DE102020200960B4 - Vehicle seat each having at least one basic structural part and upholstery element produced by 3D printing - Google Patents

Abstract

Vehicle seat (100) comprising a one-part or multi-part base structure part (10) and a one-part or multi-part upholstery element (20; 20.1, 20.2), wherein the base structure part(s) (10) and the upholstery element(s) (20; 20.1, 20.2 ) are components produced by 3D printing, wherein the padding element(s) (20; 20.1, 20.2) is/are reversibly attached to the base structure part(s) (10) in the assembled state, wherein the padding element(s) (20; 20.1, 20.2) and the base structure part(s) (10) have attachments which are components of the components (10, 20) produced by 3D printing, the base structure part(s) (10) having at least one depression that can be predetermined in terms of shape (1B, 2B) in which the upholstery element(s) (20; 20.1, 20.2) fastened by means of fastening elements (1A', 2A`) rests/lie in the assembled state, characterized in that the at least one depression (1B, 2B) as a relative to the seat plane after i innen arched concave shape is formed, wherein the at least one depression (1B, 2B) is a negative mold for the / the padding element / s (20; 20.1, 20.2), the padding element(s) (20; 20.1, 20.2), which is/are fastened to the basic structure part(s) (10) by means of the fastening elements (1A', 2A`), forming a positive shape only in the assembled state which corresponds to the negative shape of the at least one depression (1B, 2B), since the fastening elements (1A', 2A`) shape the cushion element(s) (20; 20.1, 20.2) on the basic structure part(s) (10) holds/hold.

Description

Methods for producing a component using a 3D printing method are known.

In particular, the FDM 3D printing process (FDM = Fused Deposition Modeling) as a 3D printing process is intended to serially print individual layers of a material application in order to achieve a generative build-up of a desired structure or a desired geometry of the component. This procedure is also referred to as layered printing, with such a printing process being prepared and carried out in a printing device designed for such purposes. In the FDM 3D printing process, for example, a plastic filament is melted in layer-by-layer printing and printed or deposited in layers via a nozzle device in individual tracks. In this case, the respective printing parameters are defined in advance for the webs in order to deposit constant webs in layers, for example in a user-defined pattern. In this sense, numerous examples are known from the prior art and can already be regarded as sufficiently described as established technology.

A 3D printing method for large, stable components, which in particular has a nozzle device with a particularly large nozzle opening, is also known and is referred to as so-called BAAM (Big Area Additive Manufacturing). With the BAAM process, which is a kind of sub-process of the FDM 3D printing process, stable components that contain a lot of material can be produced very quickly.

The components manufactured using the FDM 3D printing process or the BAAM process are also very environmentally friendly, since recycled plastics can be used very well.

3D printing processes have already been used in the prior art for the production of upholstery and upholstery, in particular for motor vehicles. In the pamphlet US 2018/0 043 805 A1 a method for manufacturing a seat is disclosed in which various cushioning elements are formed in the form of a network of polymers produced using a 3D printing process. The padding elements are printed, as described above, on a construction platform and the finished padding elements are then attached to a base body, which is accomplished by snap-in connections, fasteners, adhesives and ultrasonic welding.

The pamphlet EP 3 542 990 A1 describes a method in which a fastening step for the upholstery elements produced by means of 3D printing methods can be dispensed with in order to produce vehicle seats and similar products in an improved manner in this way. It is intended that in a 3D printing process the print will not take place on a construction platform, which will not become part of the finished product, but the upholstery structure will be 3D printed directly on a base body of the seat, whereby the base body and structure of the product will be obtained directly and materially are connected to each other.

In summary, the publications each exclusively disclose the production of upholstery elements using a 3D printing process.

The publications are supplemented DE 10 2016 225 837 A1 , DE 10 2018 120 660 A1 , U.S. 10,744,914 B2 and DE 10 2017 118 157 A1 as well as US 2019/0 270 395 A1 called.

The object of the present invention is to create a vehicle seat that has a simple, cost-effective and ergonomic structure that can be produced efficiently, as automated as possible and thus as cost-effectively as possible with a high level of flexibility with regard to the shape and arrangement of the upholstery elements using an associated production process.

According to the invention, a method for manufacturing a vehicle seat having the features of claim 7 is provided.

In a preferred variant of the manufacturing process, the basic structure part(s) and the cushioning element(s) are manufactured using the FDM 3D printing process.

In another preferred manufacturing method variant, the basic structure part(s) is/are manufactured using the BAAM 3D printing method and the cushion element(s) are manufactured using the FDM 3D printing method.

A vehicle seat according to the invention manufactured with one of the manufacturing process variants is characterized by the features of claim 1 .

In the non-assembled state, the upholstery element is a planar, essentially flat three-dimensional component, which only assumes its curved shape, adapted to the negative shape, as a positive form in the assembled state, in which the seat upholstery is outwards relative to the plane of the seat surface, in particular relative to the edge of the seat surface - in the direction the depression - is curved, and thus assumes a curved shape (convex curved shape), resulting in both manufacturing processes variants the production of the padding element is simplified in an advantageous manner, since the curved shape can be ignored in the production.

It is preferably provided in one embodiment variant that the upholstery element has fastening elements and the basic structure part has recesses as fastening means.

In one embodiment, the padding element(s) is/are preferably a component(s) produced using the FDM 3D printing process. It is preferably provided that the padding element produced in the FDM 3D printing process is designed as a three-dimensional network with matrix-like open pores and is elastic with resilience, as explained in more detail in the description and shown in the figures.

The basic structure part(s) of the vehicle seat is/are preferably also a component/s produced using the FDM 3D printing process or a component(s) produced using the BAAM 3D printing process.

The invention is explained below with reference to the associated drawings.

A vehicle seat 100 according to the invention and the details according to the invention are in FIGS 1 until 5B shown and explained below.

• 1 eine perspektivische Darstellung des erfindungsgemäßen Fahrzeugsitzes im Zusammenbauzustand in einer Vorderansicht;
• 2 eine perspektivische Darstellung des Fahrzeugsitzes im Zusammenbauzustand gemäß 1 in einer Rückansicht;
• 3 eine Art Explosionsdarstellung des mehrteiligen Fahrzeugsitzes gemäß 1;
• 4A eine vergrößerte perspektivische Darstellung eines Kopfstützenbereiches des Rückenlehnenteiles des Fahrzeugsitzes gemäß den 1 bis 3 in der Vorderansicht;
• 4B eine Darstellung einer Schnittfläche entlang der Schnittlinie A-A gemäß den 3 und 4A;
• 4C eine Darstellung der Schnittfläche entlang der Schnittlinie A-A gemäß 4B mit teilweise hochgeklapptem Polsterelement im Kopfstützenbereich zur Darstellung einer Befestigungslösung (Befestigungselement und Aufnahmeöffnung);
• 4D eine Darstellung des Rückenlehnenteiles von seiner Rückseite mit dem Polsterelement im Kopfstützenbereich zur Darstellung der rückenlehnenseitigen Befestigungslösung des Polsterelementes;
• 5A eine beispielhaftes Teilstück eines Polsterelementes in einer perspektivischen Vorderansicht;
• 5B das Teilstück des Polsterelementes in einer perspektivischen Hinteransicht mit dem Befestigungselement gemäß den 3, 4C und 4D.

Show it:

• 1 a perspective view of the vehicle seat according to the invention in the assembled state in a front view;
• 2 a perspective view of the vehicle seat in the assembled state according to 1 in a rear view;
• 3 according to a kind of exploded view of the multi-part vehicle seat 1 ;
• 4A an enlarged perspective view of a headrest area of the backrest part of the vehicle seat according to FIG 1 until 3 in front view;
• 4B a representation of a section along the section line AA according to the 3 and 4A ;
• 4C a representation of the section along the section line AA according to FIG 4B with partially folded up padding element in the headrest area to show a fastening solution (fastening element and mounting opening);
• 4D a representation of the backrest part from its rear side with the upholstery element in the headrest area to illustrate the backrest-side fastening solution of the upholstery element;
• 5A an exemplary portion of a padding element in a perspective front view;
• 5B the portion of the cushion element in a perspective rear view with the fastener according to 3 , 4C and 4D .

1 shows a perspective representation of the vehicle seat 100 according to the invention in the assembled state in a front view.

According to the invention, the vehicle seat 100 comprises a basic structure part 10 that is essentially non-resilient in the BAAM process, which is explained in the introduction to the description . In other words, the one-piece basic structure part 10 in the exemplary embodiment is a combined backrest and seat part shell, which can be produced very quickly and efficiently from a plastic using the BAAM process. In the finished state, the basic structural part 10 has a rigid and essentially unyielding structure, since it forms a stable and hard structure after the plastic has hardened. In a two-part design, the backrest shell and seat shell can be adjustable in inclination relative to one another. According to the invention, the hard, load-bearing basic structure part 10 is designed in such a way that it can be produced lying on its side in continuous webs without generating support. Recesses 1A, 2A for the plug-in connections can also be produced in this way as fastening means in one process step during the production of the basic structure part 10 itself. 3D printing processes usually require additional support structures. This support material is used to support filigree or overhanging structures. However, according to the present invention, the basic structure part 10 is of such simple design that such support structures are advantageously not required.

Upholstery elements 20 are arranged on the base structure part 10 or on the base structure part 10, with an upholstery element 20.1 being assigned to the seat part 1 and an upholstery element 20.2 to the backrest part 2 in the exemplary embodiment.

According to the invention it is provided that the padding elements 20; 20.1, 20.2 are manufactured using the FDM 3D printing process. This method can be used to produce structures which are constructed in the manner of a network, preferably a three-dimensional network and/or a porous matrix. The selection of the extent to which the network is filigree or less filigree or the matrix has more or less open or closed pores depends on the desired resilience of the cushioning elements 20; 20.1, 20.2 met.

In the BAAM process, cushioning elements with such flexible, resilience properties cannot be produced, since the nozzle device explained in the introduction to the description of the prior art is provided with a particularly large nozzle opening, so that this process only produces essentially only slightly filigree, stable components can be, which have hardly yielding elastic properties.

The basic idea according to the invention is therefore, in a first aspect, that a one-piece or multi-piece basic structure part 10 is produced in a first specific 3D printing process (BAAM 3D printing process), while the cushioning element is produced in another (second) specific 3D printing process (FDM 3D printing process). The invention thus consists in the combination of the specific 3D printing methods, as a result of which it is possible to produce the vehicle seat 100 in an efficient manner.

Another aspect of the invention is that the / the basic structure part / s 10 and the respective cushion element 20; 20.1, 20.2 can be connected to one another in a simple manner.

2 FIG. 1 shows a perspective view of the vehicle seat 100 in the assembled state according to FIG 1 in a rear view. In this rear view, the cutouts 2A in the backrest part 2 are already visible, with the cutouts 2A serving according to the invention to fasten the upholstered element 20.2 to the backrest part 2, as will be explained further below.

3 shows a kind of exploded view of the multi-part vehicle seat according to FIG 1 , which comprises the upholstery elements 20.1, 20.2 and a one-piece basic structural part 10, which includes the seat part 1 and the backrest part 2, with the backrest part 2 forming an upper area above a cutting line AA, which is designed and used as the headrest area integrated into the backrest part 2, which is described below referred to as headrest 3.

In this exploded view, the cutouts 1A in the seat part 1 are already visible, with the cutouts 1A serving according to the invention to fasten the upholstered element 20.1 to the seat part, as will be explained further below.

In addition, 3 fastening elements 1A' are already visible on the underside of the upholstery element 20.1, the fastening elements 1A' interacting with recesses 1A and serving to fasten the upholstery element 20.1 to the seat part 1 (backrest part 2 analogously).

In summary, one aspect of the invention consists in the fact that the upholstery elements 20.1, 20.2 can be easily attached.

According to the invention, however, not only a simple attachment of the padding elements 20.1 and 20.2 is proposed, but rather the padding element or elements 20; 20.1, 20.2 are produced on a flat, level printing bed (also advantageously without support structures) and thus, in contrast to the representation in 3 initially (after their production) a flat, even shape.

In a further aspect of the invention, the upholstery elements 20.1 and 20.2 are shaped in that indentations 1B and 2B are formed in the basic structural part 10, which each form a negative mold, so to speak, for the upholstery elements 20.1 and 20.2, which are inserted into the indentations 1B and 2B inserted and by fastening the padding elements 20.1 and 20.2 by means of the fastening elements 1A', 2A' (reference number 2A' compare in advance 4C ) are pulled into the depressions 1B and 2B that give the padding elements 20.1 and 20.2 their shape. In other words, the upholstery elements 20.1 and 20.2 take on a positive shape, also defined in the previous description, corresponding to the given negative shape defined in the previous description, and take on the ergonomic seat shape within the assembly step, since advantageously due to the specific manufacturing method in the FDM -3D printing method is also formed a predetermined flexibility of the padding elements 20.1 and 20.2.

According to the invention, several fastening elements 1A', 2A' and several recesses 1A, 2A are provided in order to ensure that the cushioning elements 20.1 and 20.2 are adapted to the negative shape, it being provided in particular that the fastening elements 1A', 2A' and recesses 1A, 2A in particular in the edge area of the padding elements 20.1 and 20.2 and the basic structure part 10 are arranged in the correct position.

The 4A shows an enlarged perspective view of a headrest area of the backrest part 2 of the vehicle seat 100 according to FIG 1 until 3 in the front view, wherein the backrest part according to the section line AA 3 is cut off. The depression 2B and the inlaid padding element 20.2 are clearly visible.

The 4B shows a representation of a section along the section line AA according to FIGS 3 and 4A , The resilience and flexibility of the upholstery element 20.2 being illustrated as representative of the upholstery elements 20 per se. The filigree three-dimensional network that can be realized in the specific FDM 3D printing process and/or the porous matrix of the upholstery element 20.2 in the headrest area is illustrated.

The 4C illustrated by the representation of the sectional area along the section line AA according to FIG 4B with the upholstery element 20.2 partially folded up in the headrest area, the already explained fastening solution for the upholstery element 20.2 using a fastening element 2A' and a recess 2A as a receiving opening within the depression 2B.

Analogously, the 4D a representation of the backrest part 2 from its rear side with the upholstery element 20.2 behind the basic structural part 10 in the headrest area to show the backrest-side fastening solution of the upholstery element 20.2.

4D shows two fastening elements 2A' and two recesses 2A in the assembled state of the padding element 20.2 on the basic structural part 10, seen from the rear of the basic structural part 10. The rough structure of the basic structural part 10 once again makes it clear that the BAAM 3D printing process was used to produce the basic structural part 10 .

It is also made clear that the layer thickness of the basic structure part 10 is only small, so that the recesses 2A also only have a small depth.

The recesses 2A are designed as through openings in order to ensure the highest possible frictional connection in addition to the positive connection of the fastening elements 2A′.

It goes without saying that in the case of basic structure parts with a greater layer thickness, recesses 2A can also be formed as blind holes.

Irrespective of this, it is provided that the elastic fastening elements 2A` (analogous to 1A') are made slightly larger than the recesses 2A (analogous to 1A) provided in the basic structure part 10, so that the frictional connection is as large as possible, it being provided that a removal the padding elements 20; 20.1, 20.2 simply remains guaranteed without great effort.

In an alternative embodiment, the fastening elements 1A′, 2A′ have retaining elements (not shown) that can be moved at their ends, which form a contact surface on the back of the basic structural part 10, which is canceled by moving the retaining elements, so that the cushioning elements 20; 20.1, 20.2 can be reversibly released from the recesses 1A, 2A after the fastening elements 1A', 2A' have been released. In this embodiment variant, of course, through-openings must be formed.

The 5A and 5B show an exemplary part of a cushion element 20 in a synopsis; 20.1, 20.2 in a perspective front view ( 5A ) and in a perspective rear view ( 5B ) with a previously explained fastening element (fastening element 1A 'according to 3 analog), shown in the 3 , 4C and 4D .

It is clear that the shown parts of the padding elements 20; 20.1, 20.2 has an open cell-like pore structure and the fastening element 1A′, 2A′ formed in one piece using the 3D printing process in the exemplary embodiment has a combination of a plastic pore structure formed on the core side (core area K) and a closed plastic structure on the edge side (edge area R).

The desired elastic properties of the 3D printed cushioning elements 20; 20.1, 20.2 can be modified by the predeterminable size of the pores/cells in order to achieve the desired comfort properties of the 20; 20.1, 20, in particular to influence the deformability (seat depth) and the resilience. The position of the 3D-printed filament webs can also be specified in order to achieve the desired elastic properties of the 3D-printed cushioning elements 20; 20.1, 20.2. The illustrated cross structure of the plastic grid of the padding elements 20; 20.1, 20.2 represents a preferred variant.

In addition, design features can be realized in an advantageous manner if the filaments of the starting plastic materials use predeterminable different colors in a 3D printing process with a plurality of nozzles or in a nozzle (changing starting plastic materials) of a nozzle device.

Plastics in all colors and shapes can be used as filaments for 3D printing, with classic filaments such as PLA and PETG, but also other starting materials such as wood/PLA mixtures. Wood species such as pine, birch, cedar and willow, but also unusual wood species such as bamboo, cherry, ebony, coconut, cork oak and olive can be mixed with PLA or the like and used in the 3D printing process.

In addition to the standard filaments (like PLA and PETG), filaments made of other materials like nylon, polycarbonate, carbon, polypropylene and so on are also suggested. Filaments that glow or are electrically conductive can even be used.

In addition, there is the advantageous recycling idea, which provides for the use of shredded plastic parts from end-of-life vehicles, so that recycled filaments are available as the starting plastic material, so that each cushion element 20; 20.1, 20.2 is unique, which can be easily separated from another upholstery element 20; 20.1, 20.2 is different because the print and color image will change automatically due to the different recycled parts.

Briefly summarized, the main advantages are that the manufacture and assembly of the vehicle seat is not very complex, the manufacture can be carried out without tools using 3D printing processes, the upholstery elements 20; 20.1, 20.2 can be produced individually using the 3D printing process, the cushioning elements 20; 20.1, 20.2 (advantageous for car-sharing vehicles) are easily interchangeable and the use of waste plastic from manufacturing material is possible. Ultimately, the vehicle seats 100 are durable, hard-wearing and, in turn, themselves recyclable. It goes without saying that chairs, upholstered furniture or the like can advantageously be produced in this way beyond use in the motor vehicle sector.

Reference List

100

vehicle seat

10

basic structural part

1

seat part

1A

recess

1A'

fastener

1B

deepening

2

backrest part

2A

recess

2A`

fastener

2 B

deepening

3

Headrest, headrest area

20

upholstery element

20.1

Upholstery element of the seat part 1

20.2

Upholstery element of the backrest part 2

R

edge area

K

core area

Claims (8)

Vehicle seat (100) comprising a one-part or multi-part base structure part (10) and a one-part or multi-part upholstery element (20; 20.1, 20.2), wherein the base structure part(s) (10) and the upholstery element(s) (20; 20.1, 20.2 ) are components produced by 3D printing, wherein the padding element(s) (20; 20.1, 20.2) is/are reversibly attached to the base structure part(s) (10) in the assembled state, wherein the padding element(s) (20; 20.1, 20.2) and the base structure part(s) (10) have attachments which are components of the components (10, 20) produced by 3D printing, the base structure part(s) (10) having at least one depression that can be predetermined in terms of shape (1B, 2B) in which the upholstery element(s) (20; 20.1, 20.2) fastened by means of fastening elements (1A', 2A`) lie(s) in the assembled state, characterized in that the at least one recess (1B, 2B) as one opposite to the plane of the seat an internally arched concave shape, the at least one depression (1B, 2B) being a negative mold for the cushion element(s) (20; 20.1, 20.2), the padding element(s) (20; 20.1, 20.2), which is/are fastened to the basic structure part(s) (10) by means of the fastening elements (1A', 2A`), forming a positive shape only in the assembled state which corresponds to the negative shape of the at least one depression (1B, 2B), since the fastening elements (1A', 2A`) shape the cushion element(s) (20; 20.1, 20.2) on the basic structure part(s) (10) holds/hold. Vehicle seat (100) according to claim 1 , characterized in that the/the basic structure part/s (10) is/are a component produced using the FDM 3D printing process or a component/s produced using the BAAM 3D printing process. Vehicle seat (100) according to claim 1 , characterized in that the / the padding element / s (20; 20.1, 20.2) is a component produced in the FDM 3D printing process / are. Vehicle seat (100) according to claim 1 , characterized in that the / the padding element / s (20; 20.1, 20.2), the fastening elements (1A ', 2A') and the / the basic structure part / s (10) have recesses (1A, 2A) as fastening means. Vehicle seat (100) according to claims 2 and 4 or 3 and 4 , characterized in that the fastening elements (1A ', 2A') in the FDM 3D printing process in one piece with the cushion element (20; 20.1, 20.2) together and the recesses (1A, 2A) in the FDM 3D printing process or are produced in one piece with the basic structural part (10) using the BAAM 3D printing process. Vehicle seat (100) according to claim 3 , characterized in that the / in the FDM 3D printing process / n padding element / s (20; 20.1, 20.2) is formed as a three-dimensional network with matrix-like, open pores elastic with a resilience. A method for manufacturing a vehicle seat (100) comprising a one-piece or multi-piece basic structure part (10) and a one-piece or multi-piece cushion element (20; 20.1, 20.2), wherein the base structure part(s) (10) and the cushion element(s) (20; 20.1, 20.2) are produced in a 3D printing process or different 3D printing processes, with the basic structure part(s) (10) and the cushion element(s) (20; 20.1, 20.2) having attachments that are simultaneously are formed in the manufacturing steps of the basic structure part(s) (10) and the padding element(s) are reversibly connected to one another in an assembled state, the basic structure part(s) (10) having at least one depression (1B , 2B) has / have, in which the / by means of the fasteners (1A ', 2A') fastened / n padding element / s (20; 20.1, 20.2) rests / lie in the assembled state, characterized in that the at least ns a depression (1B, 2B) is formed as a concavely curved shape that curves inwards relative to the plane of the seat surface, the at least one depression (1B, 2B) being a negative mold for the cushion element(s) (20; 20.1, 20.2) is formed, wherein the padding element(s) (20; 20.1, 20.2), which is/are fastened to the basic structure part(s) (10) by means of the fastening elements (1A', 2A'), only in Assembled state assumes/accept a positive shape that corresponds to the negative shape of the at least one depression (1B, 2B), since the cushion element(s) (20; 20.1, 20.2) after being inserted by means of the fastening elements (1A', 2A') into the at least one indentation (1B, 2B) is/are drawn into the at least one indentation (1B, 2B) onto the base structure part(s) (10) and held on the base structure part(s) (10). Process for manufacturing the vehicle seat claim 7 , characterized in that • the / the basic structure part / s (10) and the / the padding element / s (20; 20.1, 20.2) in the FDM 3D printing process or • the / the basic structure part / s (10) in BAAM - 3D printing process and the padding element(s) (20; 20.1, 20.2) are produced using the FDM 3D printing process.

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