and the intermediate foam layer and the base foam layer are bonded together by spray foam adhesive.

[0013] This embodiment also provides a seat cushion, wherein the foam portion of the seat cushion adopts the foam structure described above, which has supporting and resilient properties and is resistant to surface deformation.

[0014] Advantages and beneficial effects of this utility model: The foam structure provided by this utility model places a highly resilient and surface-deformation-resistant mesh-like void structure inside the middle layer of foam. The polyurethane foam material flows into the mesh-like void structure, filling the gaps in the mesh-like void structure, so that the mesh-like void structure and the foam material are integrated. The mesh-like void structure acts as an internal support structure, providing auxiliary support for the foam and improving the support and resilience performance of the foam. Test results show that the support and resilience performance is improved by more than 40%. In addition, the design of the mesh-like void structure can also distribute the surface pressure of the human buttocks and the cushion, making the force more even and preventing the surface of the cushion from deforming after sitting for a long time. Attached Figure Description

[0015] Figure 1 A top view of the foam structure with high support resilience and resistance to surface deformation provided by this utility model;

[0016] Figure 2 for Figure 1 Cross-sectional view of AA in the middle;

[0017] Figure 3 This is a schematic diagram of the foam structure processing of this utility model;

[0018] Figure 4 A top view of the mesh-like void structure provided by this utility model;

[0019] Figure 5 A cross-sectional view of the mesh-like void structure provided by this utility model.

[0020] Figure reference numerals: 1. Matrix foam layer; 2. Intermediate foam layer; 3. Soft sponge layer; 4. Filling layer; 5. Stepped column; 41. Mesh void structure; 42. Filling foam; 411. Upper woven elastic net; 412. Lower woven elastic net; 413. Rebound rope. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; or they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0023] like Figures 1 to 5As shown, this embodiment provides a foam structure with high support and resilience and resistance to surface deformation, including a base foam layer 1 at the bottom, an intermediate foam layer 2, and a soft sponge layer 3 at the top. The improvement is that the base foam layer 1 and / or the intermediate foam layer 2 are provided with a high-resilience and surface-deformation-resistant filling layer 4. The filling layer 4 is composed of a mesh-like void structure 41 and a filling foam 42 that fills the voids of the mesh-like void structure and whose upper and / or lower surfaces are integrated with the foaming material of the base foam layer 1 or the intermediate foam layer 2. The thickness of the mesh-like void structure 41 is controlled between 5-30 mm and is composed of an upper woven elastic mesh 411, a lower woven elastic mesh 412, and a rebound rope 413 disposed between the upper woven elastic mesh 411 and the lower woven elastic mesh 412.

[0024] In this embodiment, the soft sponge layer 3 and the intermediate foam layer 2 are connected by double-sided adhesive or spray adhesive, and the intermediate foam layer 2 and the base foam layer 4 are bonded together by spray foam adhesive.

[0025] In this embodiment, the high-resilience and surface-deformation-resistant filling layer 4 is disposed at the upper, middle or bottom position of the base foam layer 1 or the intermediate foam layer 2, and the specific position can be adjusted according to the actual situation.

[0026] Furthermore, in this embodiment, the high-resilience and surface-deformation-resistant filler layer 4 is preferably disposed in the middle of the intermediate foam layer 2; specifically, the intermediate foam layer 2 is, from top to bottom, a first foam layer (unmarked), a high-resilience and surface-deformation-resistant filler layer, and a second foam layer (unmarked); the upper surface of the filler foam in the filler layer 4 is integrally connected with the foaming material of the first foam layer, and the lower surface is integrally connected with the foaming material of the second foam layer.

[0027] In this embodiment, the thickness of the mesh void structure 41 can be 5mm, 8mm, 10mm, 15mm, 20mm, 25mm, or 30mm. In actual processing, the thickness specification is selected based on the requirements. The ball rebound rate of the mesh void structure (the ball material is plastic, the ball height is 500mm, and the ball rebound percentage) is controlled between 35% and 75%, and the height loss after 200,000 durability fatigue cycles is <5%.

[0028] Furthermore, in this embodiment, the grids on the upper woven elastic net 411 and the lower woven elastic net 412 are rhomboid, rectangular, square, or polygonal grids, preferably rhomboid, and the size of the rhomboid grid is controlled at 8mm*6mm, that is, the length of the long diagonal of the rhomboid grid is controlled at 8mm and the length of the short diagonal is controlled at 6mm; multiple rebound ropes 413 are arranged at intervals around the periphery of the two opposing grids, one end of the rebound rope 413 is connected to the upper woven elastic net, and the other end is connected to the lower woven elastic net.

[0029] The following example illustrates the processing of foam structures by placing a high-resilience and surface-deformation-resistant filler layer 4 in the middle of the intermediate foam layer 2:

[0030] Step 1. First, place the mesh void structure 41 into the mold cavity of the intermediate foam layer 2, and fix it in the mold cavity of the intermediate foam layer 2 by the stepped pillar 5, so that the mesh void structure 41 and the top and bottom of the mold cavity are reserved with a set height; next, pour polyurethane foam material into the mold cavity of the intermediate foam layer 2 with a foaming gun, close the mold, and the polyurethane foam material undergoes a chemical reaction in the mold cavity, bonding the polyurethane foam material with the mesh void structure 41 together. After the chemical reaction is completed, take out the product;

[0031] Step 2. Process the base foam layer 1 according to the traditional process. The process is as follows: pour polyurethane foam material into the mold, chemically react to obtain the base foam layer 1, and bond the base foam layer 1 and the intermediate foam layer 2 of the internal filling layer 4 prepared in step 1 together by spraying foam adhesive.

[0032] Step 3. Connect the product prepared in Step 2 to the soft sponge layer 3 using double-sided adhesive or spray adhesive.

[0033] This embodiment also provides a seat cushion, wherein the foam portion of the seat cushion adopts the foam structure described above, which has high support and resilience and is resistant to surface deformation.

[0034] The above describes specific embodiments of this utility model, but the scope of protection of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the scope of protection of this utility model. Therefore, the scope of protection of this utility model should be determined by the scope of the claims.

Claims

1. A foam structure with supporting and resilient properties and resistance to surface deformation, comprising a base foam layer at the bottom, an intermediate foam layer, and a soft sponge layer at the top, characterized in that, The base foam layer and / or intermediate foam layer are provided with a high-resilience and surface-deformation-resistant filling layer. The filling layer consists of a mesh-like void structure and filling foam that is integrated with the foaming material of the base foam layer or intermediate foam layer, with the upper and / or lower surfaces connected to the foaming material of the mesh-like void structure. The thickness of the mesh-like void structure is controlled between 5-30mm, and it consists of an upper woven elastic net, a lower woven elastic net, and a rebound rope disposed between the upper woven elastic net and the lower woven elastic net.

2. The foam structure with supporting resilience and resistance to surface deformation according to claim 1, characterized in that, The high-resilience and surface-deformation-resistant filler layer is disposed at the upper, middle or bottom position of the matrix foam layer or intermediate foam layer.

3. A foam structure with supporting resilience and resistance to surface deformation according to claim 1, characterized in that, The upper and lower woven elastic nets have rhomboid, rectangular, square, or polygonal grids. Multiple rebound ropes are spaced apart around the perimeter of the two opposing grids. One end of each rebound rope is connected to the upper woven elastic net, and the other end is connected to the lower woven elastic net.

4. A foam structure with supporting resilience and resistance to surface deformation according to claim 2, characterized in that, The intermediate foaming layer consists of, from top to bottom, a first foaming layer, a high-resilience and surface-deformation-resistant filler layer, and a second foaming layer; the upper surface of the filler foam in the filler layer is integrated with the foaming material of the first foaming layer, and the lower surface is integrated with the foaming material of the second foaming layer.

5. A foam structure with supporting resilience and resistance to surface deformation according to claim 3, characterized in that, The size of the rhombus grid is controlled at 8mm*6mm.

6. A foam structure with supporting resilience and resistance to surface deformation according to claim 3, characterized in that, The soft sponge layer and the intermediate foam layer are connected by double-sided adhesive or spray adhesive, and the intermediate foam layer and the base foam layer are bonded together by spray foam adhesive.

7. A seat cushion, characterized in that, The foam portion of the cushion adopts the foam structure with supportive and resilient properties and resistance to surface deformation as described in any one of claims 1 to 6.

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