FUNCTION-ADAPTED THREE-DIMENSIONAL FOAM STRUCTURE

Abstract

A function-adapted three-dimensional foam structure (2) for a vehicle seat (4) has first foam structure planes (6) to ensure a constant compressive strength of the foam structure (2) in two spatial directions x, y, second foam structure planes (8) to ensure a length variance of the foam structure (2) in a spatial direction z, that is perpendicular to the spatial directions x and y. The first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the compressive strength of the foam structure (2) is constant in the spatial directions x, y independent of the length-wise expansion of the foam structure (2) in the spatial direction z.

Claims

1. A function-adapted three-dimensional foam structure (2) for a vehicle seat (4) comprising: plural first foam structure planes (6) configured to ensure a constant compressive strength of the foam structure (2) in two spatial directions x, y; and plural second foam structure planes (8) configured to ensure a length variance of the foam structure (2) in a spatial direction z, wherein the spatial direction z is perpendicular to the spatial directions x and y, and the plural first foam structure planes (6) and second foam structure planes (8) are formed and distributed within the foam structure (2) such that a compressive strength of the foam structure (2) is constant in the spatial directions x, y independent of a length-wise expansion of the foam structure (2) in the spatial direction z.

2. The functionally adapted three-dimensional foam structure (2) of claim 1, wherein the first foam structure planes (6) and the second foam structure planes (8) are present in the foam structure (2) in equal numbers, and the first foam structure planes (6) and the second foam structure planes (8) are arranged to alternate with one another in the foam structure (2).

3. The function-adapted three-dimensional foam structure (2) of claim 2, the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the length variance of the foam structure (2) in the spatial direction z is at least 3 times the length variance of the foam structure (2) in the spatial directions x or y.

4. The function-adapted three-dimensional foam structure (2) of claim 3, wherein the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the compressive strength of the foam structure (2) in the spatial directions x and y is at least 3 times the compressive strength of the foam structure (2) in the spatial direction z.

5. The functionally adapted three-dimensional foam structure (2) of claim 4, wherein the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the compressive strength of the foam structure (2) perpendicular to the spatial direction z varies by less than 3%.

6. The function-adapted three-dimensional foam structure (2) of claim 1, the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the length variance of the foam structure (2) in the spatial direction z is at least 3 times the length variance of the foam structure (2) in the spatial directions x or y.

7. The function-adapted three-dimensional foam structure (2) of claim 1, wherein the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the compressive strength of the foam structure (2) in the spatial directions x and y is at least 3 times the compressive strength of the foam structure (2) in the spatial direction z.

8. The functionally adapted three-dimensional foam structure (2) of claim 1, wherein the first foam structure planes (6) and the second foam structure planes (8) are formed and distributed within the foam structure (2) such that the compressive strength of the foam structure (2) perpendicular to the spatial direction z varies by less than 3%.

9. A vehicle seat (4) with a seat structure (14) comprising: a seat middle web (10); left and right side wings (12) arranged respectively on left and right sides of the seat middle web (10); and a headrest (16) arranged above the seat middle web (10), wherein the vehicle seat (4) has the function-adapted three-dimensional foam structure (2) of claim 1.

10. The vehicle seat (4) of claim 9, wherein the seat structure (14) comprises an extended adjustment region configured to provide length adjustability of the seat middle web (10) and/or a height adjustability of the headrest (16) and/or a tilt adjustability of the headrest (16).

11. The vehicle seat (4) of claim 9, wherein the seat structure (14) has a height adjustability of at least 5 cm and/or a backrest reclinability of at least 5?.

12. The vehicle seat (4) of claim 9, wherein the seat structure (14) has a distance override capability in the seat middle web (10) and/or between the side wings (12) and the headrest (16).

13. A method for producing the function-adapted three-dimensional foam structure (2) of claim 1 for a vehicle seat (4), the method comprising the steps of: selecting (100) a desired compressive strength and length variance of the foam structure (2) along the spatial directions x, y, z, simulating (200) a construction and composition of the foam structure (2) from a plurality of first foam structure planes (6) to ensure a constant compressive strength of the foam structure (2) in two spatial directions x, y and a plurality of second foam structure planes (8) to ensure a length variance of the foam structure (2) in a spatial direction z, producing (300) the foam structure (2) based on the simulation.

14. The method of claim 13, wherein the production (300) of the foam structure (2) is carried out via 3D printing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a function-adapted three-dimensional foam structure according to a first embodiment.

[0023] FIG. 2 is a partial section of a function-adapted three-dimensional foam structure according to a second embodiment.

[0024] FIG. 3 is a vehicle seat having a function-adapted three-dimensional foam structure according to a first embodiment.

[0025] FIG. 4 shows the vehicle seat of FIG. 3 in a first position (left) and a second position (right).

[0026] FIG. 5 schematically illustrates the steps of a method for producing a function-adapted three-dimensional foam structure for use in a vehicle seat.

DETAILED DESCRIPTION

[0027] FIG. 1 shows a function-adapted three-dimensional foam structure 2 according to a first embodiment.

[0028] The foam structure 2 of FIG. 1 comprises first foam structure planes 6 to ensure a constant compressive strength of the foam structure 2 in two spatial directions x, y as well as second foam structure planes 8 to ensure a length variance of the foam structure 2 in a spatial direction z. The spatial direction z is perpendicular to the spatial directions x and y. The first foam structure planes 6 and second foam structure planes 8 are formed and distributed within the foam structure 2 such that the compressive strength of the foam structure 2 in the spatial directions x, y is constant independent of the length-wise expansion of the foam structure 2 in the spatial direction z.

[0029] The first foam structure planes 6 and the second foam structure planes 8 can be present in the foam structure 2 in the same number or amount and can be arranged to alternate with one another in the foam structure 2.

[0030] The first foam structure planes 6 and the second foam structure planes 8 can further be formed and distributed within the foam structure 2 such that the length variance of the foam structure 2 in the spatial direction z is at least 3 times, preferably at least 5 times, in particular at least 10 times the length variance of the foam structure 2 in the spatial directions x or y.

[0031] Likewise, the first foam structure planes 6 and the second foam structure planes 8 can be formed and distributed within the foam structure 2 such that the compressive strength of the foam structure 2 in the spatial directions x and y is at least 3 times, preferably at least 5 times, in particular at least 10 times the compressive strength of the foam structure 2 in the spatial direction z.

[0032] Furthermore, the first foam structure planes 6 and the second foam structure planes 8 can be formed and distributed within the foam structure 2 such that the compressive strength of the foam structure 2 perpendicular to the spatial direction z varies by less than 3%, preferably less than 2%, in particular less than 1%.

[0033] FIG. 2 shows a partial section of a function-adapted three-dimensional foam structure 2 of a second embodiment, in which the first foam structure planes 6 are arranged to ensure a constant compressive strength of the foam structure 2 in two spatial directions x, y, as well as, a second foam structure plane 8 to ensure a length variance of the foam structure 2 in a spatial direction z.

[0034] FIG. 3 shows a first embodiment of a vehicle seat 4 with a function-adapted three-dimensional foam structure 2. The vehicle seat 4 of FIG. 3 comprises a seat structure 14 for use in a motor vehicle with a seat middle web 10, side wings 12 arranged respectively to the left and right of the seat middle web 10, and a headrest 16 above the seat middle web 10. The vehicle seat 4 has a function-adapted three-dimensional foam structure 2.

[0035] FIG. 4 shows the vehicle seat of FIG. 3 in a first position (left) and a second position (right). The seat structure 14 of FIG. 4 has an extended adjustment region that comprises a length adjustability of the seat middle web 10, a height adjustability of the headrest 16, a tilt adjustability of the headrest 16, and a distance override capability in the seat middle web 10 in the side wings 12 and in the headrest 16.

[0036] FIG. 5 shows the individual steps of a method according to the invention for producing a function-adapted three-dimensional foam structure for use in a vehicle seat. The method of FIG. 5 comprises a first step 100 of selecting a desired compressive strength and length variance of the foam structure 2 along the spatial directions x, y, z. The method proceeds with a step 200 for simulating a construction and a composition of the foam structure 2 from a plurality of first foam structure planes 6 to ensure a constant compressive strength of the foam structure 2 in two spatial directions x, y and a plurality of second foam structure planes 8 to ensure a length variance of the foam structure 2 in a spatial direction z. The method then includes a step 300 of producing the foam structure 2 based on the simulation of the step 200.

[0037] The production 300 of the foam structure 2 in the step 300 can be carried out via a 3D printing method.

[0038] The above explanation describes the invention solely in the context of examples. Of course, if technically useful, individual features of the embodiments can be combined freely with one another without departing the scope of the invention.