IPC分类号：
A47C7/36 | B60N2/44 | B60N2/68 | B60N2/90
国民经济行业分类号：
C2190 | C2110 | C2120 | C2130 | C2042 | C2140
当前申请(专利权)人：
JOHNSON CONTROLS TECHNOLOGY COMPANY
原始申请(专利权)人：
JOHNSON CONTROLS TECHNOLOGY COMPANY
当前申请(专利权)人地址：
915 East 32nd Street,Holland, Michigan 49423 US
发明人：
WHITE, BRENNON | HARRIS, MARK | SAKKINEN, DAN | MICHALAK, ERIC | LAHO, JEFF
代理人：
MCGLEW AND TUTTLE, P.C.
摘要：
A seat structure including at least one frame having one or more thin walled complex geometry structures and a process for forming the at least one frame via an additive manufacturing process.
技术问题语段：
The technical problem addressed in this patent is to provide a seat structure that is durable, high in strength, and lightweight. The conventional seat structures are made with dozens of components that are welded, bonded or mechanically fastened together, which makes them heavier and more complex than required. The invention proposes a seat structure that is a seat back, cushion, or a combination of both, and is made of a single structural frame that is integrally connected. The structural frame comprises one or more thin walled complex geometry structures that define a channel for supporting elements within the frame. The invention provides a process for fabricating the structural frame layer by layer based on load and stress points calculated using topological optimization software. The structural frame is designed to be a one-piece frame structure that is integrally connected and has movable sections or embedded elements that define impact load areas. The invention also includes a process for making the structural frame with non-homogeneous materials and a plurality of support structures that engage the frame portions. The invention provides a seat structure that is durable, strong, and lightweight.
技术功效语段：
The present invention relates to a seat structure and a process for forming a seat structure by an additive manufacturing process. The invention provides a seat structure that is durable, high in strength, and lightweight. The structural frame of the seat is made up of one or more thin walled complex geometry structures that define a channel for supporting elements within the frame. The structural frame is integrally connected and comprises load support areas and non-load support areas. The non-load support areas have more material than the load support areas. The process for forming the seat structure involves calculating the load and stress points of the designed structural frame and fabricating layers of material based on the load and stress points. The structural frame may have movable sections or embedded elements that define impact load areas. The invention provides a seat structure that is stronger, lighter, and more efficient than conventional seat structures.
权利要求：
WHAT IS CLAIMED IS:
1. A seat, comprising:
a structural frame comprising one or more thin walled complex geometry structures, said one or more thin walled complex geometry structures comprising one or more of multiple internal channels and ribs, said one or more of multiple channels and ribs defining a structure for supporting elements within said structural frame, said one or more of said multiple channels and said ribs defining one or more of structural loading paths and a channel for one or more of transporting fluids and receiving one or more components.
2. A seat in accordance with claim 1, wherein said structural frame comprises one or more of a seat back and a cushion frame comprising additive manufacturing material, said one or more thin walled complex geometry structures comprising non-castable and non- machinable portions.
3. A seat in accordance with claim 1 or 2, wherein said structure for supporting elements within said structural frame comprises a first component and a second component, said first component defining an interior space, said second component being located in said interior space.
4. A seat in accordance with one or more of claims 1-3, wherein said first component is connected to said second component via said ribs.
5. A seat in accordance with one or more of claims 1 - 4, wherein said first component and said second component define said channel, said second component comprising a second component channel.
6. A seat in accordance with one or more of claims 1-5, wherein said channel defines a fluid flow path, wherein a wire harness is arranged in said second component channel.
7. A structural frame, comprising:
a plurality of layers, each of said layers being integrally connected to each other to form a single, one-piece frame structure, said single, one-piece frame structure comprising load support areas and non-load support areas, said load support areas comprising a greater amount of material than said non-load support areas.
8. A process, comprising:
providing a designed structural frame;
calculating load and stress points of said designed structural frame;
fabricating a structural frame layer by layer based on said calculated load and stress points of said designed structural frame such that more layers of material are used in areas of said load and stress points than in areas of said structural frame that are not subject to load and stress.
9. A process in accordance with claim 8, wherein said designed structural frame is designed using topological optimization software that iteratively runs load and stress calculations to optimize a minimum amount of material to construct said structural frame.
10. A structural frame, comprising:
a plurality of layers integrally connected to form a single, one-piece frame structure, said plurality of layers comprising movable sections.
11. A process comprising:
fabricating a one piece structural frame layer by layer with movable sections built into the one piece structural frame.
12. A structural frame, comprising:
a plurality of layers integrally connected to form a one-piece frame structure, said plurality of layers comprising embedded elements, said embedded elements defining impact load areas of said one-piece frame structure.
13. A structural frame in accordance with claim 12, wherein said embedded elements comprise one or more geometric shapes, said one or more geometric shapes comprising one or more of gussets and darts, said one or more of said gussets and darts comprising fusible links, said fusible links being deformable such that said links deform when one or more of a load and a moment is applied to said links.
14. A structural frame comprising:
a one-piece frame structure comprising non-homogeneous materials.
15. A structural frame in accordance with claim 14, wherein said one-piece frame structure comprises a first frame portion and a second frame portion.
16. A structural frame in accordance with claim 14 or 15, wherein said first frame portion defines an interior first frame portion space, said second frame portion being arranged in said interior first frame portion space.
17. A structural frame in accordance with one or more of claims 14-16, wherein said second frame portion defines a second frame portion channel.
18. A structural frame in accordance with one or more of claims 14-17, wherein said one-piece frame structure comprises a plurality of support structures, each of said plurality of support structures engaging said first frame portion and said second frame portion, wherein said first frame portion is connected to said second frame portion via said plurality of support structures.
19. A structural frame in accordance with one or more of claims 14-18, wherein said first frame portion and said second frame portion define a channel for receiving a fluid, said first frame portion comprising an opening, said opening and said channel defining a fluid flow path for delivering a fluid.
20. A structural frame in accordance with one or more of claims 14-17, wherein said second frame portion channel receives one or more of electrical wires and a wire harness.