Multi-material support pad

Abstract

To provide a vehicle seat.SOLUTION: A vehicle seat includes a seat base, a seat foam supported by the seat base, and a support pad positioned between the seat base and at least a portion of the seat foam. The support pad is formed of a combination of a first material and a second material. A seat cover covers the support pad and the seat foam. The first material has a first recovery hysteresis, and the second material has a second recovery hysteresis that is less than the first recovery hysteresis.SELECTED DRAWING: Figure 3

Description

Background Art

[0001] Parts of a vehicle such as a seat, a foot support, and a grip can define touch points for a driver of the vehicle (e.g., a motorcycle, an all-terrain vehicle, etc.). In the case of a seat, usually foam is used as the main component. During long-term use or a long journey, the seat foam may be compressed according to the riding conditions and may take a long time to return to its original shape. When compressed, the shock absorption characteristics of the material are impaired.

Summary of the Invention

[0002] In one aspect, the present invention provides a vehicle seat including a seat base, a seat foam supported by the seat base, a support pad positioned between at least a portion of the seat base and the seat foam, the support pad formed of a combination of a first material and a second material, and a seat cover covering the support pad and the seat foam. The first material has a first recovery hysteresis, and the second material has a second recovery hysteresis smaller than the first recovery hysteresis.

[0003] In another aspect, the present invention provides a vehicle seat including a seat base, a seat foam supported by the seat base, and a support pad positioned between at least a portion of the seat base and the seat foam. The support pad includes an elastomeric skeleton and a gel overmold portion on the elastomeric skeleton. A seat cover covers the support pad and the seat foam.

[0004] In another embodiment, the present invention provides a method for assembling a seat for a vehicle. The method includes providing a seat base, providing a seat foam supported by the seat base, forming support pads on an elastomer skeleton and a gel-like overmolded portion on the skeleton, positioning the support pads between the seat base and at least a portion of the seat foam, and covering the support pads and the seat foam on the seat base with a seat cover.

[0005] Other aspects of the present invention will become apparent from the detailed description and the accompanying drawings. [Brief explanation of the drawing]

[0006] [Figure 1] This is a perspective view of a vehicle seat according to one embodiment of the present invention.

[0007] [Figure 2] This is a cross-sectional view of the sheet along line 2-2 in Figure 1.

[0008] [Figure 3] Figure 1 shows a perspective view and exploded view of the sheet.

[0009] [Figure 4] Figure 1 is a perspective view of the seat support pad.

[0010] [Figure 5] Figure 4 is a perspective view of a portion of the support pad.

[0011] [Figure 6] This is a perspective view of a portion of a support pad according to another embodiment of the present invention.

[0012] [Figure 7] This is a perspective view of a portion of a support pad according to another embodiment of the present invention.

[0013] [Figure 8] This is a perspective view of a portion of a support pad according to another embodiment of the present invention.

[0014] [Figure 9] This is a perspective view of a portion of a support pad according to another embodiment of the present invention.

[0015] [Figure 10] A perspective view of a motorcycle according to one embodiment of the present invention.

[0016] [Figure 11] This is a schematic diagram of a LiDAR wearable according to one embodiment of the present invention. [Modes for carrying out the invention]

[0017] Before describing embodiments of the present invention in detail, it should be understood that the present invention is not limited to the details of the configuration and arrangement of components shown in the following description or accompanying drawings. Other embodiments of the present invention are possible and can be implemented or carried out in various ways.

[0018] Figures 1 to 3 show a seat 10 of a vehicle such as a motorcycle. In the illustrated embodiment, the seat 10 has a saddle-shaped geometry and the driver straddles it when driving the vehicle. As shown in FIGS. 2 and 3, the seat 10 includes a seat base 14, a seat foam 18 supported on the seat base 14, a support pad 22 located between at least a part of the seat base 14 and the seat foam 18, and a seat cover 26 that covers the support pad 22 and the seat foam 18 to fix them to the seat base 14. The seat base 14 can be formed of a rigid material such as polypropylene plastic and can be fixed to a vehicle (e.g., a motorcycle, etc.). The seat base 14 also includes one or more openings (not shown) formed in the base 14 (e.g., as cutouts, moldings, etc.). The openings can communicate with a cooling device (e.g., a seat air conditioner) to provide climate control for the seat 10. It should be recognized that the seat 10 described in detail here can be used for other vehicles such as scooters, bicycles, all-terrain vehicles, etc. The features can be adapted to automobiles and the like.

[0019] Continuing to refer to FIGS. 2 and 3, the seat foam 18 is shaped to be supported by the seat base 14 (e.g., having a corresponding saddle-shaped geometry). The seat foam 18 defines a driver support region 34 on the top side that can support a driver (e.g., the entire weight or a majority of the weight of the driver) when seated on the vehicle. The seat foam 18 also defines an internal cavity 38 (FIG. 3) sized to receive the support pad 22. In the illustrated embodiment, the internal cavity 38 is disposed on the bottom side opposite the driver support region 34. The seat foam 18 can be formed of open-cell polyurethane foam, closed-cell polyurethane foam, etc.

[0020] The support pad 22 is disposed within the internal cavity 38 such that the support pad 22 is disposed beneath all or most of the driver support region 34. In other embodiments, the support pad 22 may correspond to and have a geometry (shape) that covers the entire seat base 14. The support pad 22 also includes a fixed protrusion 40 that selectively engages a recess 44 formed in the seat base 14, which prevents movement of the support pad 22 relative to the seat base 14. In other embodiments, the seat base 14 may include a protrusion that engages a recess of the support pad 22. In other words, one of the seat base 14 or the support pad 22 includes a fixed protrusion, and the other of the seat base 14 or the support pad 22 includes a recess for receiving the fixed protrusion.

[0021] The seat cover 26 surrounds the upper surface of the seat foam 18 and is fixed to the seat base 14 to fix the seat foam 18 and the support pad 22 to the seat base 14. The seat cover may be formed of vinyl, leather, or the like. The seat cover 26 may be removably coupled to the seat base 14 such that the seat foam 18 and the support pad 22 can be removed from the seat base 14. In some embodiments, the seat foam 18 and the support pad 22 may be replaced with a replacement seat foam and / or a replacement support pad. In other embodiments, an alternative seat assembly may be retrofitted, including the support pad 22. For example, the support pad 22 may be disposed between the seat base and the seat foam of the alternative seat assembly.

[0022] As detailed below, the structure of seat 10 improves the support provided to the driver while the vehicle is in operation. When the seat is subjected to stress due to a compressive load during use, the material does not immediately react or return to its original shape. When the compressive load is removed, the material of the seat usually recovers to its original state, but slowly and incompletely. The ratio of the time to the final shape dimension to the initial shape dimension after the compressive load has been removed can be called compliance recovery or creep recovery. Here, it is desirable to use the inverse percentage term of these equations, which is defined as recovery hysteresis. Recovery hysteresis can be expressed as the ratio of the time to the initial shape dimension minus the final shape dimension to the initial shape dimension after the load has been removed. For example, compliance recovery and creep recovery are related to recovery hysteresis by a reverse percentage (1-x), where x is the recovery hysteresis ratio.

[0023] Typically, a higher recovery hysteresis results in greater cushioning or lower rigidity of the seat when the driver is seated. In the illustrated vehicle seat 10, the structure of seat 10 creates a low seat recovery hysteresis, resulting in lower rigidity when the driver is seated compared to other vehicle seats, without sacrificing the desired seat cushioning. However, increasing the recovery hysteresis also increases the recovery time for the material to regain its original shape. Furthermore, the structure of seat 10 has a fast seat recovery time with low seat recovery hysteresis, which better maintains the designed shape of the seat compared to other vehicle seats. It is also important to consider the environmental conditions that the vehicle seat is subjected to. In cold and hot weather, vehicle seats exposed to various weather conditions must support the driver with comfort and low recovery hysteresis. In the illustrated vehicle seat 10, the material of the support pad 22 has a low glass transition temperature (e.g., lower than in the coldest weather conditions) to provide performance in cold weather. In addition, the material of the support pad 22 also has a high-temperature material that can withstand softening in warm weather, which provides stability of performance. In addition, the low and high operating temperature ranges of the support pad 22 material provide the driver with improved vehicle seat performance in all weather conditions compared to other vehicle seats. For example, the material of the support pad 22 does not harden at extremely low temperatures (e.g., until the temperature reaches -72°F (-58°C)) and does not soften significantly at extremely high temperatures (e.g., until the temperature exceeds 100°F (38°C) or reaches between 210°F (99°C) and 400°F (204°C)). As a result, the performance of the vehicle seat 10 is stable over a wider temperature range than other vehicle seats.

[0024] Furthermore, it should be recognized that recovery hysteresis and / or recovery time may vary depending on factors such as temperature, the amount of load applied to the material, and the frequency of the load applied to the material. To determine recovery hysteresis, a creep recovery test may be performed, plotting a function of the material's strain or deformation over time. During the creep recovery test, a predetermined load and unloading of the material is performed, and the amount of deformation remaining after unloading corresponds to the recovery hysteresis. Furthermore, the load on the material is increased to determine the load required to create irreversible deformation of the material. The ratio of the initial shape dimensions to the final shape dimensions when irreversible deformation begins corresponds to the modulus of elasticity limit. Therefore, it should be recognized that the recovery hysteresis range provided here is under a first set of predetermined conditions (e.g., no overloading, within a predetermined temperature range), and the modulus of elasticity limit is provided under a second set of predetermined conditions (e.g., overloading, within a predetermined temperature range).

[0025] Other sheets known in the art (e.g., those formed from open-cell polyurethane foam, closed-cell polyurethane foam, etc.) typically have high recovery hysteresis (e.g., between 10 and 30%) to allow the sheet to be compressed during dynamic events. However, with prolonged use, the sheet tends to be repeatedly compressed without fully recovering, which reduces its cushioning or absorbency for the driver. In addition, standard sheets tend to have a long recovery time (e.g., up to several hours) for the sheet to return to its original size due to their high recovery hysteresis. In the illustrated embodiment, the sheet foam 18 has a recovery hysteresis of at least 10%.

[0026] In contrast to other sheets known in the art, the combination of the sheet form 18 and the support pad 22 allows the sheet 10 to be tuned to different required performance parameters (e.g., stiffness, damping, etc.) during the manufacturing process. Furthermore, the support pad 22 is formed as a combination of a first material and a second material to further adjust the performance of the sheet 10 during the manufacturing process. For example, the size, shape, and / or quantity of the first or second material of the support pad 22 may be adjusted to tune the support pad 22 and the entire sheet 10 to the desired performance parameters. Therefore, it should be recognized that the support pad 22 shown in Figures 2-9 is an exemplary embodiment of the support pad 22, and the shape, size, and quantity of the first and second materials may be adjusted to suit a desired application.

[0027] Referring to Figures 4 and 5, the support pad 22 includes a skeleton 42 and an overmolded portion 46 on the skeleton 42. The skeleton 42 may be an elastomer skeleton formed of a first material, where one or more polymers include polysiloxanes, ethylene-propylene copolymers, ethylene-propylene-diene ternary copolymers or polymers having methyl, trifluoropropyl, or phenyl substituents, acrylonitrile-butadiene copolymers, styrene-butadiene copolymers, isoprene polymers, isobutylene-isoprene copolymers, chloroprene polymers, butadiene polymers, chlorinated polyethylene polymers, epichlorohydrin polymers, ethylene-acrylic copolymers, polyacrylate copolymers, ethylene-vinyl acetate copolymers, polypropylene oxide copolymers, polyether-urethane polymers, polyester-urethane polymers, or combinations thereof. Compared to the seat foam 18, the skeleton 42 provides improved vibration damping, a high recovery rate, low recovery hysteresis, low heat retention, and improved durability within the driver support area 34. Specifically, the frame 42 has a first recovery hysteresis in the range of 3 to 10% and a first elastic modulus limit of 25% or less in compression.

[0028] The skeleton 42 includes a body portion 50 defining a plane and a plurality of wall portions 54 extending from the body portion 50. The plurality of wall portions 54 define a repeating pattern having a network of channels 58 defined between them. In the illustrated embodiment, the wall portions 54 extend from each side of the body portion 50. In other embodiments, the wall portions 54 may extend from a single side of the body portion 50. In addition, a given pattern is a series of polygonal (e.g., hexagonal) wall portions 54. The wall portions 54 further define the vertices 60 of the polygon and the valleys 61 between the vertices 60. The network of channels 58 (e.g., pockets or recesses) is formed between adjacent wall portions 54 and extends continuously between vertices (e.g., through the valleys 61). Thus, since the network of channels 58 is continuously connected, the overmolded portion 46 can be formed continuously across the entire network of channels or encapsulated within the network of channels 58. In other embodiments, a given pattern may be a series of triangles, quadrilaterals, circles, etc. The frame 42 may also include openings 62 formed in the body portion 50 (for example, between) within a predetermined pattern defined by the wall portion 54. The openings 62 allow airflow through the support pad 22. In other embodiments, the frame 42 may have an alternative geometry.

[0029] The overmolded portion 46 can be formed from a thixotropic material, such as a polymer gel based on a liquid polymer, typically combined with an inorganic filler. The polymer can be polysiloxane, polybutadiene, or any type of synthetic or natural liquid polymer. Because the overmolded portion 46 is thixotropic, the material can liquefy (for example, when disturbed by shaking or stirring), which allows the material to be inserted into the network of channels 58. In some embodiments, the overmolded portion 46 can be a gel overmolded portion 46. The overmolded portion 46 provides improved vibration damping, very low recovery hysteresis, and low stiffness relative to the sheet foam 18. In some embodiments, the overmolded portion 46 has a second recovery hysteresis in the range of 1 to 5% and a first modulus range limit of less than 50% in compression. Thus, combining two materials within a single support pad 22 allows the performance parameters of the support pad 22 to be tuned to the desired stiffness and recovery hysteresis.

[0030] The combination of the sheet foam 18 and the support pad 22 of the sheet 10 allows the sheet 10 to have low hysteresis loss during dynamic lining events, which increases the recovery speed of the sheet 10, improves the vibration damping of the sheet 10, and reduces the heat retention of the sheet 10. In the illustrated embodiment, the sheet 10 has a load of 1.0 lbf / in / in 2 From 8.0 lbf / in / in 2 It has a spring rate within this range. The spring rate of the seat 10 can be adjusted by adjusting the size, shape, and structure of the support pad 22 within the seat 10.

[0031] Figure 6 shows a portion of a support pad 122 according to another embodiment of the present invention. The support pad 122 is similar to the support pad 22 shown in Figures 1-5 and described above. Therefore, similar features are identified by adding "100" to the similar reference number, and only the differences between them are discussed.

[0032] The support pad 122 includes a skeleton 142 and an overmolded portion 146 on the skeleton 142. The skeleton 142 includes a body portion 150 defining a plane and a plurality of wall portions 154 extending from the body portion 150. The plurality of wall portions 154 define a repeating pattern having an array of channels 158 defined within it. In the illustrated embodiment, a given pattern is a series of polygonal (e.g., hexagonal) wall portions 154. The wall portions 154 further define the vertices 160 of the polygon and the valleys 161 between the vertices 160. The array of channels 158 is formed at the vertices 160 of the polygon. Furthermore, the array of channels 158 is discontinuous (e.g., does not extend through the valleys 161) and defines three columns extending from the vertices 160. Thus, the overmolded portion 146 is individually formed or encapsulated within each of the arrays of channels 158. In addition, the overmolded portion 146 is also formed on part of the body portion 150 of the frame 142. It should be noted that the overmolded portion 146 may also be formed on the entire frame 142. The frame 142 also includes openings 162 formed in the body portion 150 within a predetermined pattern defined by the wall portion 154. The openings 162 allow airflow through the support pad 122.

[0033] Figure 7 shows a portion of a support pad 222 according to another embodiment of the present invention. The support pad 222 is similar to the support pad 22 shown in Figures 1-5 and described above. Therefore, similar features are identified by adding "200" to the similar reference number, and only the differences between them are discussed.

[0034] The support pad 222 includes a frame 242 and an overmolded portion 246 on the frame 242. The frame 242 includes a plurality of wall portions 254 that define a repeating pattern separated by a network of channels 258 defined between them. In the illustrated embodiment, a given pattern is a series of polygonal (e.g., hexagonal) wall portions 254 having an array of channels 264 defined within the repeating pattern. The overmolded portion 246 is formed or encapsulated within the array network of channels 264 defined within the repeating pattern, whereas the network of channels 258 does not have an overmolded portion 246.

[0035] Figure 8 shows a portion of a support pad 322 according to another embodiment of the present invention. The support pad 322 is similar to the support pad 22 shown in Figures 1-5 and described above. Therefore, similar features are identified by adding "300" to the similar reference number, and only the differences between them are discussed.

[0036] The support pad 322 includes a skeleton 342 and an overmolded portion 346 on the skeleton 342. The elastomer skeleton 342 includes a plurality of wall portions 354 that define a repeating pattern separated by a network of channels 358 defined between them. In the illustrated embodiment, a given pattern is a series of polygonal (e.g., hexagonal) wall portions 354 having an array of channels 364 defined within the repeating pattern. The overmolded portion 346 is formed or encapsulated within a first network of channels 358, while the array of channels 364 does not have an overmolded portion 346.

[0037] Figure 9 shows a portion of a support pad 422 according to another embodiment of the present invention. The support pad 422 is similar to the support pad 22 shown in Figures 1-5 and described above. Therefore, similar features are identified by adding "400" to the similar reference number, and only the differences between them are discussed.

[0038] The support pad 422 includes a frame 442 and an overmolded portion 446 on the frame 442. The frame 442 includes a body portion 450 and a plurality of wall portions 454 extending from the body portion 450. The plurality of wall portions 454 define a repeating pattern having an array of channels 458 defined therein. In the illustrated embodiment, the predetermined pattern is a series of discontinuous polygonal (e.g., hexagonal) wall portions 154. The wall portions 454 define the vertices 460 of the polygons and are separated by recesses 470. The overmolded portion 446 is formed within or encapsulated within each of the array of channels 458. In addition, the overmolded portion 446 is also formed on at least a portion of the body portion 450 of the frame 442. The frame 442 also includes openings 462 formed in the body portion 450 within a predetermined pattern defined by the wall portions 454. The openings 462 allow airflow through the support pad 422.

[0039] Figure 10 shows a motorcycle 500 according to one embodiment of the present invention. The motorcycle 500 includes an engine 516, a drivetrain 520, a front wheel 524, a rear wheel 528, a pair of footrests 530 (e.g., pegs, footboards), a handlebar assembly 532, and a frame 512 supporting a seat 510. The engine 516 is mounted to the frame 512, and the drivetrain 520 connects the engine 516 to the rear wheel 528 so that the engine 516 powers the rotation of the rear wheel 528. The engine 516 may be an internal combustion engine with inherent vibration characteristics. In other embodiments, the engine 516 may be replaced with an electric motor. In the illustrated embodiment, the seat 510 includes a first or driver support area 534, a second or passenger support area 536, and a back support 538. The handlebar assembly 532 includes a pair of hand grips 540. The motorcycle 500 also includes hard saddlebags 542 and a centrally mounted luggage compartment in the form of a trunk 544 attached to the frame 512. The footrest assembly 530, the first and second driver support areas 534, 536 of the seat 510, the back support 538, the hand grips 540, etc., each define the driver's touchpoints on the motorcycle 500. Any of the support pads 22, 122, 222, 322, 422 described in detail above may be incorporated into any touchpoint on the motorcycle to reduce vibration and improve driver comfort.

[0040] Figure 11 shows a rider wearable (rider clothing) 600, such as pants. The rider wearable 600 may include one or more support cavities 638 in which a support pad 622 can be received or incorporated. It should be noted that the support pad 622 may be similar to any of the support pads 22, 122, 222, 322, and 422 described in detail above. In other embodiments, the support pad 622 may be incorporated into rider wearables of the type such as helmets, jackets, or gloves.

[0041] Various aspects of the present invention are described in the following claims.

Claims

1. Seat base; A seat foam supported by the aforementioned seat base; A support pad located between the seat base and at least a portion of the seat foam, wherein the support pad is: Elastomer skeleton; and Including the gel overmolded portion on the elastomer skeleton; Support pad; and A seat cover that covers the support pad and the seat foam; The elastomer skeleton includes a body portion and a plurality of wall portions extending from the body portion, wherein the plurality of wall portions define a repeating pattern in which channels forming a space for arranging the gel overmolded portion inside are arranged to form a net pattern. Vehicle seats.

2. The seat foam includes a cavity defined within it to receive the support pad. The vehicle seat according to claim 1.

3. The seat foam defines a driver support area on its upper side, and the cavity is located on the lower side opposite to the driver support area. The vehicle seat according to claim 2.

4. The vehicle seat has a saddle-type structure. The vehicle seat according to claim 1.

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