Vehicle seating system including a composite backrest with a honeycomb structure

Abstract

The invention relates to a vehicle seat system (1) comprising a backrest (2) made of composite material which includes a projecting honeycomb structure (7) integral with a support face (8), the honeycomb structure (7) extending from the upper part (3) to the lower part (4) of the backrest (2). According to the invention, the honeycomb structure (7) comprises at least two groups of cells (10, 11, 12): - a first group of cells (10) defining a load-bearing structure, and - a second group of cells (11) defining a back support structure, each cell (13) of the first group of cells (10) having smaller dimensions compared to the dimensions of each cell (13) of the second group of cells (11). [Figure for the abstract: Fig. 4]

Description

Title of the invention: Vehicle seat system comprising a composite backrest with a honeycomb frame Technical field

[0001] The invention relates to a vehicle seating system. The seating system may be a front seat or a rear bench seat, for example, of a motor vehicle. Prior art

[0002] Vehicle seat systems are known which comprise a metal frame equipped with a backrest and a seat which are coupled together. This metal frame is designed, on the one hand, to support padding covered with a covering envelope such as fabric, on the other hand, to support the mass of a vehicle user, but also to withstand the forces which may be applied in the event of impact of the vehicle with an element external to the vehicle which may be fixed or mobile.

[0003] When the seat system corresponds to a rear bench seat, the frame is also designed to withstand the shock which can be generated by luggage stored in the trunk during a rear impact of the vehicle.

[0004] For several years, manufacturers have been offering vehicles equipped with a rear bench seat that has two backrests that fold independently of each other. In the jargon of those skilled in the art, these backrests are called 60 / 40 or two-thirds / one-third. In practice, the largest backrest combines the backrest of the central seat and the backrest of one of the two other rear seats, while the smallest backrest corresponds to the backrest of the third seat on the rear bench seat.

[0005] The invention is part of the current trend which seeks to optimize the design of vehicles to reduce production costs, the mass of vehicles, but also to reduce the ecological footprint and more particularly the carbon footprint of the vehicle.

[0006] However, the constraints of load transfers linked to the safety of vehicle users are a significant obstacle to the lightening of the frame of the seat systems of the state of the art. That said, the inventors have observed that certain manufacturers have already attempted to produce files comprising a frame made of composite materials without, however, managing to respond to all the problems previously mentioned.

[0007] Consequently, the invention aims to overcome all of these drawbacks. Statement of the invention

[0008] More particularly, the invention aims to reduce the mass of a seat system while by meeting the safety constraints of the vehicle user.

[0009] The invention relates to a vehicle seat system comprising a backrest made of composite material which comprises: - an upper part configured to support a headrest, - a lower part configured to be secured to at least one seat of the seating system, - an intermediate part which is configured to support a passenger's back, and - a projecting honeycomb frame secured to a support face, the honeycomb frame extending from the upper part to the lower part of the backrest.

[0010] The invention is characterized in that the cellular reinforcement comprises at least two groups of cells: - a first group of cells extending, on the one hand, over the lower part of the backrest, and on the other hand, laterally on either side of the intermediate part of the backrest, the first group of cells defining a force-recovery structure, and - a second group of cells extends at the level of the intermediate part and defines a dorsal support structure of the backrest, each cell of the first group of cells has smaller dimensions compared to the dimensions of each cell of the second group of cells.

[0011] The honeycomb structure of the composite backrest as claimed makes it possible to reduce the mass of the backrest of the seat system while providing a structure meeting the standards for force absorption in the event of a vehicle impact, in particular at the level of the lumbar support. The use of a composite backrest also makes it possible to reduce the carbon footprint of the backrest compared to a metal backrest used in the prior art. Indeed, if we compare a seat system of the same dimensions and a seat system conforming to the invention of the prior art, the invention makes it possible to obtain a reduction in CO2 emissions of around 15-20%.

[0012] In embodiments, the ratio of the dimensions of each cell of the second group of cells to the dimensions of each cell of the first group of cells is at least 1.5. This allows the quantity of material used to be optimized in order to optimize the production costs and the carbon footprint of the seating system.

[0013] In embodiments, the cellular frame comprises a third group of cells which defines a support zone for a padding of the backrest and which extends in the upper part of the backrest and peripherally at least on one side of the backrest, the dimensions of each cell of the third group of cells are su larger than the dimensions of each cell in the first group of cells. The third group of cells supports the padding but also maintains its geometry.

[0014] In embodiments, the ratio of the dimensions of each cell of the third group of cells to the dimensions of each cell of the first group of cells is at least 2. This allows the material used to be reduced without compromising the safety performance of the seating system.

[0015] In embodiments, the support face constitutes the rear face of the backrest and the honeycomb frame projects in front of the rear face so as to define a receiving face for the padding of the backrest, the receiving face having a concave shape. The protruding nature and the concave shape of the honeycomb frame makes it possible to reduce the volume and mass of padding used while maintaining comfort similar to the seats of the prior art. The ecological footprint of the seat system is also reduced.

[0016] In embodiments, the cells of the honeycomb frame have different depths so as to define the concave shape of the receiving face.

[0017] In embodiments, the depth of the cells is minimal at the center of the honeycomb frame and the depth of the cells increases as the position of the cells is moved away from the center of the honeycomb frame. This provides a preformed backrest that is configured to accommodate a user's back.

[0018] In embodiments, the cellular frame comprises at least one receiving housing for a rod of a headrest, on the one hand, the receiving housing is open at a peripheral edge of the upper part of the backrest, and on the other hand, the receiving housing is defined by coaxial openings of partitions of a defined number of cells arranged along a longitudinal axis of the backrest.

[0019] In embodiments, the backrest comprises, respectively on either side of the lower part, a means of coupling to a seat support of the seat system, each coupling means comprising at least one metal insert for stiffening the honeycomb frame at the coupling means.

[0020] In embodiments, the backrest comprises a metal reinforcement bar which extends behind the force-recovery structure. In the event of an impact, the reinforcement bar makes it possible to resist the impact generated by the luggage on the rear face of the seat. Brief description of the drawings

[0021] Other characteristics and advantages of the invention will become apparent from reading the description which follows. This is purely illustrative and must be read in conjunction with the appended drawings in which:

[0022] [Fig. 1] is a perspective representation of a honeycomb frame of a backrest composite of a seating system according to one embodiment of the invention.

[0023] [Fig.2] is a perspective representation of the backrest of [Fig.l] which shows the concave shape of the surface for receiving the padding of the backrest.

[0024] [Fig.3] is a perspective representation of the rear face of the backrest of [Fig.l]

[0025] [Fig.4] is a perspective representation of an embodiment of the invention in which the honeycomb composite backrest is integrated into a rear seat of a vehicle.

[0026] [Fig.5] is a perspective view of the file of figures 1 and 4 in which the arrangement of the different groups of cells of the cellular framework is schematically represented.

[0027] [Fig.6] is a perspective representation of a longitudinal section of a backrest of a seat system according to an embodiment of the invention, in which the padding is coupled to the honeycomb frame of the backrest. Description of the embodiments

[0028] With reference to Figures 1 to 6, the present invention relates to a vehicle seat system 1 such as a motor vehicle. According to the invention, the seat system 1 may be a front vehicle seat or a rear bench seat of a vehicle.

[0029] According to one embodiment of the invention, the seat system may be a rear bench seat which has a single seat and two folding backrests which are respectively attached to the seat. In this configuration, a first backrest corresponds to 60% of the length of the bench seat while the second backrest corresponds to the remaining 40% of the length of the bench seat. This embodiment is illustrated in particular in [Fig.4].

[0030] The vehicle seat system 1 comprises a backrest 2 made of composite material. The composite material may be chosen from composite materials known in the prior art. For example, the composite material may comprise a polymer matrix filled with fibers such as glass, carbon, aramid or plant fibers. The polymer matrix may comprise at least one material chosen from the following list: polyamide, polypropylene, epoxy, vinylester, etc.

[0031] As illustrated in Figures 1 to 6, the backrest 2 extends longitudinally between two ends along an axis AA. Here, the axis AA corresponds to the longitudinal median axis of the backrest 2. A first end corresponds to an upper part 3 of the backrest which is configured to support a headrest. The second end corresponds to a lower part 4 of the backrest 2 which is configured to be secured to at least one seat 5 of the seat system 1 (see [Fig.4]). In addition, the backrest 2 comprises a intermediate part 6 which is configured to support a passenger's back. The intermediate part 6 is interposed between the upper part 2 and the lower part 3 of the backrest 2.

[0032] According to the invention, the backrest 2 comprises a honeycomb frame 7 and a support face 8, the honeycomb frame 7 being projecting and secured to the support face 8. The honeycomb frame 7 can be manufactured by injecting the composite material into a mold or by 3D printing.

[0033] In the embodiment illustrated in Figures 1 to 6, the support face 8 defines the rear face of the backrest 2. The backrest 2 is also delimited laterally by a peripheral edge 9. According to one embodiment of the invention, the honeycomb frame 7 extends over the entire surface of the backrest 2. The honeycomb frame 7 extends, here, from the upper part 3 to the lower part 4 of the backrest 2. In the embodiment illustrated in Figures 1 to 6, the honeycomb frame 7 extends in front of the support face 8.

[0034] According to one embodiment of the invention, the cellular framework 7 comprises at least two groups of cells 10, 11, 12. Each group of cells 10, 11, 12 is a set of cells which are integral with each other and have common characteristics such as their dimensions or their geometric shape. Thus, the cellular framework 7 can be defined by a determined number of cells 13 which are integral with each other. The cells 13 are delimited by partitions which intersect and thereby generate a mesh of cells 13.

[0035] As illustrated in [Fig. 5], a first group of cells 10 extends partly at the level of the lower part 4 of the backrest 2. The first group of cells 10 also extends laterally on either side of the intermediate part 6 of the backrest 2. In this embodiment, the first group of cells 10 extends in a U pattern.

[0036] The first group of cells 10 defines a force-recovery structure which has the function, on the one hand, of providing lumbar support to a user in the lower part 4, and on the other hand, of stiffening the structure of the cellular frame 7 through the two lateral extensions 70 of the first group of cells 10 which rise on either side of the intermediate part 6 (see [Fig.5]).

[0037] In this respect, the first group of cells 10 comprises the cells whose dimensions are the smallest of the cellular framework 7. For example, the cells of the first group of cells 10 may comprise a mesh dimension of between 20 mm and 40 mm. According to another exemplary embodiment, the cells of the first group of cells 10 may comprise a mesh dimension of between 25 mm and 35 mm. It should be noted that the mesh dimension of a cell 13 is determined as a function of the spacing between the respective centers of two adjacent cells 13.

[0038] Preferably, all the cells 13 of the first group of cells 10 have the same dimensions. As illustrated in Figures 1 and 4, the cells 13 of the first group of cells 10 have a hexagonal cross-section.

[0039] The cellular frame 7 comprises a second group of cells 11 which extends at the level of the intermediate part 6 and defines a back support structure of the backrest 2. The intermediate part 6 must therefore support the back of a user of the vehicle, which may represent a mass of approximately 20 to 30 kg to be supported. Consequently, the second group of cells 11 is configured to cope with constraints of lesser importance than the first group of cells 10. This is why each cell 13 of the second group of cells 11 has larger dimensions compared to the dimensions of each cell 13 of the first group of cells 10.

[0040] According to one embodiment, the ratio between the dimensions of each cell 13 of the second group of cells 11 and the dimensions of each cell 13 of the first group of cells 11 is at least 1.5. For example, the cells of the second group of cells 11 may comprise a mesh dimension of between 40 mm and 60 mm.

[0041] According to another exemplary embodiment, the cells of the second group of cells 11 may comprise a mesh dimension of between 45 mm and 55 mm. Preferably, all the cells of the second group of cells 11 have the same dimensions. As illustrated in Figures 1 and 4, the cells 13 of the second group of cells 11 have a rectangular cross-section. However, the cross-section of the cells 13 of the second group of cells 11 may take another geometric shape.

[0042] According to one embodiment, the cellular frame 7 comprises a third group of cells 12 which defines a support zone for the padding of the seat. As illustrated in [Fig. 5], the third group of cells 12 extends in the upper part 3 of the backrest and peripherally at least on one side of the backrest 2. In the example of FIGS. 4 and 5, the backrest 2 is integrated into a bench seat 14 previously described, therefore the third group of cells 12 extends on a first side of the backrest 2 which is integrated into the passenger compartment of the vehicle. The second side which is opposite the first side of the backrest 2 and cooperates with the large backrest 15 of the bench seat 14, is constituted by a branch 70 of the first group of cells 10.

[0043] The dimensions of each cell 13 of the third group of cells 12 are greater than the dimensions of each cell 13 of the first group of cells 10. According to one embodiment, the ratio between the dimensions of each cell 13 of the third group of cells 12 and the dimensions of each cell 13 of the first group of cells is at least 2.

[0044] For example, the cells of the third group of cells 12 may comprise a mesh size which can be greater than 65 mm.

[0045] According to another exemplary embodiment, the cells of the second group of cells 11 may comprise a mesh dimension of between 70 mm and 90 mm. As illustrated in Figures 1 and 4, the cells 13 of the third group of cells 12 have a rectangular cross-section on the side of the backrest 2. However, the cross-section of the cells 13 of the third group of cells 12 may also take another geometric shape such as a trapezoidal or triangular shape. This is visible in Figures 1 and 4 in the upper part 3 of the backrest 2.

[0046] As can be seen in [Fig. 4], the cells 120 arranged in the upper corners of the cellular frame 7 may comprise connectors in order to removably secure the backrest 2 to a backrest of a bench seat or to the passenger compartment of the vehicle.

[0047] In the embodiment illustrated in Figures 1 to 6, the support face 8 constitutes the rear face of the backrest 2 and the honeycomb frame 7 projects in front of the rear face so as to define a receiving face 16 for the padding 17 of the backrest 2. In this embodiment, the receiving face 16 has a concave shape. This is particularly visible in [Fig. 2] in which the receiving face 16 is represented in a surface manner in order to better visualize the concavity of the receiving face.

[0048] The radius of the curve of the concavity may be different depending on the area of ​​the receiving face 16. In the example illustrated in [Fig.2], the concavity is more pronounced at the level of the intermediate part 5 of the backrest 2.

[0049] The concavity of the receiving face 16 makes it possible to reduce the quantity of padding compared to a backrest of the prior art, while maintaining a level of comfort similar to the backrests of the prior art.

[0050] As is particularly visible in [Fig. 6], the cells 13 of the cellular reinforcement 7 have different depths, which makes it possible to give a concave character to the receiving face 16. Here, the receiving face 16 is defined by the lines of the edges of the mesh of the cells 13 of the cellular reinforcement 7.

[0051] In particular, the depth of the cells 13 is minimal at the center of the cellular framework 7 and the depth of the cells 13 increases as the position of the cells 13 is moved away from the center of the cellular framework 7. More particularly, the progressive increase in the depth of the cells 13 is made in two directions perpendicular to each other. In this example, the progressive increase in the depth of the cells 13 is made in a first direction parallel to the axis AA and in a second direction parallel to a transverse axis BB which is perpendicular to the axis AA.

[0052] According to one embodiment of the invention, the depth of the peripheral cells 13 is at least twice as great as the depth of the cells 13 arranged in the center of the cellular framework 7. Here, the peripheral cells are cells 13 of which at least the outer face of a partition belongs to the peripheral edge 8 of the cellular structure 7.

[0053] [Fig. 6] which is a longitudinal section of the backrest 2 equipped with the padding 17 shows the progressive increase in the depth of the cells 13, in a direction parallel to the axis AA, as the position of the cells 13 is moved away from the center of the cellular frame 7.

[0054] According to one embodiment, the honeycomb frame 7 comprises at least one receiving housing 18 for a rod of a headrest. As illustrated in [Fig.l], the receiving housing 18 comprises an opening 19 which is formed in the peripheral edge 9 of the upper part 3 of the backrest 2. The opening 19 allows the insertion of a rod of the headrest.

[0055] In the example illustrated by the figures in the appendix, the receiving housing 18 is defined by coaxial openings 20 of the partitions of a defined number of cells 13 arranged along a longitudinal axis which is parallel to the axis AA of the backrest 2. A first portion of the receiving housing 18 extends through the third group of cells 12 and a second portion of the receiving housing 18 extends through a determined number of cells 13 belonging to the second group of cells 11.

[0056] Preferably, the honeycomb frame 7 comprises two receiving housings 18 which extend respectively along two axes parallel to each other and arranged on either side of the axis AA.

[0057] In the event of an impact, the headrest is subjected to strong stresses to keep the user's head in position. This is why, around the receiving housings 18, the honeycomb structure 7 may comprise mechanical reinforcement elements.

[0058] The mechanical reinforcement elements may comprise a double wall 21. In this example, the double wall is arranged at the interface between the third group of cells 12 and the second group of cells 11. The mechanical reinforcement elements may also comprise a reinforcement structure 22 arranged at the first portion of the receiving housing 18.

[0059] According to one embodiment, the backrest 2 may comprise, respectively on either side of the lower part 4, a coupling means 23, 24 to a seat support 25, 26 of the seat system 1. Each coupling means 23, 24 may comprise at least one metal insert to stiffen the honeycomb frame 7 at the coupling means 23, 24. In the example of FIGS. 1 and 4, the height of the coupling means 23, 24 is different on each side of the backrest 2 in order to be integrated on the supports 25, 26 of the bench 14. However, the height of the coupling means 23, 24 may also be identical depending on the type of seat system 1 in which the backrest 2 is integrated.

[0060] According to one embodiment, the backrest 2 may comprise a metal reinforcement bar which extends behind the force-recovery structure. The reinforcement bar is not visible in the figures, however the reinforcement bar may be embedded in the composite material of the cellular frame 7 and arranged opposite the first group of cells 10. For example, the reinforcement bar may have a U shape. The reinforcement bar makes it possible to stiffen the structure of the backrest 2 in the event of impact of the luggage on the rear of the backrest 2.

[0061] In the embodiment illustrated in Figures 4 and 5, the backrest 2 is integrated into a three-seater bench seat 14 of a vehicle. In this case, it is preferable to integrate a backrest 2 made of composite material in place of the backrest which does not support the anchor point of the belt of the central seat. Thus, in this example, it is the folding backrest which corresponds to 40% of the length of the bench seat 14 which integrates a backrest 2 conforming to the present invention.

Claims

Claims

1. Vehicle seat system (1) comprising a backrest (2) made of composite material which comprises: - an upper part (3) configured to support a headrest, - a lower part (4) configured to be secured to at least one seat (5) of the seat system (1), - an intermediate part (6) which is configured to support a passenger's back, and - a projecting honeycomb frame (7) secured to a support face (8), the honeycomb frame (7) extending from the upper part (3) to the lower part (4) of the backrest (2), characterized in that the honeycomb frame (7) comprises at least two groups of cells (10, 11, 12): - a first group of cells (10) extending, on the one hand, on the lower part (4) of the backrest (2), and on the other hand, laterally on either side on the other side of the intermediate part (6) of the backrest (2), the first group of cells (10) defining a force-recovery structure,and - a second group of cells (11) extends at the level of the intermediate part (6) and defines a dorsal support structure of the backrest (2), each cell (13) of the first group of cells (10) has smaller dimensions compared to the dimensions of each cell (13) of the second group of cells (11).,

2. A vehicle seat system (1) according to claim 1, wherein the ratio of the dimensions of each cell (13) of the second group of cells (11) to the dimensions of each cell (13) of the first group of cells (10) is at least 1.

5.

3. Vehicle seat system (1) according to one of claims 1 and 2, in which the honeycomb frame (7) comprises a third group of cells (12) which defines a support zone for a mattress on the backrest (2) and which extends in the upper part (3) of the backrest (2) and peripherally at least on one side of the backrest (2), the dimensions of each cell (13, 120) of the third group of cells (12) are greater than the dimensions of each cell (13) of the first group of cells (10).

4. A vehicle seat system (1) according to claim 3, wherein the ratio of the dimensions of each cell (13, 120) of the third group of cells (12) to the dimensions of each cell (13) of the first group of cells (10) is at least 2.

5. Vehicle seat system (1) according to one of claims 1 to 4, in which the support face (8) constitutes the rear face of the backrest (2) and the honeycomb frame (7) projects in front of the rear face so as to define a receiving face (16) for the padding of the backrest (2), the receiving face (16) having a concave shape.

6. Vehicle seat system (1) according to claim 5, wherein the cells (13) of the honeycomb frame (7) have different depths so as to define the concave shape of the receiving face (16).

7. A vehicle seat system (1) according to claim 6, wherein the depth of the cells (13) is minimal at the center of the cell frame (7) and the depth of the cells (13) increases as the position of the cells (13) is moved away from the center of the cell frame (7).

8. Seat system (1) according to one of claims 1 to 7, in which the honeycomb frame (7) comprises at least one receiving housing (18) for a rod of a headrest, on the one hand, the receiving housing (18) is open at a peripheral edge (9) of the upper part (3) of the backrest (2), and on the other hand, the receiving housing (18) is defined by coaxial openings (20) of partitions of a defined number of cells (13) arranged along a longitudinal axis of the backrest (2).

9. Seat system (1) according to one of claims 1 to 8, in which the backrest (2) comprises respectively on either side of the lower part a coupling means (23, 24) to a seat support (25, 26) of the seat system, each coupling means (23, 24) comprising at least one metal insert for stiffening the honeycomb frame (7) at the coupling means (23, 24).

10. Seat system (1) according to one of claims 1 to 9, in which the backrest (2) comprises a metal reinforcement bar which extends behind the force-recovery structure. 12

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