Method for manufacturing a large-sized cushion by 3D printing

Abstract

The invention relates to a method for manufacturing cushion by 3D printing, comprising the following steps: - a step of manufacturing, by 3D printing, a first cushion section (1), a second cushion section (2) and a flexible strip (3) of material, such that the flexible strip (3) of material connects the two sections (1, 2), - a step of gradually deploying the first section (1) on the second section (2) by means of a relative pivoting of said two sections (1, 2) around the flexible strip (3) of material, - a step of securing the first section (1) to the second section (2) with catching means (18, 19, 20, 21).

Description

[0001] Title of the invention: Method for manufacturing a large cushion by 3D printing

[0002] The present invention relates to a method of manufacturing a large cushion by 3D printing.

[0003] Such a cushion is particularly but not exclusively suitable for a vehicle seat. Generally, a vehicle seat comprises a seat and a backrest. In certain cases, such as for racing vehicles intended to run on a circuit, the geometry of this seat and this backrest may appear complex, in particular by presenting different inclined walls, intended to maintain the driver's body in a stable position on his seat. In order to improve the comfort of these drivers, flexible cushions made for example of foam and surrounded by a fabric cover, are attached to the different walls constituting the structure of said backrest and said seat.

[0004] However, current manufacturing techniques for these cushions are very inflexible, as they take a certain amount of time to manufacture and are only designed for a single type of seat. Indeed, it is enough for the seat to slightly change shape and / or dimensions for these techniques to no longer be suitable. It is then necessary to modify the various equipment used in these techniques to obtain the desired product, with the right geometry and dimensions. These equipment modifications are cumbersome to carry out, are time-consuming and therefore generate additional costs.

[0005] Manufacturing these cushions using 3D printing overcomes the drawbacks mentioned above.

[0006] But in some situations, it may happen that the dimensions of the cushion to be manufactured exceed the capabilities of the 3D printer capable of manufacturing this cushion. One solution to this problem could be to simply increase the dimensions of said 3D printer to obtain a cushion with the desired dimensions. But such a solution is very expensive because it would be necessary to design new 3D printers each time that would be compatible with the dimensions of the cushions to be manufactured. A manufacturing method according to the invention makes it possible to manufacture a cushion by 3D printing, the dimensions of which are greater than the capabilities of the 3D printer and without having to make any modification to it.

[0007] The invention relates to a method for manufacturing a cushion by 3D printing.

[0008] According to the invention, the method comprises the following steps:

[0009] - a step of manufacturing by 3D printing a first cushion section, a second cushion section and a flexible strip of material, such that said first section is placed on said second section and such that the flexible strip of material connects an upper surface of the second section and a lower surface of the first section, - a step of deploying the first section on the second section by means of a relative pivoting of said two sections around the flexible strip of material, such that the first section is aligned in the same plane with the second section, - a step of securing the first section to the second section with attachment means to form a resulting cushion having the cumulative dimensions of said first section and said second section.

[0010] Since the cushion to be manufactured has dimensions that are larger than those of the 3D printer, the principle of a manufacturing method according to the invention is to manufacture a cushion in two superimposed sections constituting an assembly whose dimensions are compatible with the capabilities of the 3D printer. These two sections, which are superimposed, are connected to each other by a flexible strip of material also manufactured by 3D printing, allowing said two sections to be deployed while remaining attached to each other at all times. Once the two sections have been deployed, it is then sufficient to secure them to each other with attachment means, to obtain a resulting cushion whose dimensions are larger than those of the 3D printer used to manufacture it. The flexible strip of material connecting the first section to the second section will serve as an axis of rotation to allow relative rotation of the first section with respect to the second section.The fact that the strip of material is flexible allows said strip to be able to be bent to allow the rotation of the first section relative to the second section. The first section consists of a first mesh network and the second section consists of a second mesh network, said first mesh network being able to be identical to said second mesh network or different from it. The two sections can be identical or different from each other. A cushion manufactured using a method according to the invention can for example be a seat cushion or a back cushion of a motor vehicle seat. The fact that the first section is superimposed on the second section makes the resulting assembly compact, with dimensions that are compatible with those of the 3D printer used.

[0011] According to a possible characteristic of the invention, at the end of the step of manufacturing the first section and the second section, the lower surface of the first section is located opposite the upper surface of the second section. In other words, the lower surface of the first section and the upper surface of the second section face each other, either by being in contact with each other or by remaining at a distance from each other. The assembly constituted by the superposition of the first section and the second section is compact, having a height which is substantially equal to the sum of the heights of the two sections and a surface which is equal to that of the two sections which is the largest.

[0012] According to a possible characteristic of the invention, during the step of manufacturing the first section and the second section, the flexible strip of material forms a closed loop between the upper surface of the second section and the lower surface of the first section. In other words, the flexible strip of material is not stretched between said two surfaces. Indeed, in order not to induce any particular tension on the strip of flexible material during the step of deploying the first section on the second section, it is necessary for this strip to be greater than the distance separating the upper surface of the second section and the lower surface of the first section.

[0013] According to a possible characteristic of the invention, at the end of the step of manufacturing the first section and the second section, the flexible strip of material comprises between the lower surface of the first section and the upper surface of the second section, a first segment extending the lower surface of the first section, a second segment extending the first segment and articulated at its center, and a third segment extending the second segment and joining the upper surface of the second segment, the second segment extending perpendicularly to said lower surface and to said upper surface, the first segment and the third segment extending obliquely respectively between the lower surface of the first section and the second segment, and between the upper surface of the second section and the second segment.The position of the different segments of the flexible strip of material is that which is observed at the end of the manufacturing step for which the first section is placed on the second section.

[0014] According to a possible characteristic of the invention, at the end of the step of deploying the first section on the first section, said first section has performed a rotation of 180° around the flexible strip of material so that the lower surface of the first section and the upper surface of the second section are aligned in the same plane, the flexible strip of material forming a groove originating on each of said two surfaces and extending via the first segment and the third segment towards a V-shaped bottom which is constituted by the second segment folded in two. The loop formed by the flexible strip of material is constituted by the first segment, the second segment and the third segment. Advantageously, these three segments are rectilinear and deformable, and are therefore capable of being folded without any particular effort.Preferably, the second segment comprises a central zone of lesser thickness, favoring its folding to obtain a V-shaped part. In this way, once it has been folded, the second segment has two branches of identical length placed on either side of the folding zone and making a given angle between them.

[0015] According to a possible characteristic of the invention, the step of securing the first section to the second section is carried out by means of bringing the two branches of the second segment folded in two and forming a V-shaped part into contact, then of a connection between said two branches with the attachment means. In other words, the two branches of the second V-shaped segment are first brought together until they come into contact with each other. Once this contact is established, the two branches establish extensive surface contact between them and are then fixed to each other with the attachment means. Preferably, the contacting of the two branches of the second segment is carried out manually by means of clamping pressure applied with the fingers.

[0016] According to a possible characteristic of the invention, the attachment means consist of a layer of adhesive. This layer of adhesive is deposited at the end of the process on at least one of the two branches of the second segment, after the 3D printing manufacturing step has taken place. In other words, the step of depositing the adhesive layer and the step of bringing the two branches into contact are carried out after the 3D printing operation. There is no interaction between these two steps and the step of 3D printing manufacturing of the first section, the second section and the flexible strip of material.

[0017] According to a possible characteristic of the invention, the attachment means are constituted by a Velcro strip comprising a male part secured to one branch of the second segment and a female part secured to the other branch of said second segment. This type of connection has a certain solidity while being easily reversible.

[0018] According to a possible feature of the invention, the Velcro strip is an added part that is attached to the second segment of the flexible strip of material after the 3D printing operation. For this configuration, the manufacturing method comprises an additional step which is the attachment of the Velcro strip to the second segment. The installation of a commercially available Velcro strip has the advantage of offering the guarantees of a solid and secure attachment.

[0019] According to a possible feature of the invention, the Velcro strip is manufactured by 3D printing on the two branches of the second segment at the same time as the manufacturing operation by 3D printing of the two sections and the flexible strip of material. For this configuration, the manufacturing method does away with an additional step which is the fixing of the Velcro strip on the second segment.

[0020] Another subject of the invention is a cushion manufactured using a manufacturing method according to the invention. According to the invention, said cushion comprises a first section consisting of a first network of meshes and a second section consisting of a second network of meshes, said first section and said second section extending in the same plane and being connected to each other by means of a flexible strip of material. Such a cushion thus has a folding zone through the presence of the flexible strip of material. Advantageously, the cushion is a seat cushion, and the flexible strip of material replaces the return line that is usually found on a seat cushion and which makes it possible to manage the tension of the cover covering said seat cushion.

[0021] A 3D printing manufacturing method according to the invention has the advantage of being able to manufacture cushions whose dimensions are larger than those of the 3D printer used to manufacture them, without having to modify said 3D printer, thanks to a manufacturing trick consisting in particular of superimposing two sections of cushion. It also has the advantage of being able to manufacture an oversized cushion compared to the 3D printer and which retains all the comfort properties of a traditional cushion of the same size but which would have been manufactured by a technique other than 3D printing.

[0022] A detailed description of a preferred embodiment of a 3D printing manufacturing method according to the invention is given below, with reference to the following figures:

[0023] [Fig. 1] Figure 1 is a schematic side view of the flexible strip of material connecting the first section and the second section in an initial position obtained at the end of the 3D printing manufacturing step,

[0024] [Fig. 2] Figure 2 is a schematic side view of the flexible strip of material connecting the first section and the second section in a first position deployed from the initial position,

[0025] [Fig. 3] Figure 3 is a schematic side view of the flexible strip of material connecting the first section and the second section in a second deployed position from the first deployed position,

[0026] [Fig. 4] Figure 4 is a schematic side view of the flexible strip of material connecting the first section and the second section in a third deployed position from the second deployed position, [Fig. 5] Figure 5 Figure 3 is a schematic side view of the flexible strip of material connecting the first section and the second section in a fourth deployed position from the third deployed position,

[0027] [Fig. 6] Figure 6 is a more detailed view of the schematic view of Figure 1,

[0028] [Fig. 7] Figure 7 is an enlarged view of a specific area of ​​Figure 6, [Fig. 8] Figure 8 is a more detailed view of the schematic view of Figure 5,

[0029] [Fig. 9] Figure 9 is an enlarged view of a specific area of ​​Figure 8.

[0030] A manufacturing method according to the invention makes it possible, in particular, to manufacture a cushion with large dimensions. Indeed, it may happen that the dimensions of the cushion to be manufactured are greater than those of a cushion that the 3D printer could directly manufacture. Rather than proposing a structural adaptation of the 3D printer to manufacture these large cushions, a manufacturing method according to the invention favors the use of an already existing 3D printer by associating it with a manufacturing trick.

[0031] A manufacturing method according to the present invention comprises a step of manufacturing by 3D printing a first cushion section 1, a second cushion section 2 which is distinct from the first cushion section 1, and a flexible strip 3 of material connecting said first section 1 to said second section 2.

[0032] At the end of this manufacturing step, with reference to figures 1, 6 and 7, the first section 1 and the second section 2 are superimposed, said first section 1 being found on said second section 2.

[0033] Referring to Figures 6, 7, 8 and 9, the first section 1 comprises a first mesh network 4 and the second section 2 comprises a second mesh network 5, said first network 4 and said second network 5 being able to be identical or different at the level of their mesh networks. The second section 2 comprises an upper and flat surface 6 and the first section 1 comprises a lower and flat surface 7, said two surfaces 6, 7 being parallel to each other and being placed opposite each other without establishing contact between them. The flexible strip 3 of material connects the upper surface 6 of the second section 2 and said lower surface 7 of the first section 1 by forming a closed loop comprising:

[0034] - a first segment 8 extending the lower surface 7 of the first section 1, - a second segment 9 extending the first segment 8 and articulated at its center, and

[0035] - a third segment 10 extending the second segment 9 and joining the upper surface 6 of the second section 2.

[0036] It should be noted that the connection 11 of the first segment 8 to the second segment 9, as well as the connection 12 of said second segment 9 to the third segment 10 are both articulated. In other words, the first segment 8 and the second segment 9 can bend at their articulated connection 11, and said second segment 9 and the third segment 10 can bend at their articulated connection 12.

[0037] The second segment 9 extends perpendicularly to the lower surface 7 of the first section 1 and to the upper surface 6 of the second section 2, the first segment 8 and the third segment 10 extending obliquely respectively between the lower surface 7 of the first section 1 and the second segment 9, and between the upper surface 6 of the second section 2 and the second segment 9. The term “oblique” means “between a vertical position and a horizontal position”.

[0038] After this manufacturing step, a manufacturing method according to the invention comprises a step of deploying the first section 1 on the second section 2 by means of a relative pivoting of said two sections 1, 2 around the flexible strip 3 of material, so that the first section 1 is aligned in the same plane with the second section 2 as illustrated in Figures 4, 5, 8 and 9. The amplitude of pivoting of the first section 1 around the flexible strip 3 of material from the initial position as illustrated in Figure 1 to arrive at the aligned position for which the two sections are in continuity with each other in the same plane, as illustrated in Figures 4, 5, 8 and 9 is 180°.Referring to Figure 2, from the initial position, the flexible strip 3 of material is first rotated around the articulated connection 11 between the first segment 8 and the second segment 10, reflecting the fact that the lower surface 6 (therefore the first section 1) and the first segment 8 have started to pivot around this articulated connection 11.

[0039] Referring to Figure 3, the flexible strip 3 of material continues to rotate around the articulated connection 12 between the second segment 9 and the third segment 10.

[0040] Referring to Figure 4, the rotation of the flexible strip 3 of material ends when:

[0041] - the upper surface 7 of the second section 2 and the lower surface 6 of the first section 1 are exactly at the same height, in other words in the same horizontal plane,

[0042] - the flexible strip 3 of material forms a groove 13 originating on each side on the lower surface 7 of the first section 1 and the upper surface 6 of the second section 2, and the V-shaped bottom 14 of which is constituted by the second segment 9 folded in two, the first segment 8 and the third segment 10 converging towards each other by joining respectively the lower surface 7 of the first section 1 and the second section 9, and the upper surface 6 of the second section 2 and the second segment 9. When folded in two, the second segment 9 reveals two branches 16, 17 placed on either side of the fold. Preferably, the two branches have the same length and form a given angle between them which is advantageously less than 90°.

[0043] In this way, the groove 13 comprises an upper zone 15 delimited by the first segment 8 and by the third segment 10 and which is of convergent shape, and a V-shaped bottom 14 extending said convergent upper zone 15 downwards.

[0044] After the deployment step, a manufacturing method according to the invention comprises a step of securing the first section 1 to the second section 2, said step being carried out by means of bringing the two branches 16, 17 of the second segment 9 forming the bottom 14 of the groove 13 into contact, then of a connection between said two branches 16, 17 with attachment means. This bringing into contact is preferably carried out manually, by placing the fingers of one hand around the two branches 16, 17 of the second segment 9 then applying a clamping force to them with said fingers.

[0045] These attachment means may consist of a layer of adhesive deposited on at least one of the two branches 16, 17 of the second segment 9.

[0046] Referring to figures 6, 7, 8 and 9, these attachment means can also be constituted by a Velcro strip 18, a male part 19 of which would be fixed to one of the branches 16, 17 of the second segment 9 and a female part 20 of which would be fixed to the other branch 16, 17 of said second segment.

[0047] According to an alternative embodiment of a method according to the invention, the Velcro strip 18 is a traditional Velcro strip, constituting an added part, which is fixed to the two branches 16 of the second segment for example by gluing. This solution has the advantage of being safe and reliable, because traditional Velcro strips have already largely proven their worth.

[0048] According to another alternative embodiment of a method according to the invention, the Velcro strip 18 is manufactured by 3D printing during the same manufacturing operation as the first section 1, the second section 2 and the flexible strip 3 of material. For this configuration, the male part 19 and the female part 20 are identical and consist of a multiplicity of pins 21 each having a body surmounted by an enlarged head, said pins providing receiving spaces between them. When the male part 19 and the female part 20 are brought into contact with each other to establish the connection between the two branches 16, 17 of the second segment 9, the enlarged heads of the pins 21 of one of the two parts 19, 20 enter the receiving spaces of the other part 19, 20.

[0049] Referring to figures 8 and 9, it is possible, using the 3D printer, to easily create free spaces 22 in the first section 1 and in the second section 2 to be able to pass fingers through in order to tighten the two branches 16, 17 of the second segment 9 during the step of securing the first section 1 and the second section 2.

Claims

Claims

1. Method for manufacturing a cushion by 3D printing, characterized in that it comprises the following steps: - a step of manufacturing by 3D printing a first section (1) of cushion, a second section (2) of cushion and a flexible strip (3) of material, so that said first section (1) is placed on said second section (2) and so that the flexible strip (3) of material connects an upper surface (6) of the second section (2) and a lower surface (6) of the first section (1), - a step of deploying the first section (1) on the second section (2) by means of a relative pivoting of said two sections (1, 2) around the flexible strip (3) of material, so that the first section (1) is aligned in the same plane with the second section (2), - a step of securing the first section (1) to the second section (2) with attachment means (18, 19, 20, 21) to form a resulting cushion having the cumulative dimensions of said first section (1) and said second section (2).

2. Manufacturing method according to claim 1 characterized in that at the end of the step of manufacturing the first section (1) and the second section (2), the lower surface (7) of the first section (1) is located opposite the upper surface (6) of the second section (2)

3. Manufacturing method according to claim 2, characterized in that during the step of manufacturing the first section (1) and the second section (2), the flexible strip (3) of material forms a closed loop between the upper surface (6) of the second section (2) and the lower surface (7) of the first section (1).

4. Manufacturing method according to claim 3, characterized in that at the end of the step of manufacturing the first section (1) and the second section (2), the flexible strip (3) of material comprises between the lower surface (7) of the first section (1) and the upper surface (6) of the second section (2), a first segment (8) extending the lower surface (7) of the first section (1), a second segment (9) extending the first segment (8) and articulated at its center, and a third segment (10) extending the second segment (9) and joining the upper surface (6) of the second segment (2), and in that the second segment (9) extends perpendicularly to said lower surface (7) and to said upper surface (6), the first segment (8) and the third segment (10) extending obliquely respectively between the lower surface (7) of the first section (1) and the second segment (9), and between the upper surface (6) of the second section (2) and the second segment (9).

5. Manufacturing method according to claim 4, characterized in that at the end of the step of deploying the first section (1) on the second section (2), said first section (1) has performed a rotation of 180° around the flexible strip (3) of material so that the lower surface (7) of the first section (1) and the upper surface (6) of the second section (2) are aligned in the same plane, and in that the flexible strip (3) of material forms a groove (13) originating on each of said two surfaces (6, 7) and extending via the first segment (8) and the third segment (10) towards a V-shaped bottom (14) which is constituted by the second segment (9) folded in two.

6. Manufacturing method according to claim 5, characterized in that the step of securing the first section (1) to the second section (3) is carried out by means of bringing the two branches (16, 17) of the second segment (9) folded in two and forming a V-shaped part into contact, then a connection between said two branches (16, 17) with the attachment means (18, 19, 20, 21).

7. Manufacturing method according to claim 6, characterized in that the attachment means consist of a layer of adhesive.

8. Manufacturing method according to claim 6, characterized in that the attachment means consist of a Velcro strip (18) comprising a male part (19) secured to one branch (16, 17) of the second segment (9) and a female part (20) secured to the other branch (16, 17) of said second segment (9).

9. Manufacturing method according to claim 8, characterized in that the Velcro strip (18) is an attached part which is attached to the second segment (9) of the flexible strip (3) of material after the 3D printing operation.

10. Manufacturing method according to claim 8, characterized in that the Velcro strip (18) is manufactured by 3D printing on the two branches (16, 17) of the second segment (9) at the same time as the manufacturing operation by 3D printing of the two sections (1, 2) of cushion and the flexible strip (3) of material.

11. Cushion manufactured by means of a manufacturing method according to any one of claims 1 to 10, characterized in that it comprises a first section (1) consisting of a first network of meshes and a second section (2) consisting of a second network of meshes, and in that said first section (1) and said second section (2) extend in the same plane and are connected to each other by means of a flexible strip (3) of folded material.

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