Comfortable multilayer air fiber structure, method for manufacturing the same, and seat cushion, backrest, and seat made from the comfortable multilayer air fiber structure.

Abstract

The comfortable multilayer air fiber structure disclosed in this invention includes a comfortable upper layer and a supporting lower layer, each of which is manufactured by hot-pressing single-layer air fiber sheets formed from air fibers with different spinning directions, and the bottom surface of the comfortable upper layer is mechanically connected to the top surface of the supporting lower layer. The invention also discloses a method for manufacturing the comfortable multilayer air fiber structure. The seat cushion or backrest disclosed in this invention is manufactured from the above-described comfortable multilayer air fiber structure. The seat disclosed in this invention is formed from the above-described seat cushion and backrest. The invention satisfies the requirements for comfort by adjusting the density and hardness of the comfortable upper layer and the supporting lower layer, while also achieving the objective of material saving.

Description

[Technical Field]

[0001] The present invention relates to the technical field of seats. In particular, the present invention relates to a comfortable multilayer air fiber structure applicable to seat backrests and seat cushions, a method for manufacturing the same, and a seat cushion, backrest, and seat made from the comfortable multilayer air fiber structure. [Background technology]

[0002] Currently, seat cushions and backrests are generally formed by extruding single-layer air fiber sheets, meaning that the molding of the air fiber sheet can only be controlled in one direction. Such single-layer molded products typically have the disadvantages of high density and uneven hardness. Refer to Figure 1, taking a seat cushion as an example. When a seat cushion is made from a single-layer air fiber sheet, the thickness B1 at the maximum thickness span must exceed 60 mm, while the thickness B2 at the minimum thickness span is less than 30 mm. As a result, the compression exceeds 30 mm, and the hardness of the entire seat cushion becomes uneven.

[0003] On October 29, 2021, the applicant filed Patent Document 1 with the China National Intellectual Property Administration as "Thermoplastic Fiber Web Structure and Automotive Interior Parts." This patent application discloses a front seat cushion, which includes transverse pieces supplied separately and later fused together (see Figure 2). The disclosed automotive interior part is a front backrest, which includes longitudinal pieces supplied separately and later fused together (see Figure 3).

[0004] The solution proposed in this patent can improve the flexibility of the seat's density and hardness to some extent, and thus improve comfort, but there is still a need for further improvement. After continued research by the applicant, it has been found that the spinning direction of the air fibers during the molding of the thermoplastic fiber web sheet, and the subsequent pressing process, have a significant influence on the overall flexibility of the seat's density and hardness, as well as the improvement of ride comfort, during the manufacturing process of the seat cushion and backrest. Therefore, the present invention is proposed.

[0005] The present invention primarily aims to solve the problem that, currently, when a seat cushion or backrest is formed by hot pressing a single-layer air fiber sheet, the compression ratio becomes uneven, and therefore the density and hardness become non-uniform, making it impossible to meet the requirements for comfort. It also aims to mitigate the problem of material waste caused by excessive compression during the process of forming a seat cushion or backrest by hot pressing a single-layer air fiber sheet. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Chinese Patent Application Publication No. 113930900(A) [Overview of the project] [Means for solving the problem]

[0007] Therefore, one of the technical problems to be solved by the present invention is to provide a novel, comfortable, multilayer air fiber structure.

[0008] The second technical problem to be solved by the present invention is to provide a method for producing a comfortable multilayer air fiber structure.

[0009] A third technical problem to be solved by the present invention is to provide a seat cushion made from the above-described comfortable multilayer air fiber structure.

[0010] A fourth technical problem to be solved by the present invention is to provide a backrest made from the above-described comfortable multilayer air fiber structure.

[0011] A fifth technical problem to be solved by the present invention is to provide a seat formed by the above-described seat cushion and backrest.

[0012] According to a first aspect of the present invention, the comfortable multilayer air fiber structure of the present invention comprises a comfortable upper layer and a supporting lower layer, the comfortable upper layer and the supporting lower layer being formed by hot pressing of single-layer air fiber sheets made from air fibers with different spinning directions, and the bottom surface of the comfortable upper layer being mechanically connected to the top surface of the supporting lower layer.

[0013] Thermoplastic elastomers, abbreviated as TPE or TPR (abbreviation for thermoplastic rubber), are materials known to those skilled in the art. Thermoplastic elastomers are a type of elastomer that has the elasticity of rubber at room temperature and plasticity at high temperatures. Suitable materials for thermoplastic elastomers include TPEE (thermoplastic polyester elastomer) and POE ( Polyolefins Elastomer ) This includes TPO (olefin-based thermoplastic elastomer), etc. Structurally, thermoplastic elastomers are characterized by different resin and rubber parts formed by chemical bonds. The resin parts form physical crosslinks through inter-chain forces, while the rubber parts are highly elastic chains that contribute to elasticity. The physical crosslinks of the plastic parts change reversibly with temperature changes, which demonstrates the plastic processing characteristics of thermoplastic elastomers. Therefore, thermoplastic elastomers possess the physical and mechanical properties of vulcanized rubber and the processability of thermoplastic plastics, making them intermediate polymer materials between rubber and resin. In the automotive industry, for example in seat technology, these fibrous thermoplastic fibrous materials (also known as "air fibers") are typically formed into mesh structures within specific equipment and used as thin sheets for manufacturing automotive accessories and interior parts, such as seats.

[0014] In the context of the present invention, "comfortable upper layer" refers to the portion of the seat cushion and backrest that is in contact with the human body leaning against the seat cushion and backrest, respectively, in a normal seated position, and has at least an upper surface, a lower surface, and a side defined between these two surfaces. The upper surface of the comfortable upper layer faces the occupant's body, and the lower surface faces away from the occupant's body. For example, the comfortable upper layer of the seat cushion usually contacts the buttocks and legs of the human body, and the comfortable upper layer of the backrest contacts the back, head, and neck of the human body. The comfortable upper layer itself may consist of one or more regions formed from air fiber sheets of different hardness or density.

[0015] In a preferred embodiment of the present invention, the comfort upper layer may encompass an insertion area and two bolster areas, with the insertion area positioned between the two bolster areas. The insertion area may be positioned in the center of the comfort upper layer between the two bolster areas to provide comfort to the human body, while the two bolster areas provide enveloping comfort to the human body. Preferably, the density of air fibers in the insertion area is less than the density of air fibers in the bolster areas.

[0016] In the context of the present invention, “supporting lower layer” refers to the portion of the seat cushion and backrest of a seat that does not come into contact with the human body in a normal seated position, is located on the side away from the human body from the comfortable upper layer, and primarily serves to support the comfortable upper layer. The supporting lower layer has at least an upper surface, a lower surface, and sides defined between these two surfaces. The upper surface of the supporting lower layer faces the occupant's body, and the lower surface faces away from the occupant's body. For example, the supporting lower layer of a seat cushion is usually located directly below the comfortable upper layer of the seat cushion, and the supporting lower layer of a backrest is usually located behind the comfortable upper layer of an upright backrest. In one embodiment, the supporting lower layer may encompass the remaining portion of the seat cushion and backrest elements of the seat, excluding the comfortable upper layer, which is made of air fiber sheets.

[0017] In the context of the present invention, the "spinning direction" refers to the direction in which air fibers are discharged from the machine along the nozzles during the formation of the air fiber thin plate in the production process of the comfortable upper layer, the supporting lower layer or their respective lower regions. The spinning direction determines the direction in which the fibers are aligned or oriented within the thin plate.

[0018] "The spinning directions are different" means that the spinning direction M of the air fibers in the comfortable upper layer and the spinning direction N of the air fibers in the supporting lower layer are not collinear or parallel.

[0019] In an advantageous embodiment of the present invention, the spinning direction M of the air fibers in the comfortable upper layer and the spinning direction N of the air fibers in the supporting lower layer form an included angle of 55° to 90°, preferably 65° to 90°, for example 75° to 85°. In the present invention, the "included angle" is defined as the angle formed by the intersection line of two different directions, for example, the intersection line of two different spinning directions (for example, an X-shaped intersection line), and the value of this included angle is always represented by an acute angle or a right angle of 90° or less. For example, when the actual vectors of the two spinning directions are 135°, the included angle will be defined as 45°. In particular, when the included angle between the spinning direction M and the spinning direction N of the fibers of the two layers exceeds the above range, this will adversely affect the uniformity of the density and hardness of the seat cushion and the backrest of the produced sheet, and thus the riding comfort may be significantly deteriorated.

[0020] In a preferred embodiment of the present invention, the spinning direction M of the air fibers in the comfortable upper layer is perpendicular or substantially perpendicular to the spinning direction N of the air fibers in the supporting lower layer.

[0021] According to the present invention, in order to obtain a comfortable upper layer or a supporting lower layer, it is necessary to spin air fibers, form a fiber thin plate, and then press the fiber thin plate. During the pressing process, the cross-sections of the fiber thin plates of the comfortable upper layer and the supporting lower layer are compressed and may be deformed to a certain extent due to the pressure. Therefore, a difference may occur between the cross-section of the pressed fiber thin plate and the cross-section of the fiber thin plate that is not pressed at the initial stage. By adjusting the spinning direction according to the change amount of the cross-section after pressing, the adverse effect of pressing on the density and hardness of the comfortable upper layer can be reduced.

[0022] In a preferred embodiment of the present invention, the spinning direction M of the comfortable upper-layer air fiber is substantially perpendicular to the extension of the cross-section with the least change amount after pressing, and / or the spinning direction N of the supporting lower-layer air fiber is substantially perpendicular to the extension of the cross-section with the least change amount after pressing.

[0023] In a preferred embodiment of the present invention, the spinning direction of the comfortable upper-layer air fiber is substantially perpendicular to the extension of the maximum cross-section after pressing, and / or the spinning direction of the supporting lower-layer air fiber is substantially perpendicular to the extension of the maximum cross-section after pressing.

[0024] The change amount of the cross-section may be determined by comparing the area change amounts of a certain cross-section on the thin plate before and after pressing. Preferably, the cross-section with the least change amount after pressing is the maximum cross-section after pressing.

[0025] In a more preferred embodiment, the cross-section with the least change amount after pressing is a cross-section perpendicular to the longitudinal extension line of the comfortable upper layer in the thin plate, or a cross-section perpendicular to the lateral extension line of the supporting lower layer.

[0026] In this specification, the "longitudinal extension line" of the comfort upper or support lower layer refers to a straight line within the comfort upper or support lower layer that is parallel to the line of the cross-section (e.g., a sagittal plane perpendicular to the ground) that divides the human body into symmetrical parts when the occupant is in a normal seated position and leaning against the seat cushion and backrest. Therefore, in the case of a seat cushion, the longitudinal extension line of the comfort upper layer is a line in the front-to-back direction relative to the occupant. The longitudinal extension line can indicate the distance between two sides of the comfort upper or support lower layer of the seat cushion in the longitudinal direction, and may also correspond to the direction of movement of the vehicle, for example, in a car. Correspondingly, a cross section perpendicular to the longitudinal extension line is a cross section in the direction from the left to the right (or right to the left) direction of the occupant, and may correspond to the cross section in the width direction of the vehicle, for example, in a car, and is perpendicular to the ground as a whole. Regarding the backrest, the longitudinal extension of the comfort upper layer is a line in the vertical direction relative to the occupant and is perpendicular to the direction from left to right (or right to left) of the occupant. The longitudinal extension can indicate the distance between two sides in the longitudinal direction of the comfort upper or support lower layer of the backrest.

[0027] In this specification, the “lateral extension line” of the comfort upper layer or support lower layer refers to a straight line within the comfort upper layer or support lower layer that is perpendicular to the line of the cross-section (e.g., the sagittal plane perpendicular to the ground) that divides the human body into symmetrical parts when the occupant is in a normal seated position and leaning against the seat cushion and backrest. Therefore, the “lateral extension line” and the “longitudinal extension line” are perpendicular to each other. Thus, in the case of a seat cushion or backrest, the lateral extension line of the support lower layer is a line in the lateral direction (from left to right or right to left) relative to the occupant, and may correspond to the width direction of the vehicle, for example, in a car. Correspondingly, the cross section perpendicular to the lateral extension line is a cross section parallel to the occupant's sagittal plane, and may correspond to the cross section in the longitudinal direction of the vehicle, for example, in a car, and is perpendicular to the ground as a whole. The “lateral extension line” of the comfort upper layer or support lower layer can indicate the distance between their two sides in the width direction.

[0028] Accordingly, in another embodiment, the spinning direction of the air fibers of the comfort upper layer may be substantially parallel to the longitudinal extension of the comfort upper layer, and / or the spinning direction of the air fibers of the support lower layer may be substantially parallel to the transverse extension of the support lower layer.

[0029] In another exemplary embodiment, the spinning direction of the air fibers in the comfortable upper layer of the seat cushion may be substantially parallel to the X direction, the spinning direction of the air fibers in the comfortable upper layer of the backrest may be substantially parallel to the Z direction, and / or the spinning direction of the air fibers in the supporting lower layer of the seat cushion and backrest may be substantially parallel to the Y direction. In this embodiment, the X, Y, and Z directions are defined as follows: When the occupant is leaning against the seat cushion and backrest in a normal seating position and the seat cushion and backrest are substantially perpendicular to each other, the Z direction is the height direction of the vehicle, i.e., the direction perpendicular to the ground, the Y direction is the width direction of the vehicle, perpendicular to both the X and Z directions, and the X direction is the length direction or direction of movement of the vehicle, perpendicular to both the Y and Z directions.

[0030] Here, it can be recognized by those skilled in the art that the "width direction" and "length direction" related to the seat cushion or backrest, as described above, are actually relative to the direction of the occupant or vehicle, and do not depend on the actual length value. In other words, for example, the actual distance between two sides of a seat cushion in the width direction may exceed the actual distance between two sides in the length direction.

[0031] In the context of the present invention, the term “approximately perpendicular” means that the angle between two lines or planes (for example, the angle between M and N) is 75° to 90°, preferably 80° or 85° to 90°, for example 88°, as can always be determined from the fact that the intersecting angle is acute. This can mean, for example, that the spinning direction is deflected by 15° or less or by only 10°, for example, by at most 8°, 5°, 3° or 1°, with reference to the vertical line of a certain cross-section.

[0032] Furthermore, it will be obvious to those skilled in the art that the aforementioned "cross-section" may be understood as a "normal cross-section" distinct from an "oblique cross-section."

[0033] In the context of the present invention, the term “approximately parallel” means that, as always determined from the fact that the intersecting angle is acute, the angle between two lines or planes is 15° or 10° to 0°, preferably 5° to 0°, for example, less than 2°.

[0034] In a preferred embodiment of the present invention, the comfortable upper insertion area has a thickness of 10 to 50 mm.

[0035] In a preferred embodiment of the present invention, the comfortable upper insertion area is 30-50 kg / m 3 It has a density of .

[0036] In a preferred embodiment of the present invention, the comfortable upper bolster region is 40-70 kg / m². 3 It has a density of .

[0037] In a preferred embodiment of the present invention, the supporting layer has a thickness of 10 to 50 mm.

[0038] In a preferred embodiment of the present invention, the support layer is 40-70 kg / m 3 It has a density of .

[0039] In a preferred embodiment of the present invention, the density and hardness of the comfortable upper layer and supporting lower layer are adjustable. In an advantageous embodiment, this adjustment can be achieved, for example, by changing the thickness of the single fibers by adjusting the height or discharge speed of the spinning apparatus nozzle relative to the water level, or by adjusting the draw speed, the density of the holes in the spinneret, or the softness and hardness of the material itself. Furthermore, such adjustments can also be achieved during the hot pressing process. For example, by increasing the thickness difference between the sheet and the final product, the amount of compression can be increased, and therefore the hardness and density of the product can be increased. Conversely, the smaller the thickness difference and the smaller the amount of compression, the closer the density and hardness of the product will be to the density and hardness of the sheet.

[0040] According to the present invention, after the comfortable upper layer and the supporting lower layer are manufactured, the bottom surface of the comfortable upper layer needs to be connected to the top surface of the supporting lower layer by a mechanical connection.

[0041] In a preferred embodiment of the present invention, the mechanical connection includes connecting the bottom surface of the comfort upper layer to the top surface of the support lower layer by one or any two of the following means: suspension wire and C-rings, hook-and-loop fasteners, felt cloth, magnetic powder sheets, binders, pins and insertion sleeves, elastomers, direct snapping, annular hooks and surface protection molding strips, and reinforcing connection layers and hot irons.

[0042] In a preferred embodiment of the present invention, the connecting means using felt cloth includes integrally forming the supporting lower layer with a porous adhesive-coated felt cloth by in-mold hot pressing, and joining this supporting lower layer to the comfortable upper layer through a porous binder layer by heating and pre-pressing.

[0043] In a preferred embodiment of the present invention, a reinforced connecting layer is provided at the connection between a comfortable upper layer and a supporting lower layer.

[0044] The method for producing a comfortable multilayer air fiber structure according to the present invention involves the following steps: Step 1: Continuously spinning air fibers in the spinning direction M to form a comfortable upper layer of air fiber sheets, and then heat-pressing the comfortable upper layer of air fiber sheets to form the comfortable upper layer. Step 2: The air fibers are continuously spun in the spinning direction N to form a thin air fiber sheet for the support layer, and then the air fiber sheet for the support layer is heat-pressed to form the support layer. Step 3: Connect the bottom surface of the comfortable upper layer to the top surface of the supporting lower layer by mechanical connection to form a comfortable multilayer air fiber structure. It includes, The spinning direction M and the spinning direction N are different.

[0045] In a preferred embodiment of the present invention, the spinning direction M of the comfortable upper layer air fibers and the spinning direction N of the supporting lower layer air fibers form a combined angle of 55° to 90°, preferably 65° to 90°, for example, 75° to 85°.

[0046] In a preferred embodiment of the present invention, the method involves the following steps: Step 1': The air fibers are continuously spun in a spinning direction approximately perpendicular to the direction of the maximum cross-section of the comfortable upper layer to form a thin sheet of air fibers for the comfortable upper layer, and then the thin sheet of air fibers for the comfortable upper layer is heat-pressed to form the comfortable upper layer. It includes.

[0047] In a preferred embodiment of the present invention, the method involves the following steps: Step 2': The air fibers are continuously spun in a spinning direction approximately perpendicular to the direction of the maximum cross-section of the support layer to form an air fiber sheet of the support layer, and then the air fiber sheet of the support layer is heat-pressed to form the support layer. It includes.

[0048] The seat cushion of the present invention is made from the comfortable multilayer air fiber structure described above.

[0049] The backrest of the present invention is made from the comfortable multilayer air fiber structure described above.

[0050] The seat of the present invention is formed by a seat cushion and a backrest as described above.

[0051] Finally, the present invention also relates to a vehicle that incorporates the seat as described above. The vehicle is preferably an automobile, such as a car, bus or truck, train, airplane or spacecraft.

[0052] By employing the aforementioned technical solution, the comfortable upper layer and supporting lower layer within the seat cushion and backrest of the seat are each manufactured by hot pressing air fiber sheets formed from air fibers with different spinning directions, and the bottom surface of the comfortable upper layer is mechanically connected to the top surface of the supporting lower layer. In this way, the present invention satisfies the requirements for comfort by adjusting the density and hardness of the comfortable upper layer and supporting lower layer, while simultaneously achieving the objective of material saving. [Brief explanation of the drawing]

[0053] [Figure 1] This is a schematic cross-sectional view of an existing seat cushion manufactured by hot pressing a single layer of air fiber sheet. [Figure 2] This is a schematic diagram of the front seat cushion as described in Patent Document 1. [Figure 3] This is a schematic diagram of the front backrest as described in Patent Document 1. [Figure 4] This is a schematic diagram of the comfortable upper layer within a seat cushion according to the present invention, which is formed by hot pressing a single layer of air fiber thin sheet. [Figure 5] This is a cross-sectional view taken along line A-A in Figure 4 (showing the maximum contour in the Y-Z plane of the comfortable upper layer). [Figure 6]This is a schematic perspective view of the comfortable upper layer within a seat cushion according to the present invention, which is formed by hot pressing a single layer of air fiber sheet. [Figure 7] This is a schematic diagram of the support lower layer within a seat cushion according to the present invention, which is formed by hot pressing a single layer of air fiber thin sheet. [Figure 8] This is a cross-sectional view taken along line A-A in Figure 7 (showing the maximum contour in the X-Z plane of the supporting sublayer). [Figure 9] This is a schematic perspective view of the support lower layer within a seat cushion according to the present invention, which is formed by hot pressing a single layer of air fiber thin sheet. [Figure 10] This is a schematic diagram of the comfortable upper layer within the backrest according to the present invention, which is formed by hot pressing a single layer of air fiber thin sheet. [Figure 11] This is a cross-sectional view taken along line A-A in Figure 10 (showing the maximum contour in the X-Y plane of the comfortable upper layer). [Figure 12] This is a schematic perspective view of the comfortable upper layer within the backrest according to the present invention, which is formed by hot pressing a single layer of air fiber sheet. [Figure 13] This is a schematic diagram of the support lower layer within the backrest according to the present invention, which is formed by hot pressing a single-layer air fiber sheet. [Figure 14] This is a cross-sectional view taken along line A-A in Figure 13 (showing the maximum contour in the X-Z plane of the supporting sublayer). [Figure 15] This is a schematic perspective view of the support lower layer within a backrest according to the present invention, which is formed by hot pressing a single layer of air fiber sheet. [Figure 16] This is a schematic cross-sectional view of a seat cushion formed from the comfortable multilayer air fiber structure of the present invention. [Figure 17] This is a schematic cross-sectional view of a backrest formed from the comfortable multilayer air fiber structure of the present invention. [Figure 18] This is a schematic cross-sectional view of Embodiment 1 of the present invention. [Figure 19] This is a schematic cross-sectional view of Embodiment 2 of the present invention. [Figure 20]This is a schematic cross-sectional view of Embodiment 3 of the present invention. [Figure 21] This is a schematic cross-sectional view of Embodiment 4 of the present invention. [Figure 22] This is a schematic cross-sectional view of Embodiment 5 of the present invention. [Figure 23] This is a schematic diagram showing the connection between a comfortable upper layer and a supporting lower layer, formed by using annular hooks, surface protection molded strips, and a reinforcing connecting layer to create a comfortable multilayer air fiber structure according to the present invention. [Figure 24] This is a schematic diagram showing the connection between the comfortable upper layer and the supporting lower layer, formed by direct snapping, for creating the comfortable multilayer air fiber structure of the present invention. [Figure 25a] This is a schematic diagram showing the connection between the comfortable upper layer and the supporting lower layer, formed by using a reinforcing connecting layer and a hot iron, for creating the comfortable multilayer air fiber structure of the present invention. [Figure 25b] This is a schematic diagram showing the connection between the comfortable upper layer and the supporting lower layer, formed by using a reinforcing connecting layer and a hot iron, for creating the comfortable multilayer air fiber structure of the present invention. [Figure 26] This is a schematic diagram showing a connecting means for forming the comfortable multilayer air fiber structure of the present invention, in which a supporting layer and a porous adhesive-coated felt cloth are integrally molded by hot pressing, and then joined to a comfortable layer together with a porous binder. [Figure 27] This is a schematic diagram showing an elastomer-based connecting means for forming the comfortable multilayer air fiber structure of the present invention. [Figure 28] This is a schematic diagram of a seat cushion formed by a comfortable multilayer air fiber structure of the present invention, using a binder, annular hooks, and adhesive felt fabric as connecting means. [Figure 29] This is a schematic diagram of a backrest formed by a comfortable multilayer air fiber structure of the present invention, using a binder, annular hooks, and adhesive felt fabric as connecting means. [Figure 30] This is a schematic diagram of a seat cushion in which the comfortable multilayer air fiber structure of the present invention is formed by connecting means using a binder and adhesive felt fabric. [Figure 31] This is a schematic diagram of a backrest formed by a comfortable multilayer air fiber structure of the present invention, using a binder and adhesive felt fabric as connecting means. [Figure 32] This is a schematic diagram of the first annular hook of the present invention. [Figure 33] This is a schematic diagram of the second annular hook of the present invention. [Figure 34] This is a schematic diagram of the third annular hook of the present invention. [Figure 35] This is a schematic diagram of the fourth annular hook of the present invention. [Figure 36] This is a schematic diagram of the fifth annular hook of the present invention. [Figure 37] This is a schematic diagram of the sixth annular hook of the present invention. [Figure 38] This is a schematic diagram of the X, Y, and Z directions as referred to in a particular embodiment of the present invention. [Modes for carrying out the invention]

[0054] The present invention will be further described with reference to the attached drawings and specific embodiments.

[0055] Referring to Figures 4 to 17, the illustrated comfortable multilayer air fiber structure may be used to make a seat cushion 20 and a backrest 10, the seat cushion and backrest each being divided into a comfortable upper layer 21, 11 and a support lower layer 22, 12.

[0056] The comfortable upper layers 21 and 11 and the supporting lower layers 22 and 12 are each made by hot pressing single-layer air fiber sheets formed from air fibers with different spinning directions, and the bottom surfaces of the comfortable upper layers 21 and 11 are mechanically connected to the top surfaces of the supporting lower layers 22 and 12.

[0057] Referring to Figures 4-6, the spinning direction of the air fibers in the comfortable upper layer 21 of the seat cushion 20 is perpendicular to the direction of the cross section where the change after pressing is minimized (i.e., the maximum cross section), that is, perpendicular to the plane of Figure 5. In other words, this spinning direction is perpendicular to the direction of the maximum contour in the Y-Z plane of the comfortable upper layer 21 of the seat cushion 20, that is, the X direction, which achieves the minimum compression (i.e., saves the most material). If spinning is performed along the plane of Figure 5, that is, along the Y or Z direction, there may also be air fibers in the cavity within the insertion region 21a, as well as within the two bolster regions 21b and 21c. During pressing, these air fibers have nowhere to go and can only be pressed into the insertion region 21a, as well as within the two bolster regions 21b and 21c, so in some cases there may be more air fibers in the insertion region 21a. This can result in the insertion region 21a becoming high-density and high-hardness, which can affect ride comfort and lead to unnecessary material waste.

[0058] As shown in Figure 38, a particular embodiment of the present invention describes a seat cushion and backrest of a seat in a normal mounting and usage state inside a vehicle, where the seat cushion and backrest are substantially perpendicular to each other. In these embodiments, the X, Y, and Z directions are related to a spatial orthogonal coordinate system, where the Z direction is the height direction of the vehicle, i.e., the direction perpendicular to the ground; the Y direction is the width direction of the vehicle, which is perpendicular to both the X and Z directions; and the X direction is the length direction of the vehicle, which is perpendicular to both the Y and Z directions.

[0059] The comfortable upper layer 21 of the seat cushion 20 is divided into one insertion area 21a and two bolster areas 21b and 21c. The insertion area 21a is located between the two bolster areas 21b and 21c and is the part that contacts the occupant's buttocks on the front side. The bolster areas 21b and 21c are protruding parts of the seat cushion 20 and are used to fix the position of the occupant's buttocks relative to the seat cushion 20 and to limit the occupant's buttocks.

[0060] The density of the air fibers in insertion region 21a differs from the density in the two bolster regions 21b and 21c. The density in insertion region 21a is 30-50 kg / m³. 3 The thickness of the insertion region 21a is 10 to 50 mm, and may be adjusted within this range. The density of the bolster regions 21b and 21c is 40 to 70 kg / m³. 3 This range may be adjusted. Hardness can be adjusted by adjusting the density.

[0061] After the comfortable upper layer 21 of the seat cushion 20 is formed by pressing, surface protection hooks 21d and 21e are pressed between the insertion area 21a and the two bolster areas 21b and 21c.

[0062] Referring to Figures 7-9, the spinning direction of the air fibers in the supporting lower layer 22 of the seat cushion 20 is also perpendicular to the direction of the cross-section where the change after pressing is minimized (i.e., the maximum cross-section), that is, perpendicular to the plane in Figure 8. In other words, this spinning direction is perpendicular to the direction of the maximum contour in the X-Z plane of the supporting lower layer 22 of the seat cushion 20, that is, the Y direction, and reaches the minimum compression amount (i.e., saves the most material). The density of the supporting lower layer 22 of the seat cushion 20 is 40-70 kg / m³ 3 This range may be adjusted. Hardness can be adjusted by adjusting the density.

[0063] Referring to Figures 10-12, the spinning direction of the air fibers in the comfortable upper layer 11 of the backrest 10 is perpendicular to the plane of Figure 11, which is the direction of the cross section where the change after pressing is minimized (i.e., the maximum cross section). In other words, this spinning direction is perpendicular to the direction of the maximum contour in the X-Y plane of the comfortable upper layer 11 of the backrest 10, i.e., the Z direction, which achieves the minimum compression (i.e., saves the most material). Similarly, if spinning is performed along the plane of Figure 11, there may also be air fibers in the cavity within the insertion region 11a, as well as within the two bolster regions 11b and 11c. During pressing, these air fibers have nowhere to go and can only be pressed into the insertion region 11a, as well as within the two bolster regions 11b and 11c, so in some cases there may be more air fibers in the insertion region 11a. This can result in the insertion region 11a becoming high density and high hardness, which therefore affects ride comfort and leads to unnecessary material waste.

[0064] The comfortable upper layer 11 of the backrest 10 is divided into one insertion area 11a and two bolster areas 11b and 11c. The insertion area 11a is located between the two bolster areas 11b and 11c and is the part that contacts the occupant's back on the front side. The bolster areas 11b and 11c are protruding parts of the backrest 10 and are used to fix the position of the occupant's back relative to the backrest 10 and to limit the occupant's back.

[0065] The density of air fibers within insertion region 11a differs from the density of air fibers within the two bolster regions 11b and 11c. The density within insertion region 11a is 30-50 kg / m³. 3 The thickness of the insertion region 11a is 10 to 50 mm, and may be adjusted within this range. The density within the bolster regions 11b and 11c is 40 to 70 kg / m³. 3 This range may be adjusted. Hardness can be adjusted by adjusting the density.

[0066] After the comfortable upper layer 11 of the backrest 10 is formed by pressing, surface protection hooks 11d and 11e are pressed between the insertion region 11a and the two bolster regions 11b, 11c.

[0067] Referring to FIGS. 13 to 15, the spinning direction of the air fiber of the support lower layer 12 of the backrest 10 is also the direction of the cross section with a small change amount after pressing, preferably the direction of the maximum cross section, that is, perpendicular to the plane of FIG. 14. In other words, this spinning direction is perpendicular to the direction of the maximum contour in the X-Z plane of the support lower layer 12 of the backrest 10, that is, the Y direction, and reaches the minimum compression amount (that is, the most material is saved). The density of the support lower layer 12 of the backrest 10 is 40 to 70 kg / m 3 and may be adjusted within this range. The adjustment of the hardness can be achieved by adjusting the density.

[0068] In the prior art, since the thickness of the thickest area formed by hot pressing of a single-layer air fiber thin plate is interpreted as the thickness of the single-layer air fiber thin plate, in a relatively thin product, the compression amount may increase, and the density after thermoforming may reach 105 kg / m 3 or more. On the other hand, in the present invention, since at least two layers of air fiber thin plates are hot pressed, the insertion regions of the comfortable upper layers 11, 21 and the entire support lower layers 12, 22 produced have a consistently small compression amount and have a density of less than 80 kg / m after thermoforming. 3 For example, the density of the comfortable upper layers 11, 21 is 30 to 50 kg / m 3 and the density of the support lower layer is 40 to 70 kg / m 3 is.

[0069] In a specific embodiment according to the present invention, a thin plate made of air fiber with its spinning directions M and N being 90° is used, and a double-layer comfortable upper layer and a support lower layer are produced respectively. Later, the comfortable upper layer and the support lower layer are compared with a single-layer molded product, and their respective measurement data are shown in Table 1.

[0070] In this embodiment, the density of each thin plate formed from air fiber is about 50 kg / m 3It is maintained in the following manner. A single-layer molded seat cushion or backrest contains a single sheet with a constant spinning direction of air fibers, whereas a double-layer molded seat cushion or backrest, which includes a comfortable upper layer and a support lower layer, contains two sheets with different spinning directions M and N, and are 90 degrees to each other. The sheets are pressed to obtain single-layer or double-layer molded parts. The volume of the sheets before pressing, the volume of each molded part after pressing, the density after pressing, and the weight after pressing are measured in the conventional manner, and these data are shown in Table 1. Furthermore, the weight loss rate is also calculated using the following formula. Weight reduction rate (%) = (Weight of double-layer molded part after pressing - Weight of single-layer molded part after pressing) / Weight of single-layer molded part after pressing

[0071] As can be seen in the table below, compared to a seat cushion 20 or backrest 10 formed by hot pressing a single layer of air fiber sheet, the density and weight are reduced by more than 25%, the compression is consistent, and the uniform hardness of the comfortable upper layers 11, 21 and the supporting lower layers 12, 22 can also be ensured.

[0072] [Table 1]

[0073] Referring to Figures 18 to 22, the comfortable upper layers 11 and 21 have a thickness of 10 to 50 mm, for example, 10 mm as shown in Figure 18, 20 mm as shown in Figure 19, 30 mm as shown in Figure 20, 40 mm as shown in Figure 21, and 50 mm as shown in Figure 22. The supporting lower layers 12 and 22 have a thickness of 10 to 50 mm, for example, 50 mm as shown in Figure 18, 40 mm as shown in Figure 19, 30 mm as shown in Figure 20, 20 mm as shown in Figure 21, and 10 mm as shown in Figure 22.

[0074] The density and hardness of the comfortable upper layers 11 and 21 and the supporting lower layers 12 and 22 are adjustable.

[0075] The bottom surfaces of the comfortable upper layers 11 and 21 and the top surfaces of the supporting lower layers 12 and 22 are connected by one or any two of the following means: suspension wires and C-rings, hook-and-loop fasteners, felt cloth, magnetic powder sheets, binders, pins and insertion sleeves, elastomers, direct snapping, annular hooks and surface protection molding strips, and reinforcing connecting layers and hot irons. Specifically, these are as follows:

[0076] Referring to Figure 23, the comfortable upper layers 11, 21 and the supporting lower layers 12, 22 are each molded using a mold to create connecting structures 11a, 12a, 21a, 22a that satisfy the interconnection between the comfortable upper layers 11, 21 and the supporting lower layers 12, 22, and reinforcing connecting layers 11b, 21b, 12b, 22b with a thickness of 0.4 to 4 mm are created. Subsequently, surface protection molding strips 41 are connected to the two reinforcing connecting layers 11b, 21b, 12b, and 22b using conventional annular hooks 31. This connection method is purely physical, reduces the assembly process and improves assembly strength, is environmentally friendly, has no excess VOC emissions, and does not affect the original performance of the seat cushion or backrest.

[0077] Referring to Figure 24, the comfortable upper layers 11, 21 and the supporting lower layers 12, 22 are each molded using a mold to create connecting structures 11a, 12a, 21a, 22a that satisfy the interconnection between the comfortable upper layers 11, 21 and the supporting lower layers 12, 22, and reinforcing connecting layers 11b, 21b, 12b, 22b with a thickness of 0.4 to 4 mm. During assembly, it is only necessary to insert the connecting structures 12a and 22a into the connecting structures 11a and 21a. This connection method is purely physical, which reduces the assembly process and improves assembly strength, is environmentally friendly, has no excess VOC emissions, and does not affect the original performance of the seat cushion or backrest.

[0078] Referring to Figures 25a and 25b, the comfort upper layers 11 and 21 and the support lower layers 12 and 22 are molded using a mold, respectively, to create connecting structures 11a, 12a, 21a, and 22a that satisfy the interconnection between the comfort upper layers 11 and 21 and the support lower layers 12 and 22, and to create reinforcing connecting layers 11b, 21b, 12b, and 22b with a thickness of 0.4 to 4 mm. Subsequently, a hot ironing machine 51 is used and heated to 210 to 250°C, thereby melting and connecting the reinforcing connecting layers 11b, 21b, 12b, and 22b together. This reduces the assembly process by eliminating the use of elements such as molded strips and annular hooks, while ensuring connection strength.

[0079] Referring to Figure 26, the support lower layers 12 and 22 and the porous adhesive felt fabric 62 are integrally molded by in-mold hot pressing. These support lower layers and porous adhesive felt fabric are then joined together with the comfortable upper layers 11 and 21 through a porous binder 61 by heating and pre-pressing. This allows the seat cushion or backrest to maintain breathability. The use of the porous binder 61 makes the connection between the comfortable upper layers 11 and 21 and the support lower layers 12 and 22, as well as the porous adhesive felt fabric 62, more stable and ensures breathability.

[0080] Referring to Figure 27, the use of an air-filled filament structure allows the elastomer 71 to be embedded in a built-in manner within the comfort upper layers 11, 21 and the support lower layers 12, 22. The elastomer 71 not only improves the overall support performance, elasticity, and compression fatigue deformation resistance of the seat cushion or backrest, but also acts as a connection between the comfort upper layers 11, 21 and the support lower layers 12, 22.

[0081] Referring to Figure 28, the seat cushion A is assembled from a comfortable upper layer 11, a support lower layer 12, a porous adhesive felt fabric 81, a porous binder 82, and an annular hook 83.

[0082] Referring to Figure 29, the backrest B is assembled from a comfortable upper layer 21, a support lower layer 22, a porous adhesive felt cloth 84, a porous binder 85, and an annular hook 86.

[0083] Referring to Figure 30, the seat cushion is assembled from a comfortable upper layer 11, a support lower layer 12, a porous adhesive felt fabric 82, and a porous binder 81.

[0084] Referring to Figure 31, the backrest is assembled from a comfortable upper layer 21, a support lower layer 22, a porous adhesive felt fabric 84, and a porous binder 85.

[0085] Referring to Figure 32, the opening 91aa of the annular hook 91a is less than 90°. Referring to Figure 33, triangular clips 91c are attached to both ends of the annular hook 91b. Referring to Figure 34, straps 91e and 91f are provided at the two ends of the annular hook 91d, and these straps overlap each other. Referring to Figure 35, the annular hook 91g is triangular, and triangular clips 91h are attached to both ends of the annular hook 91g. Referring to Figure 36, insertion sleeves 91j and pins 91k are equipped at the two ends of the annular hook 91i, and protrusions are provided on both the insertion sleeves 91j and pins 91k, with the pins 91k being inserted into the insertion sleeves 91j during assembly. Referring to Figure 37, insertion sleeves 91n and pins 91p are equipped at the two ends of the annular hook 91m, with the pins 91p being inserted into the insertion sleeves 91n during assembly.

[0086] The triangular clips 91c, straps 91e and 91f, triangular clip 91c, triangular clip 91h, insertion sleeve 91j, pin 91k, insertion sleeve 91n, and pin 91p described above can be made of metal, PP plastic, ABS plastic, and PA plastic.

Claims

1. A comfortable multilayer air fiber structure comprising a comfortable upper layer and a supporting lower layer, wherein the comfortable upper layer and the supporting lower layer are each manufactured by hot pressing single-layer air fiber sheets formed from air fibers with different spinning directions, and the bottom surface of the comfortable upper layer is mechanically connected to the top surface of the supporting lower layer. Comfortable multi-layer air fiber structure.

2. The comfortable multilayer air fiber structure according to claim 1, characterized in that the spinning direction M of the air fibers in the comfortable upper layer and the spinning direction N of the air fibers in the supporting lower layer form a bounding angle of 55° to 90°, preferably 65° to 90°, for example, 75° to 85°.

3. The comfortable multilayer air fiber structure according to claim 2, characterized in that the spinning direction M of the air fibers of the comfortable upper layer is substantially perpendicular to the extension of the cross-section where the amount of change after pressing is minimized, and / or the spinning direction N of the air fibers of the supporting lower layer is substantially perpendicular to the extension of the cross-section where the amount of change after pressing is minimized.

4. The comfortable multilayer air fiber structure according to claim 3, characterized in that the spinning direction of the air fibers in the comfortable upper layer is substantially perpendicular to the extension of the maximum cross-section after pressing, and / or the spinning direction of the air fibers in the supporting lower layer is substantially perpendicular to the extension of the maximum cross-section after pressing.

5. The comfortable multilayer air fiber structure according to claim 1, wherein the comfortable upper layer includes one insertion region and two bolster regions, the insertion region is located between the two bolster regions, and preferably the density of the air fibers in the insertion region is lower than the density of the air fibers in the bolster regions.

6. The comfortable multilayer air fiber structure according to claim 5, characterized in that the insertion region of the comfortable upper layer has a thickness of 10 to 50 mm.

7. The aforementioned comfortable upper insertion area has a load capacity of 30-50 kg / m ３ The comfortable multilayer air fiber structure according to claim 5, characterized by having a density of [density].

8. The aforementioned comfortable upper bolster region has a load capacity of 40-70 kg / m². ３ The comfortable multilayer air fiber structure according to claim 5, characterized by having a density of [density].

9. The comfortable multilayer air fiber structure according to claim 5, characterized in that the supporting lower layer has a thickness of 10 to 50 mm.

10. The aforementioned support layer has a load capacity of 40-70 kg / m ３ The comfortable multilayer air fiber structure according to claim 5, characterized by having a density of [density].

11. The comfortable multilayer air fiber structure according to claim 1, characterized in that the density and hardness of the comfortable upper layer and the supporting lower layer are adjustable.

12. The comfortable multilayer air fiber structure according to claim 1, characterized in that the mechanical connection specifically includes connecting the bottom surface of the comfortable upper layer to the top surface of the supporting lower layer by one or any two of the following means: suspension wire and C-ring, hook and loop fastener, felt cloth, magnetic powder sheet, binder, pin and insertion sleeve, elastomer, direct snapping, annular hook and surface protection molding strip, and a reinforcing connecting layer and a hot iron.

13. The connecting means using the felt cloth is, specifically, characterized in that the supporting lower layer is integrally molded with the porous adhesive-coated felt cloth by in-mold hot pressing, and then joined to the comfortable upper layer through the porous binder layer by heating and pre-pressing, as described in claim 12.

14. The comfortable multilayer air fiber structure according to claim 12 or 13, characterized in that a reinforcing connecting layer is provided at the connection between the comfortable upper layer and the supporting lower layer.

15. A method for producing a comfortable multilayer air fiber structure according to any one of claims 1 to 14, comprising the following steps: Step 1: Continuously spinning air fibers in the spinning direction M to form a comfortable upper layer of air fiber thin sheet, and then heat-pressing the comfortable upper layer of air fiber thin sheet to form the comfortable upper layer, Step 2: The air fibers are continuously spun in the spinning direction N to form the air fiber sheet of the support lower layer, and then the air fiber sheet of the support lower layer is heat-pressed to form the support lower layer. Step 3: Connect the bottom surface of the comfortable upper layer to the top surface of the supporting lower layer by mechanical connection to form the comfortable multilayer air fiber structure. Includes, A manufacturing method characterized in that the spinning direction M and the spinning direction N are different.

16. A seat cushion characterized by being made from a comfortable multilayer air fiber structure as described in any one of claims 1 to 14.

17. A backrest characterized by being made from a comfortable multilayer air fiber structure as described in any one of claims 1 to 14.

18. A seat characterized by being formed by a seat cushion according to claim 16 and a backrest according to claim 17.

19. A vehicle comprising the seat described in claim 18, preferably an automobile, such as a car, bus or truck, train, airplane or spacecraft.

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