Seat obtained by 3D printing

Abstract

The invention relates to an element of a vehicle seat comprising padding (4) and an encasing wall (5) surrounding said padding (4). According to the invention, the padding (4) and the encasing wall (5) are manufactured by means of 3D printing, said padding (4) having certain deformation zones (12) providing a free space (13) with the encasing wall (5) to allow said zones (12) to deform without being constrained by said encasing wall (5).

Description

Description Title of the invention: Seat obtained by 3D printing

[0001] The present invention relates to a seat obtained by 3D printing.

[0002] Vehicle seats generally include a seat and a backrest, each consisting of foam padding encased in a cover that can be made of textile fabric or leather, for example.

[0003] A current trend is to manufacture these seats, primarily the padding and the cover, using 3D printing, a simple, automated, and rapid manufacturing technique. In fact, it is simply a matter of programming the 3D printer with the characteristics of the different layers to be produced for both the padding and the cover to obtain a ready-to-use seat. It is worth noting that during this 3D printing process, the padding and the cover are manufactured simultaneously and progressively. The materials used for the cover and padding are chosen to replace, with the same effectiveness, the materials traditionally used for manufacturing these same padding and cover.

[0004] However, a problem encountered when manufacturing vehicle seats with 3D printing is that the padding must be able to deform easily under the weight of a person sitting on the seat, without being constrained by the casing which would enclose the padding too tightly and prevent it from doing so.

[0005] A seat according to the invention is manufactured using 3D printing while solving the aforementioned problem.

[0006] The invention relates to a component of a vehicle seat comprising padding and an enclosing wall surrounding said padding.

[0007] According to the invention, the padding and the outer wall are manufactured using 3D printing. The padding has certain deformation zones that create a free space with the outer wall, allowing these zones to deform without being constrained by the outer wall. In other words, during the 3D printing of this seat element, the padding and the outer wall are manufactured simultaneously and progressively, after the process has been programmed into the 3D printer. The presence of a free space between certain deformation zones of the seat element's padding and the outer casing provides these zones with additional clearance to deform, thus offering comfort to a person seated on the seat without exerting pressure on the outer casing that could otherwise impede the padding's deformation. Similarly, if the padding were to protrude from the outer casing, pressure exerted on it by a person sitting in the seat or exiting the vehicle would result in a relatively gentle deformation, made possible by the free space between the padding and the outer casing. Without this free space, the padding would fold against an edge of the casing, extending beyond that edge.Repeating this sequence could lead to premature wear of the padding, or even its rupture. The outer wall is designed to completely or partially surround the padding. Preferably, the outer shell and the padding are made of different materials. During the 3D printing of the seat element, the padding consists of at least two layers of cells, which may be made of the same or different materials. The cells are preferably identical and each defines a unit pattern that is repeated several times within the same layer. The presence of a free space between the deformation zone and the outer shell indicates that these two elements are not bonded. The seat element could be, for example, a seat or a backrest.

[0008] According to one possible feature of the invention, said element represents a seat cushion. The presence of certain flexible and deformable areas in the padding is perfectly justified in a seat, insofar as a person who sits on the seat must experience a certain level of comfort by being able to sink into said cushion.

[0009] According to one possible feature of the invention, the cladding wall is a lateral flank of the base having two lateral edges, including an inner lateral edge and an outer lateral edge, and a front edge connecting said two lateral edges by being perpendicular to them, a free space being provided between the outer lateral edge of the lateral flank and an upper deformation zone of The seat padding. When the seat is installed in the vehicle, the outer edge of the side panel is located on the door side, and the inner edge of said side panel is located on the side of the vehicle's center console. Each time a person sitting in the seat wants to exit the vehicle, they will exert downward pressure on the seat padding, which will flow towards the outer edge of the side panel. The gap between this padding and the outer edge of the side panel allows the padding to deform moderately above this outer edge, thus preserving the padding. If no gap were left between the padding and the outer edge of the side panel, the padding would fold directly around this outer edge, extending beyond it, resulting in premature wear or even rupture of the padding.

[0010] The width is the dimension of the free space, representing the distance between the padding and the side panel. A free space less than 10 mm wide is sufficient to ensure proper deformation of the padding. The upper area of ​​the seat represents the thickness of the seat against which a passenger is designed to sit.

[0011] According to a possible feature of the invention, the free space between the deformation zone and the lateral flank has a width that is less than 5mm.

[0012] According to one possible feature of the invention, no gap is provided between the upper deformation zone of the seat padding and the front edge of the side panel. Indeed, if a gap were provided between the front edge of the side panel and the seat padding, a person sitting on the seat could experience pinching in that gap. Such pinching would provide an unpleasant sensation to the person sitting on the seat.

[0013] According to one possible feature of the invention, the padding has a lower zone which is positioned beneath and continuous with the upper zone, the lower zone being connected to the lateral side. It is important that the padding maintains good stability within the seat, this stability being ensured in particular by the lower zone which is connected on the lateral side. Preferably, there is no interface layer between the lower and upper zones of the padding.

[0014] According to a possible feature of the invention, the height of the upper zone, which is its dimension considered along a vertical axis, is less than or equal to 20mm.

[0015] According to one possible feature of the invention, the height of the upper zone is less than or equal to 10mm.

[0016] According to one possible feature of the invention, the lower zone is connected to the lateral side over the entire height of the contact zone between said lower zone and the lateral side.

[0017] According to one possible feature of the invention, the padding is composed of a stack of cell layers, the layers constituting the lower zone being made of a relatively rigid material and the layers constituting the upper zone being made of a deformable material. 3D printing allows the use of a wide variety of materials to obtain a final object that is as precise and complete as possible, possessing the desired properties.

[0018] The invention also relates to a method for manufacturing a seat element according to the invention using 3D printing.

[0019] According to the invention, the process comprises the following steps: -a stage of simultaneous and progressive manufacturing of the padding and the encapsulating envelope using a 3D printer, -a step of creating a free space between a deformable area of ​​the padding and the encasement.

[0020] During 3D printing manufacturing, also known as simultaneous additive manufacturing, the 3D printer must be programmed beforehand so that the seat obtained at the end of this manufacturing process has a free space between the deformable area of ​​the padding and the side panel.

[0021] The invention also relates to a vehicle comprising at least one seat having at least one element conforming to the invention.

[0022] According to the invention, said element comprises a padding and an enclosing wall surrounding said padding, said padding and said enclosing wall being manufactured by means of 3D printing, said padding having certain deformation zones providing a free space with the a cover wall to allow said areas to deform without being constrained by said cover wall.

[0023] A seat component according to the invention has the advantage of being able to be manufactured quickly, automatically, and precisely, while possessing the properties required to ensure good seating comfort. Furthermore, it has the advantage of being able to be manufactured with a wide range of materials thanks to 3D printing, and therefore to have structural characteristics adapted to the materials used. Thus, for example, the material used to manufacture the deformable zone of the padding will determine the width of the free space between said padding and the side panel.

[0024] A detailed description of a preferred embodiment of a seat element according to the invention is given below, with reference to the following figures:

[0025] [Fig. 1] Figure 1 is a perspective view of a seat according to the invention manufactured by 3D printing,

[0026] [Fig. 2] Figure 2 is a cross-sectional view of a seat according to the invention in the absence of stress, showing the padding and the outer lateral edge of the side panel, between which a free space has been provided,

[0027] [Fig. 3] Figure 3 is a cross-sectional view of a seat according to the invention subjected to a vertical thrust, showing the padding and the outer lateral edge of the side panel, between which a free space has been provided,

[0028] [Fig. 4] Figure 4 is a cross-sectional view of a seat according to the invention in the absence of stress, showing the padding and the front edge of the side panel in contact with each other,

[0029] [Fig. 5] Figure 5 is a cross-sectional view of a seat according to the invention subjected to a vertical thrust, showing the padding and the front edge of the side panel in contact with each other,

[0030] [Fig. 6] Figure 6 is a simplified cross-sectional view of the deformable area of ​​a seat cushion according to the invention, showing superimposed cell layers in the absence of external stress,

[0031] [Fig. 7] Figure 7 is a simplified cross-sectional view of the deformable area of ​​a seat cushion according to the invention, showing superimposed cell layers in the presence of an external stress in the form of a downward vertical thrust.

[0032] The detailed description that follows will be made assuming that the seat element according to the invention is a seat.

[0033] Referring to Figure 1, a vehicle seat 1 generally comprises a seat cushion 2 and a backrest 3, which is often adjustable in tilt. In the context of this invention, the seat cushion 2 is produced using 3D printing, also known as simultaneous additive manufacturing. This seat cushion 2 includes padding 4 and a side panel 5, formed by a band surrounding said padding 4. This side panel 5 is made of a relatively rigid material, and the padding 4 is made of a relatively flexible material to ensure seating comfort for a person sitting in the seat 1. The padding 4 has a certain thickness and exhibits deformation capabilities, while the side panel 5 has at least three edges 6, 7, 8, each extending in a vertical plane.Among these three edges, two parallel lateral edges 6 and 7 are distinguished, including an outer edge 6 and an inner edge 7, and a front edge 8 connecting two ends of the two parallel lateral edges 6 and 7. The two lateral edges 6 and 7 border the padding 4 on the sides, and the front edge 8 connects said two lateral edges 6 and 7, being perpendicular to these two lateral edges 6 and 7. The front edge 8 of the side panel 5 borders a front edge of the padding 4. This side panel 5 is intended to ensure that the padding 4 is held within the seat 2. The outer lateral edge 6 of the side panel 5 is located opposite a door of the vehicle through which access is made to the seat in question, and the inner lateral edge 7 is located opposite a center console of said vehicle.

[0034] Referring to Figures 4 and 5, the padding 4, which is manufactured using a 3D printer, consists of several layers 9 of cells 10. When the seat 1 is installed in a vehicle, these layers 9 of cells 10 extend horizontally over one another. The cells 10 are preferably identical 9 and each represents a particular pattern that is repeated several times within the same layer 9. The cells 10 of a layer 9 are in contact with cells 10 of the same layer 9 and with cells 10 of adjacent layers 9, so as to form a continuous, three-dimensional network of cells 10. The side panel 5, which is also manufactured using 3D printing, consists of its three edges 6, 7, 8 and does not have a cellular structure 10.

[0035] Referring to Figure 2, when seat 1 is installed in a vehicle, the padding 4 has a lower zone 11 and an upper zone 12, with the upper zone 12 positioned above the lower zone 11. These two zones 11 and 12 are superimposed and continuous with each other; that is, they are not separated by an interface layer. The upper zone 12 can be considered a surface layer of the padding 4 against which a person sitting in the seat will be in direct contact. The lower zone 11 can be considered as a deep layer of the padding 4 which will ensure a certain firmness to said padding 4. The upper zone 12 of the padding 4 is deformable to ensure a certain seating comfort for a person who would be sitting on the padding 4. The lower zone 11 of the padding 4 is much less deformable than the upper zone 12, or even not deformable at all.The upper zone 12 of the padding 4 can be made of the same material as the lower zone, and in this case, the deformability or non-deformability of said zones 11, 12 will be a function of the concentration of the cells 10. These two zones 11, 12 can also be made of two different materials, one deformable for the upper zone 12 and the other less (or not) deformable for the lower zone 11.

[0036] With reference to Figures 2, 3, 6 and 7, during the manufacture of the seat 2, i.e. the padding 4 and the side panel 5, by means of 3D printing, it was decided to create a free space 13 between the upper deformable area 12 of the seat 2 and the outer lateral edge 6 of the side panel 5. Indeed, it was observed that each time a person sitting on the seat wanted to get out of the vehicle through the door, they systematically exerted a vertical push with their leg on the padding 4 located on the side of the outer lateral edge 6 of the side panel 5, as indicated by the arrow 14 in Figures 2, 3 and 7.

[0037] Referring to Figures 3 and 7, thanks to the presence of the free space 13 and therefore the offset between the outer lateral edge 6 of the side panel 5 and the edge of the padding 4 located opposite said outer lateral edge 6, the padding 4 can deform moderately with each leg passage, without undergoing an excessively pronounced crease that could prematurely damage or even break it. It must be emphasized, in fact, that in the absence of free space 13 Between the padding 4 and the outer lateral edge 6, the padding 4 would fold markedly around said outer lateral edge 6 with a high risk of tearing. The width of this free space 13, which represents the distance separating the upper deformable zone 12 of the padding 4 and the outer lateral edge 6 of the side panel 5, is less than or equal to 7 mm. The height of the upper deformable zone 12 is less than or equal to 13 mm, the height being the dimension of said zone 2 considered along a direction perpendicular to a mean plane in which said upper zone 12 would lie.

[0038] Referring to figures 2 and 3, the lower zone 11 of the padding 4 is connected to the outer lateral edge 6 of the lateral side 5, that is to say that said lower zone 11 does not allow any play with said outer lateral edge 6. Preferably, the lower zone 11 is connected to the outer lateral edge 6 over the entire height of the contact area between said lower zone 11 and said outer lateral edge 6.

[0039] Referring to figures 4 and 5, during the manufacture of the seat 2, i.e. the padding 4 and the side panel 5, using 3D printing, it was decided not to create a free space 13 between the upper deformable zone 12 of the seat 2 and the front edge 8 side panel 5. Indeed, if such a free space If a gap 13 had been created between the front edge 8 of the side panel 5 and the upper deformable area 12 of the padding 4, there would be a significant risk of pinching the leg of a person sitting on the seat, between said front edge 8 and said upper deformable area 12. In order to prevent such pinching from occurring, no free space 13 was created between the front edge 8 of the side panel 5 and the upper deformable area 12 of the padding 4.

[0040] In this way, referring to figure 5, the front edge 8 and the upper deformable area 12 of the padding 4 are linked, and can deform together without creating a space that could pinch the leg of a person sitting on the seat.

Claims

Claims

1. Element (2, 3) of a vehicle seat (1) comprising padding (4) and a covering wall (5) surrounding said padding (4), characterized in that the padding (4) and the covering wall (5) are manufactured by means of 3D printing, and in that said padding (4) has certain deformation zones (12) providing a free space (13) with the covering wall (5) to allow said zones (12) to deform without being constrained by said covering wall (5).

2. Element of a seat according to claim 1, characterized in that said element represents a seat (2) of the seat.

3. Element of a seat according to claim 2, characterized in that the covering wall is a lateral flank (5) of the seat (2) having two lateral edges (6, 7), including an inner lateral edge (7) and an outer lateral edge (6), and a front edge (8) connecting said two lateral edges (6, 7) while being perpendicular to them, and in that a free space is provided between the outer lateral edge (6) of the lateral flank (5) and an upper deformation zone (12) of the padding (4) of the seat (2).

4. Seat element according to claim 3, characterized in that no free space (13) is provided between the upper deformation zone (12) of the padding (4) of the seat (2) and the front edge (8) of the lateral flank (5).

5. Element of a seat according to any one of claims 3 or 4, characterized in that the padding (4) has a lower zone (11) which is placed under the upper zone (12) and in the continuity of said upper zone (12), and in that said lower zone (11) is linked to the lateral flank (5).

6. Element of a seat according to claim 5, characterized in that the height of the upper zone (12) which is its dimension considered along a vertical axis is less than or equal to 20mm.

7. Element of a seat according to any one of claims 5 or 6, characterized in that the lower zone (11) is connected to the lateral flank (5) over the entire height of the contact zone between said lower zone (11) and the lateral flank (5).

8. Element of a seat according to any one of claims 5 to 7, characterized in that the padding (4) is composed of a stack of layers (9) of cells (10), and in that the layers (9) of cells (10) constituting the lower zone (11) are made of a material that is not very deformable and the layers (9) of cells (10) constituting the upper zone (12) are made of a deformable material.

9. Method for manufacturing a seat element (2, 3) according to any one of claims 1 to 8 by means of 3D printing, characterized in that it comprises the following steps: - a step of simultaneous and progressive manufacturing of the padding (4) and the coating wall (5) using a 3D printer, - a step of creating a free space (13) between a deformable zone (12) of the padding (4) and the coating envelope (5).

10. Vehicle comprising at least one seat having at least one element (2, 3) according to any one of claims 1 to 8, characterized in that said element (2, 3) comprises padding (4) and a covering wall (5) surrounding said padding (4), said padding (4) and said covering wall (5) being manufactured by means of 3D printing, and in that said padding (4) has certain deformation zones (12) providing a free space (13) with the covering wall (5) to allow said zones (12) to deform without being constrained by said covering wall (5).

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