Patent Publication Number: US-2023150408-A1

Title: Seat for a vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims priority from Italian patent application no.102021000029159 filed on Nov. 18, 2021, the entire disclosure of which is incorporated herein by reference. 
     TECHNICAL SECTOR 
     The invention relates to a seat for a vehicle. 
     PRIOR ART 
     The seat of a vehicle consists of a seat cushion having a substantially horizontal arrangement and of a backrest having a substantially vertical arrangement. 
     From a constructive point of view, the seat of a vehicle comprises a frame (typically made of metal or composite material), which is fixed to the floorboard of the vehicle, a bearing structure, which is mounted on the frame and is elastically yielding, and an upholstery, which covers the bearing structure and makes up the aesthetic and tactile interface to the outside (the upholstery can be made of fabric or leather). 
     Manufacturers recently suggested manufacturing the bearing structure of a seat by means of a net-like structure, which is built with 3D printers (namely, through additive manufacturing). 
     Pat. US10272800B2 discloses a seat for a car having a main cushion, which is coupled to a shield, which surrounds at least part of the lateral sides of the main cushion and is made of a foam that is less compressible (namely, harder) compared to the main cushion. 
     DESCRIPTION OF THE INVENTION 
     The object of the invention is to provide a seat for a vehicle, which offers high comfort combined with reduced weight and small sizes. 
     According to the invention, there is provided a seat for a vehicle as claimed in the appended claims. 
     The appended claims describe preferred embodiments of the invention and form an integral part of the description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described with reference to the accompanying drawings, showing some non-limiting embodiments thereof: 
         FIG.  1    is a perspective view of a seat for a vehicle according to the invention; 
         FIG.  2    is a schematic view of a cushion of the seat of  FIG.  1   ; 
         FIG.  3    is a schematic, longitudinal section view of the cushion of  FIG.  2   ; 
         FIG.  4    is a schematic, longitudinal section view of a variant of the cushion of  FIG.  2   ; 
         FIG.  5    is a schematic view of a backrest of the seat of  FIG.  1   ; 
         FIG.  6    is a schematic view of a different embodiment of the cushion of  FIG.  3   ; 
         FIG.  7    is a schematic view of a different embodiment of the backrest of  FIG.  2   ; and 
         FIG.  8    is a table summing up the value of the bearing capacity of different parts of a bearing structure of the seat of  FIG.  1   . 
     
    
    
     PREFERRED EMBODIMENTS OF THE INVENTION 
     In  FIG.  1   , number  1  indicates, as a whole, a seat for a vehicle. 
     The seat  1  consists of a seat cushion  2  having a substantially horizontal arrangement and of a backrest  3  having a substantially vertical arrangement; together, the cushion  2  and the backrest  3  give the seat  1  an “L” shape. The backrest  3  ends, at the top, with a headrest  4 , which is included in the backrest  3  (namely, forms one single indivisible body with the backrest  3 ). 
     From a constructive point of view, the seat  1  comprises a frame (typically made of metal or composite material), which is fixed to the floorboard of the vehicle, a bearing structure  5  (better shown in  FIGS.  2 - 5   ), which is mounted on the frame and is elastically yielding, and an upholstery  6  (visible in  FIG.  1   ), which covers the bearing structure  5  and makes up the aesthetic and tactile interface to the outside (the upholstery  6  can be made of fabric or leather). 
     According to a preferred embodiment, the upholstery  6  covering the bearing structure  5  has two twins through windows  7 , which are arranged at a given distance from one another, expose the bearing structure  5  lying underneath and are arranged in the area of the backrest  3 ; in particular, each through window  7  has an oblong shape (namely, has a length that is significantly greater than the width) arranged vertically. 
     The bearing structure  5  of the seat  1  is obtained by means of a polyurethane foam having a net-like structure, which is built with 3D printers (namely, through additive manufacturing). As described more in detail below, the bearing structure  5  does not feature an even bearing capacity (namely, the same bearing capacity everywhere), but it has a differentiated bearing capacity changing from zone to zone. 
     The bearing capacity (or compression resistance) of a foam is a measure of the load resistance (namely, of the compression resistance) thereof: the higher the value of the bearing capacity, the stiffer and harder (namely, more rigid) the foam and vice versa. The bearing capacity is usually measured in KPa for it is measured as pressure needed to obtain a predetermined deformation of the foam. In particular according to the IOS 1798 method corresponding to the UNI 6351 regulation, the bearing capacity of a foam is equal to the pressure (measured in KPa) needed to obtain a deformation value corresponding to 40% of a sample (having a surface of 323 square centimetres) subjected to compression (namely, the pressure needed to obtain a deformation that reduces by 40% the initial value of the thickness of the sample subjected to compression). 
     According to  FIGS.  2  and  3   , the bearing structure  5  of the cushion  2  comprises an outer zone  8 , which extends along the entire periphery of the cushion  2  and has a first bearing capacity P1 (ranging from 7.5 to 10.0 kPa), and an inner zone  9 , which extends at the centre, is completely surrounded - on all sides - by the outer zone  8  and has a bearing capacity P2 (ranging from 5.4 to 6.6 kPa) smaller than the bearing capacity P1. According to a preferred embodiment, the bearing capacity P2 ranges from 55% to 85% of the bearing capacity P1. 
     The bearing structure  5  of the cushion  2  comprises an insert  10 , which is completely arranged within the inner zone  9 , is at the centre of the cushion  2  and has a third bearing capacity P3 (ranging from 5.4 to 6.6 kPa) smaller than the bearing capacity P2. According to a preferred embodiment, the bearing capacity P3 ranges from 75% to 90% of the bearing capacity P2. According to a preferred embodiment, the insert  10  at least partially has the shape of a truncated cone, which reduces its size moving away from the cushion  2 ; in particular, the insert  10  has a rear part with a rectangular shape, which is arranged at the back of the cushion  2  (namely, in the area of the backrest  3 ), and a front part (joined to the rear part without gaps) with a trapezoidal shape, which is arranged at the front of the cushion  2 . 
     According to a preferred embodiment, the bearing structure  5  of the cushion  2  comprises two twin inserts  11 , which are separate from one another, are arranged next to one another completely within the inner zone  9 , are located between the insert  10  and the backrest  3  (remaining at a given distance other than zero both from the insert  10  and from the backrest  3 ), and have a bearing capacity P4 (ranging from 3.6 to 4.4 kPa) smaller than the bearing capacity P3. According to a preferred embodiment, the bearing capacity P4 ranges from 60% to 72% of the bearing capacity P2. According to a preferred embodiment, each insert  11  has a rectangular shape. 
     According to a preferred embodiment, the outer zone  8  comprises two separate twin ribs  12 , which extend within the inner zone  9  and flank part of the insert  10 . 
     In the embodiment shown in  FIG.  4   , the bearing structure  5  of the cushion  2  also comprises a cover  13 , which covers, at the top, both the outer zone  8  and the inner zone  9  (namely, covers the entire cushion  2 ) and has a bearing capacity P5 (ranging from 1.6 to 2.4 kPa) smaller than the bearing capacity P2 (and also smaller than the bearing capacities P3 and P4). According to a preferred embodiment, the bearing capacity P5 ranges from 25% to 40% of the bearing capacity P2. In the embodiment shown in  FIG.  4   , the bearing structure  5  of the cushion  2  is not provided with the cover  13 . 
     According to  FIG.  5   , the bearing structure  5  of the backrest  3  comprises an outer zone  14 , which has the shape of an upside-down “U”, extends along the periphery of the backrest  3  and has at least a bearing capacity P6 (ranging from 5.5 to 7.0 kPa), which is comprised between the bearing capacity P1 and the bearing capacity P2. Furthermore, the bearing structure  5  of the backrest  3  comprises an inner zone  15 , which extends at the centre, is surrounded on three sides by the outer zone  14 , on the lower side borders the bearing structure  5  of the cushion  2  and has the bearing capacity P4 smaller than the bearing capacity P6 and the bearing capacity P2. According to a preferred embodiment, the bearing capacity P4 ranges from 55% to 80% of the bearing capacity P6 and the bearing capacity P2 ranges from 85% to 95% of the bearing capacity P6. 
     According to a preferred embodiment, the bearing structure  5  of the backrest  3  includes the headrest  4 , which completely belongs to the outer zone  14  and, hence, has the bearing capacity P6. 
     According to a preferred embodiment, the bearing structure  5  of the backrest  3  comprises an insert  16 , which is arranged at the centre within the outer zone  14  and above the inner zone  15  and has the bearing capacity P2 smaller than the bearing capacity P6. 
     According to a preferred embodiment, the bearing structure  5  of the backrest  3  comprises two twin inserts  17 , which are separate from one another, are arranged on the two opposite sides of the inner zone  15  between the inner zone  15  and the outer zone  14  and have the bearing capacity P2 smaller than the sixth bearing capacity P6. 
     According to a preferred embodiment, the bearing structure  5  of the backrest  3  comprises two twin inserts  18 , which are separate from one another, are arranged on the two opposite sides of the inner zone  15  between the inner zone  15  and the outer zone  14 , are located above the inserts  17  and have the bearing capacity P3 smaller than the bearing capacity P2. According to a preferred embodiment, the bearing capacity P2 ranges from 75% to 90% of the bearing capacity P3. 
     In the alternative embodiment shown in  FIG.  6   , the outer zone  8  (having the bearing capacity P1 ranging from 7.5 to 10.0 kPa) of the bearing structure  5  of the cushion  2  does not extend along the entire periphery of the cushion  2 , but it extends only on three sides of the cushion  2 , thus having the shape of a “U” where the open zone faces the front (namely, faces the opposite way relative to the backrest  3 ). Namely, the outer zone  8  is U-shaped and surrounds on three sides (at the back and on the sides) the inner zone  9  and, hence, the outer zone  8  engages on three sides (at the back and on the sides) the periphery of the cushion  2 . 
     Furthermore, in the alternative embodiment shown in  FIG.  6   , the bearing structure  5  of the cushion  2  has a contour zone  19 , which is U-shaped and surrounds on three sides (at the front and on the sides) the inner zone  9  and the outer zone  8 , namely the contour zone  19  engages on three sides (at the front and on the sides) the periphery of the cushion  2 . The contour zone  19  has a bearing capacity P7 (ranging from 11.0 to 13.0 kPa) higher than the bearing capacity P1. According to a preferred embodiment, the bearing capacity P7 ranges from 110% to 170% of the bearing capacity P1. In particular, on the sides, the contour zone  19  rises from the remaining part of the cushion  2  so as to define two side panels that provide a suitable lateral containment to the cushion  2 ; on the other hand, at the front, the contour zone  19  is lowered relative to the remaining part of the cushion  2 . 
     Finally, in the alternative embodiment shown in  FIG.   6   , the outer zone  8  is not provided with the two separate twin ribs  12 , which extend within the inner zone  9  and flank part of the insert  10 . 
     In the alternative embodiment shown in  FIG.  7   , the outer zone  14  (shaped like an upside-down “U”) of the bearing structure  5  of the backrest  3  has two different bearing capacities: an upper part of the outer zone  14  (shaped like an upside-down “U”) has the bearing capacity P6 (ranging from 5.5 to 7.0 kPa) while a lower part of the outer zone  14  (shaped like an upside-down “U”) has the bearing capacity P1 (ranging from 7.5 to 10.0 kPa). Namely, the upper cusp of the outer zone  14  (shaped like an upside-down “U”) has the bearing capacity P6 while the two legs of the outer zone  14  (shaped like an upside-down “U”) have the bearing capacity P1. 
     In the alternative embodiment shown in  FIG.  7   , the bearing structure  5  of the backrest  3  has two contour zones  20 , which laterally delimit the outer zone  14  (namely, the two contour zones  20  are arranged on the opposite sides of the outer zone  14 ) and have the bearing capacity P7 (ranging from 11.0 to 13.0 kPa) higher than the bearing capacity P1 and the bearing capacity P6. In particular, the two contour zones  20  rise from the remaining part of the backrest  3  so as to define two side panels that provide a suitable lateral containment to the backrest  3 . 
     In the alternative embodiment shown in  FIG.  7   , the bearing structure  5  of the backrest  3  comprises is not provided with the insert  16 , which is arranged at the centre within the outer zone  14  and above the inner zone  15  and has the bearing capacity P2 smaller than the bearing capacity P6. 
     Even in the embodiment shown in  FIG.  7   , the bearing structure  5  of the backrest  3  includes the headrest  4 , which belongs to the upper part of the outer zone  14  and, hence, has the bearing capacity P2 except for a central insert  21  (right in the area of the head of the passenger), which has the bearing capacity P3 (ranging from 5.4 to 6.6 kPa) (slightly) smaller than the bearing capacity P2. 
     The embodiments described herein can be combined with one another, without for this reason going beyond the scope of protection of the invention. 
     The seat  1  described above has numerous advantages. 
     First of all, the seat  1  described above offers passengers a very high comfort, though featuring reduced weight and small size. 
     Furthermore, the seat  1  disclosed above can completely be customized so as to adjust to the actual anthropometric features of the end user. 
     Finally, the seat  1  described above can be manufactured in a relatively simple and quick fashion using a marketed 3D printer. 
     
       
         
           
               
               
               
             
               
                 LIST OF THE REFERENCE NUMBERS OF THE FIGURES 
               
             
            
               
                 
                   1 
                 
                 seat 
               
               
                 
                   2 
                 
                 cushion 
               
               
                 
                   3 
                 
                 backrest 
               
               
                 
                   4 
                 
                 headrest 
               
               
                 
                   5 
                 
                 bearing structure 
               
               
                 
                   6 
                 
                 upholstery 
               
               
                 
                   7 
                 
                 through windows 
               
               
                 
                   8 
                 
                 outer zone 
               
               
                 
                   9 
                 
                 inner zone 
               
               
                 
                   10 
                 
                 insert 
               
               
                 
                   11 
                 
                 insert 
               
               
                 
                   12 
                 
                 ribs 
               
               
                 
                   13 
                 
                 cover 
               
               
                 
                   14 
                 
                 outer zone 
               
               
                 
                   15 
                 
                 inner zone 
               
               
                 
                   16 
                 
                 insert 
               
               
                 
                   17 
                 
                 insert 
               
               
                 
                   18 
                 
                 insert 
               
               
                 
                   19 
                 
                 contour zone 
               
               
                 
                   20 
                 
                 contour zone 
               
               
                 
                   21 
                 
                 insert 
               
               
                 P1 
                 bearing capacity 
               
               
                 P2 
                 bearing capacity 
               
               
                 P3 
                 bearing capacity 
               
               
                 P4 
                 bearing capacity 
               
               
                 P5 
                 bearing capacity 
               
               
                 P7 
                 bearing capacity 
               
               
                 P7 
                 bearing capacity