CN115284987A - Multi-hardness foam body for ultrathin cushion of automobile seat and forming method of multi-hardness foam body - Google Patents

Abstract

The invention discloses an ultrathin multi-hardness foam body of an automobile seat and a forming method thereof. In the vertical direction, the foam body I in the bearing area and the foam body II in the non-bearing area are composed of 3 foam layers, namely a supporting foam layer in contact with the framework, a soft foam layer in contact with the coating skin and a transition foam layer sandwiched between the supporting foam layer and the soft foam layer. The transition foam layer is formed by foam supporting blocks with supporting foam layer hardness and foam filling with soft foam layer hardness, and the hardness of a bearing area and the hardness of a non-bearing area required by seat riding perception are respectively met by adjusting the thickness of the transition foam layer, the width of the foam supporting blocks and the number of the foam supporting blocks.

Description

A kind of car seat ultra-thin cushion multi-hardness foam body and forming method thereof

technical field

The invention belongs to the technical field of automobile seat foams, and in particular relates to an automobile seat ultra-thin cushion multi-hardness foam and a forming method thereof.

Background technique

At present, vehicle seats are mainly composed of skeleton, foam and skin. Foam is mainly used to make the occupant sit in the safest position in the vehicle seat, and at the same time, it is used to improve the comfort of the seat, reduce the impact of collision, protect People and utensils are protected from damage, among which the cushion foam of various vehicles such as automobiles is undoubtedly the most used. Generally speaking, the cushion should make people sit comfortably and reduce fatigue. Generally speaking, the softer the better, but if it is too soft, it will make people feel sticky in the seat, which makes it difficult to move the body and change posture. If it is too hard, the comfort will be reduced. , so each production factory is improving its softness by adjusting it, in order to obtain an optimal effect.

With the improvement of comfort awareness, there is an increasing demand for a layer of soft foam on the seat core and a layer of soft foam on the side wings of the seat, which increases the cost. The hardness of the existing double-hardness foam body for seats is generally in the horizontal direction, that is, only the side wings and the core have double hardness. This dual-hardness foaming process produces a foam body, which is prone to the situation that the side hard foam is mixed with the core soft foam. Quality control in the industry is difficult, and repeated debugging is required, resulting in waste of cost.

However, for car seats, the foam hardness of the load-bearing area and the non-load-bearing area of the whole seat cushion have different driving perception requirements, and only considering the dual hardness of the side wings and the core can no longer meet the driving comfort requirements.

Contents of the invention

In order to solve the above-mentioned problems existing in the prior art, the present invention provides an ultra-thin seat cushion multi-hardness foam body and its forming method, aiming at the gradual shortening of the development cycle of the seat, the increase of the used parts and the thinning of the seat in recent years. More and more features, from the horizontal and vertical directions of driving comfort, the ultra-thin seat cushion is designed with multi-hardness foam.

The purpose of the present invention is achieved through the following technical solutions:

An ultra-thin multi-hardness foam body for a car seat, including a seat cushion core and seat cushion flanks integrally extending from the seat cushion core to both sides; along the direction of the thighs in a sitting posture, the foam body at the seat cushion core is divided into load-bearing area foams Body and foam in non-load bearing areas.

Preferably, the width of the foam body in the load-bearing area is 200-300 mm, and the width of the foam body in the non-load-bearing area is 250-350 mm.

Further, the foam body in the load-bearing area and the foam body in the non-load-bearing area are both composed of three layers of foam layers, which are respectively the support foam layer in contact with the skeleton, the soft foam layer in contact with the covering skin, and the foam layer sandwiched between the support foam layers. The transition foam layer between the soft foam layer and the soft foam layer; the hardness of the soft foam layer is less than that of the supporting foam layer.

Preferably, the supporting foam layer has a hardness of 7-10 kPa; the soft foam layer has a hardness of 2-5 kPa.

Further, the transition foam layer includes several foam support blocks integrally formed on the upper surface of the support foam layer, and the foam support blocks are filled with foaming foam; the hardness of the foam support blocks is the same as that of the support foam layer; The foamed foam has the same hardness as the flexible foam layer.

Furthermore, by adjusting the thickness of the transitional foam layer, the width of the foam support block and the number of foam support blocks, the adjustment of the hardness of the foam body in the load-bearing area and the foam body in the non-load-bearing area is realized.

Further, in the transitional foam layer, steel wires are respectively fixed on the two rows of foam support blocks close to the side wings of the seat cushion, and the steel wires are bonded and fixed on the top of the entire row of foam support blocks along the sitting direction for hooking the covering skin.

Further, the cushion side wing part is composed of the foam side wing of the supporting foam layer and the foam side wing of the soft foam layer; the foam side wing of the supporting foam layer is integrally casted with the supporting foam layer, and the foam side wing of the soft foam layer is integrally cast with the soft foam layer forming. Under normal driving conditions, the soft foam layer foam side wings provide the softness required by the driver and passenger to make contact with the side wings. During cornering and side impacts, the supportive foam layer foam side wings provide the driver and passenger with the stable occupant posture needed to make contact with the side wings performance.

The invention also provides a method for forming an ultra-thin multi-hardness foam body of an automobile seat, comprising:

First complete the pouring of the foam support blocks in the support foam layer and the transition foam layer, and use the poured foam as a general foam piece;

On the foaming operation line, the foam formed in the previous step within 3 to 10 minutes is used as a female mold, which is combined with the foam surface mold in contact with the cushion skin, and poured to form the foamed foam and soft foam layer in the transitional foam layer.

Preferably, within the stable period of foam hardness performance, for example, within 6 months, the general-purpose foam parts can be stored as revolving parts for standby use; they can also be used directly on the production line.

The present invention has the following beneficial effects:

The invention provides an ultra-thin seat cushion multi-hardness foam body of an automobile seat and a forming method thereof. In view of the characteristics of the gradually shortened development cycle of the seat, the increase of the number of parts used and the increasing demand for thinning the seat in recent years, from the horizontal and the Longitudinal and 2-direction driving comfort is carried out, and the ultra-thin seat cushion is designed with multi-hardness foam. The transition foam layer sandwiched between the support foam layer and the soft foam layer is designed to provide a hardness transition between the support layer and the soft layer, which is beneficial to the ride perception.

Description of drawings

Fig. 1 is an axonometric view of a multi-hardness foam body of an ultra-thin cushion of a car seat according to an embodiment of the present invention;

Fig. 2 is a schematic diagram of the internal structure of a multi-hardness foam body of an ultra-thin seat cushion for an automobile seat according to an embodiment of the present invention;

Fig. 3 is a schematic diagram of the internal structure of a multi-hardness foam body of an ultra-thin seat cushion for an automobile seat according to an embodiment of the present invention;

Fig. 4 is a front sectional view of an ultra-thin cushion multi-hardness foam body of an automobile seat according to an embodiment of the present invention;

In the picture:

I-foam in load-bearing area; II-foam in non-load-bearing area;

1-soft foam layer; 2-transition foam layer; 3-support foam layer; 4-steel wire

11-Cover skin contact surface; 12-Soft foam layer pouring inner cavity; 13-Soft foam layer foam side wings

21 - foam support block;

31-skeleton contact surface; 32-supporting foam layer casting inner cavity; 33-supporting foam layer foam flanks.

Detailed ways

An ultra-thin multi-hardness foam body for a car seat, including a seat cushion core and seat cushion flanks integrally extending from the seat cushion core to both sides; along the direction of the thighs in a sitting posture, the foam body at the seat cushion core is divided into load-bearing area foams Body I and non-load bearing area foam II.

Further, the width of the foam body in the load-bearing area is 200-300 mm, and the width of the foam body in the non-load-bearing area is 250-350 mm.

Further, the foam body I in the load-bearing area and the foam body II in the non-load-bearing area are composed of three layers of foam layers, which are respectively the support foam layer 3 in contact with the skeleton, the soft foam layer 1 in contact with the covering skin, and the sandwich layer. The transition foam layer 2 between the support foam layer and the soft foam layer; the hardness of the soft foam layer 1 is less than that of the support foam layer 3 .

Furthermore, the supporting foam layer 3 has a hardness of 7-10 kPa; the soft foam layer 1 has a hardness of 2-2.5 kPa.

Further, the transition foam layer 2 includes several foam support blocks 21 integrally formed on the upper surface of the support foam layer 3, and the foam support blocks 21 are filled with foam foam; the hardness of the foam support blocks 21 is the same as that of the support foam layer. 3 have the same hardness; the foamed foam has the same hardness as the soft foam layer 1 .

Furthermore, by adjusting the thickness of the transitional foam layer, the width of the foam support block and the number of foam support blocks, the hardness adjustment of the foam body I in the load-bearing area and the foam body II in the non-load-bearing area is realized.

Further, a steel wire 4 is fixed in the transitional foam layer for hooking the covering skin, and the steel wire 4 is fixed on the foam support block 21, and its position is determined by the position of the tension wire on different shapes, which is suitable for different shapes. The skin is pulled closer.

Further, the cushion side wing part is composed of the foam side wing 33 of the supporting foam layer and the foam side wing 13 of the soft foam layer. Layer 1 is integrally cast.

Under normal driving conditions, the soft foam layer foam side wings provide the softness required by the driver and passenger to make contact with the side wings. During cornering and side impacts, the supportive foam layer foam side wings provide the driver and passenger with the stable occupant posture needed to make contact with the side wings performance.

A method for forming an ultra-thin multi-hardness foam body for an automobile seat, comprising:

First complete the pouring of the foam support block 21 in the support foam layer 3 and the transition foam layer 2, and use the poured foam as a general foam part; such as within 6 months during the foam hardness performance stability period, the general foam part can be As a revolving stock, it is ready for use; it can also be used directly on the production line.

On the foaming operation line, the foam formed in the previous step within 3 to 10 minutes is used as a female mold, which is combined with the foam surface mold that is in contact with the cushion skin, and poured to form the foamed foam in the transitional foam layer 2 and the soft foam layer 1 .

Example 1

As shown in Figures 1 and 2, an ultra-thin multi-hardness foam body for a car seat includes a cushion core and cushion flanks extending integrally from the cushion core to both sides; The foam body in the part is divided into the foam body I in the load-bearing area and the foam body II in the non-load-bearing area, wherein the width c of the foam body I in the load-bearing area is 200-300 mm, and the width d of the foam body II in the non-load-bearing area is 250-350 mm.

In the vertical direction, the foam body I in the load-bearing area and the foam body II in the non-load-bearing area are all composed of 3 layers of foam layers, which are respectively the support foam layer 3 (thickness b mm) in contact with the skeleton, and the layer 3 (thickness b mm) in contact with the covering skin. The soft foam layer 1 (thickness is a mm), and the transition foam layer 2 (thickness is n mm) is sandwiched between the supporting foam layer and the soft foam layer.

The hardness of the soft foam layer 1 is less than that of the supporting foam layer 3 .

The hardness of the support foam layer 3 is 7-10 kPa; the hardness of the soft foam layer 1 is 2-2.5 kPa.

As shown in FIG. 4 , in the transitional foam layer 2 , it is composed of a foam support block 21 with the hardness of the supporting foam layer and a foam filling with the hardness of the soft foam layer. The hardness of the foam supporting block 21 is the same as that of the supporting foam layer 3 and is integrally molded; the hardness of the foaming foam is the same as that of the soft foam layer 1 and is integrally molded. Relying on the adjustment of the thickness n of the transitional foam layer, the width m of the foam support block, and the increase or decrease in the number of foam support blocks, the hardness of the load-bearing area and the non-load-bearing area required by the seating perception of the seat are respectively met. The width of the upper edge of the foam support block is designed to be 1/3-2/3 of the width m of the root.

As shown in Figure 3, steel wires are fixed in the transitional foam layer for hooking the cladding skin. The steel wires are fixed on the foam support block, and its position is determined by the position of the tension wire on different shapes, which is suitable for different shapes. The skin is pulled closer. In this embodiment, steel wires 4 are respectively fixed on the two rows of foam support blocks 21 near the side wings of the seat cushion. Leather hook strength.

The cushion side wing part is composed of the foam side wing 33 of the supporting foam layer and the foam side wing 13 of the soft foam layer. Casting molding; the side wings of the cushion and the core of the cushion realize the soft function at the same time and also meet the support function required by the side impact.

Under normal driving conditions, the soft foam layer foam side wings provide the softness required by the driver and passenger to make contact with the side wings. During cornering and side impacts, the supportive foam layer foam side wings provide the driver and passenger with the stable occupant posture needed to make contact with the side wings performance.

Example 2

A method for forming an ultra-thin multi-hardness foam body for an automobile seat, comprising:

Divided into a support layer and a soft layer, two foaming pouring inner chambers, two-step molding: first, use the support foam layer 3 and the foam support block 21 within the foam hardness range of 7-10kPa to have fast shaping and small shrinkage of the foam after shaping Features, the pouring of the foam support block 21 in the support foam layer 3 and the transition foam layer 2 is completed first, and the foam body after pouring is used as a general-purpose foam part (such as within 6 months during the stable period of foam hardness performance, the general-purpose foam Components can be used as revolving parts inventory, ready to use; can also be used directly on the production line).

On the foaming operation line, within 3 to 10 minutes, the foam body formed in the previous step is used as the bottom (female mold), and the foam surface mold (male mold) in contact with the cushion skin is combined for pouring to form the foam in the transitional foam layer 2. Bubble foam and soft foam layer.

The transition layer between the support layer and the soft layer is designed with support blocks of different sizes. There are 3 benefits:

(1) Provide a hardness transition between the support layer (7-10kPa) and the soft layer (2-5kPa), which is beneficial to the ride perception;

(2) It is conducive to the demoulding of the support layer foam;

(3) The support layer and the soft layer are firmly combined.

(4) It is beneficial to avoid the possibility of foam tearing caused by the small foam thickness or soft foam hardness during the demoulding process. Compared with the conventional foaming process, the foam thickness obtained by this process can be smaller and the foam hardness can be softer.

Claims (9)

1. An ultrathin multi-hardness foam body of an automobile seat is characterized by comprising a cushion core part and cushion side wing parts integrally extending from the cushion core part to two sides; along the thigh direction of sitting posture, divide into bearing area foam and non-bearing area foam with the foam of cushion core.

2. The ultrathin, multi-hardness foam for automobile seats of claim 1, wherein the width of the load-bearing zone foam is 200 to 300mm and the width of the non-load-bearing zone foam is 250 to 350mm.

3. The ultrathin, multi-durometer foam of claim 1 wherein the load-bearing zone foam and the non-load-bearing zone foam are each comprised of 3 foam layers, a support foam layer in contact with the frame, a soft foam layer in contact with the covering skin, and a transition foam layer sandwiched between the support foam layer and the soft foam layer; the soft foam layer has a hardness less than the support foam layer.

4. The ultra-thin, multi-durometer foam for car seats of claim 3, wherein the support foam layer has a hardness of 7-10 kPa; the hardness of the soft foam layer is 2-5 kPa.

5. The ultra-thin multi-hardness foam body for automobile seats as claimed in claim 3, wherein the transition foam layer comprises a plurality of foam support blocks integrally formed on an upper surface of the support foam layer, the foam support blocks being filled with foam; the foam support block hardness is the same as the support foam layer hardness; the foamed foam and the soft foam layer have the same hardness.

6. The ultra-thin multi-hardness foam for car seats of claim 5, wherein the adjustment of the hardness of the foam at the load-bearing area and the foam at the non-load-bearing area is achieved by adjusting the thickness of the transition foam layer, the width of the foam supporting blocks and the number of the foam supporting blocks.

7. The ultra-thin multi-hardness foam body for automobile seats of claim 5, wherein steel wires are fixed in the transition foam layer for hanging the covering skin, and the steel wires are fixed on the foam supporting block, and the positions of the steel wires are determined by the positions of the tension lines on different shapes.

8. The ultra-thin, multi-durometer foam for automotive seats of claim 3 wherein the cushion side flap portion is comprised of a supporting foam layer foam side flap and a soft foam layer foam side flap; the supporting foam layer foam side wings and the supporting foam layer are integrally cast and molded, and the soft foam layer foam side wings and the soft foam layer are integrally cast and molded.

9. The method of claim 5, wherein the method comprises:

firstly, pouring foam supporting blocks in a supporting foam layer and a transition foam layer, and taking a poured foam body as a universal foam piece;

on a foaming operation line, the foam body formed in the previous step within 3-10 min is taken as a female die, and is combined with a foam surface die in contact with the cushion skin for casting to form foaming foam and a soft foam layer in the transition foam layer.

Images