Vehicle Seat Lattice Bearing Structure for Residual Powder Containment
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Solution Overview
Problem
Existing methods for producing vehicle seats with lattice bearing structures using additive manufacturing face significant challenges in removing residual powder, leading to increased manufacturing costs and times, especially for structures thicker than 50 mm, which can contaminate the passenger compartment.
Innovation Solution
Encapsulating the lattice bodies of the seat components in sealed bags made of air-permeable and powder-impermeable material, such as nonwoven fabric, to contain residual powder and prevent it from detaching during use, thereby eliminating the need for extensive post-manufacturing cleanup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing (powder bed fusion) is used to produce lattice bearing structures, then manufacturing flexibility and complex geometry capability are improved, but residual powder removal becomes more difficult and time-consuming
Solution Approach 1:
The invention extracts and removes residual powder from the lattice bearing structure using a vibration-based cleaning system. The seat frame is equipped with vibrators that generate vibrations to detach residual powder particles from the lattice structure, and a suction device extracts the detached powder. This extraction approach directly addresses the time-consuming powder removal problem while preserving the benefits of additive manufacturing.
Solution Approach 2:
The invention applies mechanical vibration to the lattice bearing structure through vibrators mounted on the seat frame. These vibrators generate vibrations at frequencies that cause residual powder particles to detach from the lattice structure. The vibration mechanism transforms the static adhesion problem into a dynamic removal process, significantly reducing cleaning time while maintaining manufacturing flexibility.
2Productivity
If residual powder is not completely removed from the lattice bearing structure, then manufacturing time and costs are reduced, but powder detaches during use and contaminates the passenger compartment
Solution Approach 1:
The invention introduces an intermediary cleaning system consisting of vibrators and a suction device with a filter. The vibrators act as intermediaries to detach powder, while the suction device with filter captures and contains the detached powder, preventing it from reaching the passenger compartment. This intermediary approach allows manufacturing efficiency to improve without compromising passenger compartment cleanliness.
Solution Approach 2:
The invention implements a feedback mechanism where the suction device continuously monitors and extracts powder particles as they detach during seat usage. The system provides real-time containment of harmful particles, creating a closed-loop solution that maintains both manufacturing efficiency and passenger compartment cleanliness by actively managing powder contamination throughout the product lifecycle.
3Strength
If thick lattice bearing structures (>50 mm) are used for adequate support, then structural performance is improved, but residual powder removal becomes exponentially more difficult
Solution Approach 1:
The invention uses mechanical vibration applied through seat frame vibrators to effectively remove residual powder from thick lattice structures (>50 mm). The vibration mechanism penetrates deep into the lattice structure, dislodging powder particles that would be inaccessible to conventional cleaning methods. This enables adequate structural support through thick lattices while maintaining ease of manufacture through effective powder removal.
Solution Approach 2:
The invention performs preliminary powder removal immediately after additive manufacturing while the lattice structure is still in the seat frame assembly position. By addressing powder removal as a preliminary action integrated into the manufacturing process rather than a separate post-processing step, the system makes thick lattice structure manufacturing more feasible without exponentially increasing difficulty.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces manufacturing costs and time by eliminating the need for thorough residual powder removal, while maintaining the seat's functionality and cleanliness by containing powder within the bags, thus preventing compartment contamination.
Implementation Method 1
Encapsulating the lattice bodies of the seat components in sealed bags made of air-permeable and powder-impermeable material, such as nonwoven fabric
Implementation Method 2
a source of heat (high-power laser in 'SLS') is used to sinter small particles of polymer powder and turn them into a solid structure
Implementation Method 3
sinter small particles of polymer powder and turn them into a solid structure based on a three-dimensional model
Data Source
AI summary
A seat (1) for a vehicle and having: a bearing structure, which is elastically yielding and has at least one component provided with a lattice body (6) manufactured by means of additional manufacturing involving powder bed fusion; a cover (5), which covers the lattice body (6) and makes up the aesthetic and tactile interface to the outside; and a closed bag (7), which contains, on the inside, the lattice body (6) and is arranged more on the inner side of the cover (5) and, hence, is arranged between the cover (5) and the lattice body (6).