WO2020141555A1

WO2020141555A1 - Vehicle seat and manufacturing method thereof

Info

Publication number: WO2020141555A1
Application number: PCT/IN2020/050007
Authority: WO
Inventors: Tripathi SUMIT MANI; Arya MOHIT MADHUR
Original assignee: Hero MotoCorp Limited
Priority date: 2019-01-04
Filing date: 2020-01-03
Publication date: 2020-07-09

Abstract

A seat (300) of a vehicle (10) is disclosed. The seat (300) comprising: a front portion (302) composed of a foam material having a first predetermined density D1; a rear portion (303) composed of a foam material having a second predetermined density D2; a first pair of side portions (304); and, a second pair of side portions (306). The front portion (302) is connected to each of the rear portion (303) and the first pair of side portions (304). The second pair of side portions (306) is connected to each of the rear portion (303) and the first pair of side portions (304). The first predetermined density D1 is different from the second predetermined density D2.

Description

“VEHICLE SEAT AND MANUFACTURING METHOD THEREOF”

The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

FIELD OF INVENTION

[0001] The present invention relates to vehicles and, more particularly, to a seat of a vehicle.

BACKGROUND [0002] Vehicles are provided with seats supported on vehicle frames. The seats provide a platform on which rider or pillion rider rest. Particularly, buttock portions of the riders or pillion riders rest on the seats, when the vehicle are being ridden. The seats are therefore required to be compressible in order to keep the rider and the pillion rider comfortable, even after prolonged occupation thereof. The seats are composed of a compressible material, such as foam, enclosed within a flexible cover. During operation of a vehicle, when a rider or a pillion rider occupies the seat, the compressible material marginally compresses within the flexible cover.

[0003] Typically, the seat includes different portions, such as a front portion on which the rider sits, a rear portion on which the pillion rider sits. Further, the seats also typically includes a set of thigh supporting portions. These different portions of the seat have different thickness of compressible material, and the amount of compressibility offered by these different portions of the seat is different.

[0004] However, after prolonged usage, certain of the different portions of the seat, such as the front portion, which experiences higher or more frequent loads, tends to become flat, stiff and incompressible. This can be undesirable as an incompressible and stiff seat fails to serve its intended purpose. Further, certain other different portions of the seat, such as the set of thigh supporting portions or the rear portion, which experience lower or less frequent loads, tend to remain compressible, causing the seat to have different height, and different compressibility.

SUMMARY OF INVENTION

[0005] In one aspect of the present invention, a seat of a vehicle is provided. The seat comprising: a front portion , the front portion is composed of a foam material having a first predetermined density Dl; a rear portion , the rear portion is composed of a foam material having a second predetermined density D2; a first pair of side portions ; and, a second pair of side portions , the front portion is connected to each of the rear portion and the first pair of side portions , the second pair of side portions is connected to each of the rear portion and the first pair of side portions . Each of the first pair of side portions, and the second pair of side portions are composed of the foam material having the second predetermined density D2. The first predetermined density Dl is different from the second predetermined density D2. In an example, the first predetermined density Dl is greater than the second predetermined density D2.

[0006] The front portion has a different compressibility than the rear portion of the seat. The first pair of side portions, and the second pair of side portions have a different compressibility than the front portion. The at least one parting portion separates the front portion from the rear portion. The parting portion further separates the front portion from the first pair of side portions, and the rear portion from the second pair of side portions.

[0007] Therefore, the seat of the present invention provides different level of softness or comfort to occupants. More specifically, the present invention provides the seat composed of the foam material having a first predetermined density Dl and the second predetermined density D2, wherein the first predetermined density Dl is different from the second predetermined density D2. Owing to different density of foam material, the front portion has a different compressibility than the rear portion of the seat. As such, due to such different densities of foam material, the front portion is more compressible, and therefore soft, than the rear portion of seat. Accordingly, the seat of the present invention can provide different levels of softness or comfort to occupants.

[0008] In another aspect of the present invention, a system for manufacturing a seat of a vehicle having a parting portion is provided. The system includes a mold base having a base surface; a mold core having a pressing surface, the mold core is adapted to be placed over the mold base, wherein when the mold core is placed over the mold base, the base surface faces the pressing surface; one or more separating members extending vertically from the base surface of the mold base to separate the mold base into at least one first cavity, and at least one second cavity. Vertical extension of the separating member corresponds to the extension of the parting portion. The width of the separating member corresponds to the width of the parting portion. The system of the present invention is used for manufacturing the seat that provides different level of softness or comfort to occupants.

[0009] In yet another aspect of the present invention a method of manufacturing a seat is provided. The method includes introducing form material in molten form, having a first predetermined hardness, in a first cavity ; introducing form material in molten form, having a second predetermined hardness, in a second cavity ; restricting, via a separating member, mixing of the foam material having the first predetermined density D1 with the foam material having the second predetermined density D2, until either of the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 have expanded up to a height of the separating member ; and closing a mold core over a mold base , such that the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 is compressed between the base surface and the pressing surface to form the seat . [00010] The method of the present invention is used for manufacturing the seat that provides different level of softness or comfort to occupants. More specifically, the method of the present invention is used for manufacturing the seat that is composed of the foam material having a first predetermined density D1 and the second predetermined density D2, wherein the first predetermined density D1 is different from the second predetermined density D2.

BRIEF DESCRIPTION OF DRAWINGS

[00011] The invention itself, together with further features and attended advantages, will become apparent from consideration of the following detailed description, taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example only wherein like reference numerals represent like elements and in which:

[00012] Figure 1 illustrates a side view of an exemplary two wheeled vehicle, according to an embodiment of the present invention;

[00013] Figure 2 illustrates a view of a frame of the exemplary two wheeled vehicle, according to an embodiment of the present invention;

[00014] Figure 3 illustrates a top view of a seat of the exemplary two wheeled vehicle, in accordance with an embodiment of the present invention; [00015] Figure 4 illustrates a perspective view of the seat of the exemplary two wheeled vehicle, in accordance with an embodiment of the present invention;

[00016] Figure 4A illustrates a sectional view seat of the exemplary two wheeled vehicle, in accordance with an embodiment of the present invention;

[00017] Figure 5 illustrates a perspective view of the system for making the seat, in accordance with an embodiment of the present invention;

[00018] Figure 6 illustrates a perspective view of a system for making the seat, in accordance with an embodiment of the present invention;

[00019] Figure 6A illustrates a sectional view of system for making the seat, in accordance with an embodiment of the present invention; and, [00020] Figure 7 illustrates a flow chart of a method of manufacturing the seat, in accordance with an embodiment of the present invention.

[00021] The drawings referred to in this description are not to be understood as being drawn to scale except if specifically noted, and such drawings are only exemplary in nature. DETAILED DESCRIPTION

[00022] While the invention is susceptible to various modifications and alternative forms, an embodiment thereof has been shown by way of example in the drawings and will be described here below. It should be understood, however that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention.

[00023] The term “comprises”, comprising, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, structure or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or structure or method. In other words, one or more elements in a system or apparatus proceeded by“comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus. [00024] For better understanding of this invention, reference would now be made to the embodiment illustrated in the accompanying Figures and description here below, further, in the following Figures, the same reference numerals are used to identify the same components in various views.

[00025] While the present invention is illustrated in the context of a vehicle, however, seats and aspects and features thereof can be used with other type of vehicles as well. The terms“vehicle”,“two wheeled vehicle” and“motorcycle” have been interchangeably used throughout the description. The term“vehicle” comprises vehicles such as motorcycles, scooters, bicycles, mopeds, scooter type vehicle, all-terrain vehicles (ATV) and the like.

[00026] The terms“front / forward”,“rear / rearward / back / backward”,“up / upper / top”,“down / lower / lower ward / downward, bottom”,“left / leftward”,“right / rightward” used therein represents the directions as seen from a vehicle driver sitting astride and these directions are referred by arrows Fr, Rr, U, Lr, L, R in the drawing Figures. [00027] Referring to Figures 1, a vehicle (10) according to an embodiment of the present invention is illustrated. The vehicle (10) referred to herein, embodies a two wheeled motorcycle. Alternatively, the vehicle (10) may embody any other ridden vehicles such as scooters, three-wheeled vehicles, All-Terrain Vehicles (ATV) etc. without limiting the scope of the invention.

[00028] The vehicle (10) comprises one or more body parts, such as a frame (12), a handle bar (14), a front wheel (16), a rear wheel (20), an engine (22), a headlight (24), and a fuel tank (26). The frame (12) supports the engine (22) in middle portion of the vehicle (10). In the illustrated example, the engine (22) provides necessary power required to drive the rear wheel (20) of the vehicle (10). Alternatively, the engine (22) may provide necessary power to the drive the front wheel (16), or both the front wheel (16) and the rear wheel (20) simultaneously, without limiting the scope of the invention. The rear wheel (20) is linked to the engine (22) through a transmission mechanism (not numbered). The fuel tank (26) provides necessary fuel to the engine (22) to generate power within the vehicle (10). [00029] As shown in Figure 2, the frame (12) of the vehicle (10) comprises the head pipe (30), a single main frame (32), and a down frame (34). The single main frame (32) extends downwards and rearwards from a rear portion of the head pipe (30) so as to form a relatively mild slope in side view. The down frame (34) extend downward and rearward in a manner branching into left and right, respectively, so as to form a relatively steep slope in side view. The frame (12) comprises a pair of lower frames (36). The pair of lower frames (36) are curved to extend rearwardly from lower ends of the down frame (34).

[00030] Further, the frame (12) comprises a pair of middle frames (38). The pair of middle frames (38) extend downward and rearward from a main frame cross bar (40). The frame (12) comprises a mount bracket (42) coupled to the front side of lower portions of the pair of middle frames (38). A pivot pipe (P) is coupled to a lower portion of the mount bracket (42) in a state of penetrating there through. [00031] Further, the frame (12) further comprises a pair of sub frame members (50). In an embodiment, the pair of sub frame members (50) are embodied as a pair of seat frames are disposed rearward of the upper ends of the pair of respective middle frames (38).

[00032] Referring now to Figure. 3, the frame (12) supports a seat (300) which extends from middle portion towards a rear (28) of the vehicle (10). The seat (300) provides seating for a rider and / or a passenger of the vehicle (10). The seat (300) includes a front portion (302), also referred to as a rider portion, a rear portion (303), also referred to as a pillion portion, a first pair of side portions (304), and a second pair of side portions (306). In an embodiment, the front portion (302) is connected to the rear portion (303), and the first pair of side portions (304). Likewise, the second pair of side portions (306) is connected to the rear portion (303) and the second pair of side portions (306).

[00033] In an embodiment, the first pair of side portions (304) includes a side portion (304a), and a side portion (304b). Each of the side portion (304a), and the side portion (304b) are connected to opposite sides of the front portion (302), such that a part of each of the side portion (304a), and the side portion (304b) rests on the fuel tank (26).

[00034] The seat (300) is composed of foam material. The front portion (302) of seat (300) is composed of a foam material having a first predetermined density Dl, also referred to as first predetermined hardness. On the other hand, the rear portion (303) is composed of a foam material having a second predetermined density D2, also referred to as second predetermined hardness. In an embodiment, the first predetermined density Dl is different from the second predetermined density D2.

[00035] Further, the first pair of side portions (304), and the second pair of side portions (306) are composed of a foam material having a predetermined density. In an embodiment, each of the first pair of side portions (304), and the second pair of side portions (306) are composed of the foam material having the second predetermined density

D2. In alternative embodiments, the first pair of side portions (304), and the second pair of side portions (306) may have a predetermined density different from the first predetermined density Dl and the second predetermined density D2. [00036] Owing to different density of foam material in the front portion (302) and the rear portion (303), the front portion (302) has a different compressibility than the rear portion (303) of seat (300). Likewise, owing to different density of foam material in the first pair of side portions (304), and the second pair of side portions (306), with respect to the front portion (302), the first pair of side portions (304), and the second pair of side portions (306) have a different compressibility than the front portion (302).

[00037] In the disclosed embodiment, the first predetermined density D1 is greater than the second predetermined density D2. Owing to such different densities of foam material in the front portion (302) and the rear portion (303), the front portion (302) is more compressible, and therefore soft, than the rear portion (303) of seat (300). Further, in the disclosed embodiment, Owing to such different densities of foam material in the front portion (302), with respect to the first pair of side portions (304), and the second pair of side portions (306), the front portion (302) is more compressible, and therefore soft, than the first pair of side portions (304), and the second pair of side portions (306). [00038] Referring now to Figure 4 and Figure 4 A, the seat (300) further includes a top surface (308), and a bottom surface (310), connected to, and opposite to the top surface (308). A seat cover (not illustrated) encloses the top surface (308) and a portion of the bottom surface (310). The seat cover may be composed of an elastic material, such as leather. The bottom surface (310) of the seat (300) is connected to a seat base (not illustrated). The seat base may be composed of a suitable material, such as plastic. In an embodiment, the seat cover encloses the top surface (308) and is connected to the seat base by stapling.

[00039] As shown in Figure 4 and Figure 4 A, the seat (300) further includes at least one parting portion, such as a parting portion (312). The parting portion (312) separates the front portion (302) from the rear portion (303). The parting portion (312) also separates the front portion (302) from the first pair of side portions (304), the rear portion (303) from the second pair of side portions (306). It may herein be noted that there may be fewer or more number of parting portions, such as the parting portion (312) provided on the seat (300). [00040] As shown in Figure 4A, the parting portion (312) extends from the top surface (308) towards the bottom surface (310). In an embodiment, the parting portion (312) are embodied as a groove formed on the top surface (308) having a predetermined width“W,” and extending towards the bottom surface (310). In an embodiment, the extension of the parting portion (312) is up to a predetermined distance“Dl,” from the bottom surface

(310). In an example, the predetermined distance“Dl,” from the bottom surface (310) is 10 mm. As such, through the stretch of the predetermined distance“Dl,” the front portion (302) is connected to the rear portion (303). In an example, the predetermined width“W,” of the parting portion (312) is 1 mm. As such, the front portion (302) is separated from the rear portion (303) by the predetermined width“W.”

[00041] Referring now to Figure. 5 and 5 A which illustrates a system (500) for manufacturing a seat, such as the seat (300). The system (500) includes a mold base (502) and a mold core (504). The mold core (504) is adapted to be placed over the mold base (502). The mold base (502) includes a base surface (506), and the mold core (504) includes a pressing surface (508). The mold core (504) is adapted to be placed over the mold base

(502). When the mold core (504) is placed over the mold base (502), the base surface (506) faces the pressing surface (508).

[00042] The system (500) further includes one or more separating members, such as a separating member (510). In an embodiment, the separating member (510) is integral to the base surface (506) of the mold base (502). In alternative embodiments, the separating member (510) is removably connected to the base surface (506) of the mold base (502). The separating member (510) extends upwardly from the base surface (506) of the mold base (502). The vertical extension of the separating member (510) corresponds to the extension of the parting portion (312). Further, the width of the separating member (510) corresponds to the predetermined width“W,” of the parting portion (312). In an example, the separating member (510) is embodied as a metallic strip welded to the base surface (506) of the mold base (502).

[00043] As shown in Figure. 6, the separating member (510) separates the mold base (502) into multiple cavities. Therefore the system (500) further includes a first cavity (512) and a second cavity (514), separated from the first cavity (512) by the separating member (510). In an embodiment, the first cavity (512) may be shaped corresponding to the shape of the front portion (302), whereas the second cavity (514), may be shaped corresponding to the shape of the rear portion (303), the first pair of side portions (304), and the second pair of side portions (306).

[00044] It may herein be noted that the shape and size of the first cavity (512), the second cavity (514) and the separating member (510), as explained herein is for explanation purposed, and in various other embodiments of the present invention the first cavity (512), the second cavity (514) and the separating member (510) may have different shapes and sizes, corresponding to the shape and side of the seat (300). Further, it may herein be noted that, although in the present disclosure there is one separating member (510) and it defines only two cavities, in alternative embodiments there may be any multiple number of the separating members, such as the separating member (510) and defining multiple number of cavities, without deviating from the spirit of the present invention. [00045] The first cavity (512) is adapted to receive molten form of the foam material having the first predetermined density Dl. Further, the second cavity (514) is adapted to receive the foam material having the second predetermined density D2. Both the first cavity (512) and the second cavity (514) are adapted to allow expansion of the respective foam materials. [00046] Referring now to Figure. 7, a method (700) of manufacturing a seat, such as the seat (300), is illustrated. The method (700) at step (702), includes, pouring form material in molten form and having a first predetermined hardness, also referred to as first predetermined density Dl, in a first cavity, such as the first cavity (512) of the system (500). Subsequently, the foam material having the first predetermined density Dl in the first cavity (512) is allowed to cool down and expand.

[00047] The method (700) at step (704), includes, pouring form material in molten form and having a second predetermined hardness, also referred to as second predetermined density D2, in a second cavity, such as the second cavity (514) of the system (500). Subsequently, in an embodiment, the foam material having the second predetermined density D2 in the second cavity (514) is allowed to cool down and expand. The separating member (510), restricts mixing of the foam material having the first predetermined density D1 with the foam material having the second predetermined density D2, until either of the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 have expanded fully. Once either of the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 have expanded beyond height of the separating member (510), the foam material having the first predetermined density D1 gets joined with the foam material having the second predetermined density D2.

[00048] The method (700) at step (706), includes closing the mold core (504) over the mold base (502), such that the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 is compressed between the base surface (506) and the pressing surface (508). The method (700) at subsequent steps includes de-molding, air releasing by compression of form, and curing, for manufacture the seat (300).

[00049] The seat (300) manufactured by the method (700) includes a front portion

(302) composed of foam material having the first predetermined density Dl, and the rear portion (303) composed of foam material having the second predetermined density D2. Owing to different density of the foam material in the front portion (302) and the rear portion (303), the front portion (302) has a different compressibility than the rear portion

(303) of the seat (300).

[00050] In light of the foregoing, the present invention provides a seat (300) that provides different level of softness or comfort to occupants. More specifically, the present invention provides the seat (300) having the front portion (302) composed of the foam material having a first predetermined density Dl and the rear portion (303) composed of the foam material having the second predetermined density D2. The first predetermined density Dl is different from the second predetermined density D2. [00051] Owing to different density of foam material in the front portion (302) and the rear portion (303), the front portion (302) has a different compressibility than the rear portion (303) of the seat (300). As such, due to such different densities of foam material in the front portion (302) and the rear portion (303), the front portion (302) is more compressible, and therefore soft, than the rear portion (303) of seat (300). Accordingly, the seat (300) of the present invention can provide different levels of softness or comfort to occupants. The present invention also provides the system and method for manufacturing the seat (300).

[00052] While few embodiments of the present invention have been described above, it is to be understood that the invention is not limited to the above embodiments and modifications may be appropriately made thereto within the spirit and scope of the invention.

[00053] While considerable emphasis has been placed herein on the particular features of this invention, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other modifications in the nature of the invention or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

Claims

1 The claims:

1. A seat (300) of a vehicle (10), the seat (300) comprising:

a front portion (302), the front portion (302) is composed of a foam material having a first predetermined density Dl;

a rear portion (303), the rear portion (303) is composed of a foam material having a second predetermined density D2;

a first pair of side portions (304); and,

a second pair of side portions (306), the front portion (302) is connected to each of the rear portion (303) and the first pair of side portions (304), the second pair of side portions (306) is connected to each of the rear portion (303) and the first pair of side portions (304); each of the first pair of side portions (304), and the second pair of side portions (306) are composed of the foam material having the second predetermined density D2,

wherein the first predetermined density Dl is different from the second predetermined density D2.

2. The seat (300) of the vehicle (10) as claimed in claim 1, wherein the first predetermined density Dl is greater than the second predetermined density D2.

3. The seat (300) of the vehicle (10) as claimed in claim 1, wherein the front portion (302) has a different compressibility than the rear portion (303) of the seat (300).

4. The seat (300) of the vehicle (10) as claimed in claim 1, wherein the first pair of side portions (304), and the second pair of side portions (306) have a different compressibility than the front portion (302).

5. The seat (300) of the vehicle (10) as claimed in claim 1 further comprises a top surface (308), and a bottom surface (310) opposite to the top surface (308).

6. The seat (300) of the vehicle (10) as claimed in claim 5 further comprises at least one parting portion (312) extending from the top surface (308) towards the bottom surface (310). 2

7. The seat (300) of the vehicle (10) as claimed in claim 6, wherein the at least one parting portion (312) separates the front portion (302) from the rear portion (303).

8. The seat (300) of the vehicle (10) as claimed in claim 7, wherein the parting portion (312) further separates the front portion (302) from the first pair of side portions (304), and the rear portion (303) from the second pair of side portions (306).

9. A system (500) for manufacturing a seat (300) of a vehicle (10) having a parting portion (312), the system (500) comprising:

a mold base (502) having a base surface (506);

a mold core (504) having a pressing surface (508), the mold core (504) is adapted to be placed over the mold base (502), wherein when the mold core (504) is placed over the mold base (502), the base surface (506) faces the pressing surface (508);

one or more separating members (510) extending vertically from the base surface (506) of the mold base (502) to separate the mold base (502) into at least one first cavity (512), and at least one second cavity (514),

wherein vertical extension of the separating member (510) corresponds to the extension of the parting portion (312), and wherein the width of the separating member (510) corresponds to the width of the parting portion (312).

10. A method (700) of manufacturing a seat (300), the method (700) comprising:

introducing form material in molten form, having a first predetermined hardness, in a first cavity (512);

introducing form material in molten form, having a second predetermined hardness, in a second cavity (514);

restricting, via a separating member (510), mixing of the foam material having the first predetermined density D1 with the foam material having the second predetermined density D2, until either of the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 have expanded up to a height of the separating member (510); and 3 closing a mold core (504) over a mold base (502), such that the foam material having the first predetermined density D1 and the foam material having the second predetermined density D2 is compressed between the base surface (506) and the pressing surface (508) to form the seat (300).