FIELD OF INVENTION
[001] This invention relates to anti-squeak cushion 5 structure of
automobile seat. This invention offers a solution for preventing the
noise possibility in interface of seat cushion plastic foam and other
material. Typical application for the design is automobile seating.
However same can be implemented in other applications wherein
10 plastic foam is used.
BACKGROUND/PRIOR ART
[002] Plastic foams like EPP / EPS are widely used by automotive
15 manufacturers because of its performance benefits like lightweight,
energy management, durability performance and recyclability.
[003] To ensure the safety of the occupant travelling in a car, the
occupant (can be a child seat also) is secured by seat belts. However,
20 at the event of sudden deceleration or accident due to frontal crash,
the occupant or child seat tends to rotate and move forward. In order
to limit this movement, plastic foam structures are provided in the
seat cushion.
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[004] With the normal structure of cushion (without EPP) as in fig. 1
comprising of foam (F) on vehicle body floor (F'), the occupant or child
seat undergoes movement upon sudden deceleration or due to frontal
crash.
5
[005] In order to restrict the abovesaid movement, plastic foam pad
is incorporated as an anti-rotation component in the foam. So that,
the same can be employed as an anti-rotation element to serve the
necessary purpose.
10
[006] According to another prior art, EPP Pad (1) is provided to rest
on the vehicle body floor (2) as shown in fig. 2 such that, the pad is
interposed between the floor and foam pad (3). Thus, the EPP insert
pad directly remains in contact with the floor, which generates
15 squeaking noise in dynamic condition of vehicle.
[007] Still according to another known provision, EPP Pad (1') is
embedded in the foam (PU) (2') as illustrated in fig. 2A maintaining a
gap (G) from the vehicle body floor (3'). The EPP Pad does not serve
20 the necessary purpose because the foam therebelow gets compressed
which results in degraded anti-rotation performance.
[008] Thus, as per the present technology, the EPP pad is either fully
touching with the floor or completely inside the PU pad, which give
25 rise the following situations:-
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- When EPP pad touches the floor: The EPP pad rubs against
the floor and produces squeaking noise.
- When EPP pad is completely inside the PU pad: The EPP
pad does not act as an anti rotation member 5 for avoiding
rotation. In addition, the space between the occupant and
EPP pad reduces giving the hard feeling on thighs.
[009] According to another prior teaching, PU is molded around
10 expended polyolefin (EPO) to make a composite structure consisting
of PU foam around the polyolefin core.
[0010] In view of the above, there is a requirement to develop a novel
seat cushion structure of automobile, which can address issues of
15 prior arts. Now, the present invention will be disclosed hereinunder.
OBJECTS OF THE INVENTION
[0011] An object of this invention is to propose anti-squeak cushion
20 structure of automobile seat which obviates shortcomings of prior
arts.
[0012] Another object of this invention is to propose anti-squeak
cushion structure of automobile seat which is simple in design.
25 [0013] Yet another object of this invention is to propose anti-squeak
cushion structure of automobile seat which is comfortable to use.
5
[0014] Further object of this invention is to propose anti-squeak
cushion structure of automobile seat which prevents movement of
occupant or child seat secured to the seat.
SUMMARY 5 ARY OF INVENTION
[0015] According to this invention there is provided anti-squeak
cushion structure of automobile seat comprising a cushion foam pad
embodying insert pad mounted on floor of vehicle body, wherein the
10 insert pad constituting a rib structure which is virtually in contact
with the floor of vehicle body.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
15 [0016] Further objects and advantages of this invention will be more
apparent from the ensuing description when read in conjunction with
the accompanying drawings of exemplary embodiments of invention
and wherein:
20 Fig. 1 shows: Conventional rear seat cushion made of foam.
Fig. 2 shows: Rear seat cushion with plastic foam (partly outside
and touching the floor) of prior art.
25 Fig. 2A shows: Rear seat cushion with plastic foam (completely
inside) in known art.
6
Fig. 3 shows: Anti-squeak cushion structure of automobile seat
5 according to invention.
Fig. 4 shows: Isometric and sectional view of cushion structure
of rear seat according to present invention.
10 Fig. 5 shows: PU foam with EPP Pad of cushion in accordance
with present invention.
DETAIL DESCRIPTION OF THE INVENTION WITH REFERENCE
TO THE ACCOMPANYING DRAWINGS
15
[0017] The instant invention imparts teaching regarding a technology
relating to cushion structure of rear seat in automobile. The present
invention introduces anti-squeak rear seat cushion foam pad with
insert molded anti-rotation plastic foam pad. In respect of this,
20 reference may be made to fig. 3, in which the expanded poly
propylene (EPP) pad (1A) is accommodated inside the polyurethane
(PU) pad (2A), which is mounted on the floor of vehicle body (3A) such
that the EPP pad is virtually in contact with the floor due to provision
of a thin layer (L) of PU pad.
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[0018] The invention focuses on the design of Expanded Poly
Propylene (EPP) pad which is specially devised according to present
invention in order to serve the purpose.
[0019] In this regard, reference may be made to fig. 4, wherein 5 the
EPP pad of cushion structure of said seat forms an elongated
member with a plurality of through holes (H) in its surface. The holes
can take any shape. However, the through holes are preferred to be
circular in shape as shown. The holes are equidistantly placed across
10 the surface of EPP pad by placing the same in two rows and in front
of each other i.e. side by side.
[0020] In conjunction with the above, there is provision of a
strengthening rib (R) between two holes (H). So that, the whole
15 structure of the EPP pad comprises multitude of ribs (R) on bottom
surface thereof to virtually establish contact with the underlying floor
owing to presence of a thin layer of PU pad therebetween.
[0021] Thus, the EPP pad is devised in such a way that it does not
20 produce squeaking noise and acts as anti-rotational structural
component.
[0022] The surface of EPP pad is designed in such a way that it allows
the smooth flow of PU foam through its surface and makes the pads
25 easy to manufacture.
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[0023] The equi distantly placed holes across the length of EPP pad
maintains uniformity in the PU forming process, otherwise (in case of
staggered arrangement) it creates vacuum in the cushion structure.
5
[0024] The gap i.e. wall to wall distance between two adjacent holes in
horizontal and vertical direction (X and Y) is according to the process
feasibility otherwise it causes breakage of EPP part.
10 [0025] The opening (O1, O2) of holes at both ends is filleted for smooth
flow of chemical composition of PU during forming. The holes are
preferred to be circular as it provides best results.
[0026] During manufacturing of cushion structure by molding the
15 structural design of EPP pad allows small amount of PU foam to flow
under the ribs of said EPP pad. When PU is poured in the mould, it
travels through the holes to make the thin layer under the ribs,
wherein thickness of the thin layer is such that it is sufficient enough
to support the EPP layer. The provision of the ribs is made to rest on
20 the thin layer of PU. By doing so, the EPP part can bear the load of
user and acts as anti-rotation member for the child seat. At the same
time, it does not come in direct contact with floor thereby avoiding
squeaking noise.
25 [0027] Now, reference may be made to fig. 5 indicating the EPP Pad
integrated to PU pad.
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[0028] In order to avoid hard feeling of the user, the EPP pad has been
placed accordingly.
5
[0029] The insert pad can be made of any material such as EPP
without restricting scope of the invention to the same. Thus, any
other material which is formable, manufacturable, automotive
compliant, light weight and cost effective is applicable to the
10 invention.
[0030] Similarly, any other material in the place of PU can be
implemented which is automotive compliant, formable,
manufacturable and can meet comfort requirement of occupant and
15 also styling requirement of cushion.
[0031] Further, composition of PU is variable according to the need of
performance requirement of cushion.
20 [0032] The cushion structure of instant invention can be
manufactured by the method of molding without restricting ambit of
invention to the same. Thus, other methods readily apparent to a
person skilled in the art are understood to be within scope of the
invention.
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Advantageous Features
[0033] - 5 No squeaking noise.
- Avoids rotation of baby seat.
- Comfortable feeling to users.
- Sufficient load bearing capacity.
10 [0034] It is to be noted that the present invention is susceptible to
modifications, adaptations and changes by those skilled in the art.
Such variant embodiments employing the concepts and features of
this invention are intended to be within the scope of the present
invention, which is further set forth under the following claims:-
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WE CLAIM:
1. Anti-squeak cushion structure of automobile seat comprising a
cushion pad embodying insert pad mounted on floor of 5 vehicle
body, wherein the insert pad constituting a rib structure which
is virtually in contact with the floor of vehicle body.
2. Anti-squeak cushion structure of automobile seat as claimed in
10 claim 1 wherein the cushion pad comprising a material which
is automotive compliant, formable, manufacturable and can
meet comfort requirement of occupant.
3. Anti-squeak cushion structure of automobile seat as claimed in
15 claim 1 or 2 wherein the insert pad comprising a material
which is formable, manufacturable, automotive compliant, light
weight and cost effective such as EPP.
4. Anti-squeak cushion structure of automobile seat as claimed in
20 any of the preceding claims wherein the insert pad includes an
elongated member with a plurality of through holes distributed
across the surface thereof.
5. Anti-squeak cushion structure of automobile seat as claimed in
25 any of the preceding claims wherein the holes are preferably
circular, opening of which at both ends is filleted.