CN100343040C - 一种具有降低薄膜效应的含有凝胶的垫子的生产方法 - Google Patents

一种具有降低薄膜效应的含有凝胶的垫子的生产方法 Download PDF

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CN100343040C
CN100343040C CNB008193940A CN00819394A CN100343040C CN 100343040 C CN100343040 C CN 100343040C CN B008193940 A CNB008193940 A CN B008193940A CN 00819394 A CN00819394 A CN 00819394A CN 100343040 C CN100343040 C CN 100343040C
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J·-L·马丁
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Abstract

本发明涉及一种含凝胶的包括一种至少部分地包裹在一个薄膜(20)中的凝胶材料(21)的垫子(40)的生产方法，该方法包括如下步骤：在一个模具(30)内的薄膜的热定型步骤，用一种准备的液体(21)填充该垫子的步骤，通过将垫支架(22)焊接或者粘合到该薄膜边缘封闭该垫子的步骤，和使液体制品(21)聚合的步骤。根据本发明，该方法包括通过在至少该热定型薄膜的一点上施加一个变型力，在该薄膜热定型步骤之后插入该垫子的薄膜(20)的变型步骤，以便在生产过程中，该薄膜的表面恒定地具有至少一个空腔或者波纹。

Description

一种具有降低薄膜效应的含有凝胶的垫子的生产方法
技术领域
本发明涉及生产在EP96400277申请中描述的具有降低薄膜效应的类型的垫子。
背景技术
为了回忆现有技术，图1A，1B和1C示出在EP96400277申请中所公开的一个技术问题并被在这里所描述的本发明所解决。图1A表示一个传统结构的含有凝胶的垫子1，在这里它采用了用于眼睛架的鼻垫的形状。该垫子1包括一个热定型弹性的薄膜2，它的边缘焊接或者粘和在一个板状支架3上。该薄膜2与该板状支架3前表面一起形成一个密封袋，在该密封袋中束缚有一种凝胶材料，一般为一种硅树脂。
在辗压作用下，特别是当该垫子1支架在鼻子上时，凝胶材料4应该吸收辗压力，使冲击缓冲，并且提供一种优良的舒适度。然而如果更注意地观察该垫子1的辗压的反作用，如图1B所示，将看到随着在该垫子1上的压力的加强，由于通过压缩凝胶材料产生的该薄膜2的拉伸导致的弹性效应，而使该凝胶效应消失。这个弹性效应在EP96400277申请中称为“薄膜效应”。因此，当该垫子支架在鼻子上时，如图1C所示，由该架子的重量产生的该辗压是这样的，即该薄膜效应压倒凝胶效应占主导地位。导致了缺少可靠的舒适度。
图2A是一种EP9640027申请中所述类型的降低了薄膜效应的垫子5的一个实施例的截面视图，该实施例没有这个缺点。如前述该垫子5包括一个包裹一种凝胶材料7的柔韧的薄膜6，该薄膜6的边缘焊接在一个支架板8上。该薄膜6具有至少一个褶，这里具有两个朝向该垫子内部定向的褶9，9’，以便在该垫子的表面形成多种缝隙，该胶体与这些褶的形状贴和。如图2B所示，当该垫子5受到碾压时，受挤压的胶体7压在被展开的薄膜6上。由于该薄膜的展开，在压力作用下展开附加的薄膜面积可以延迟该薄膜6达到弹性应力状态的时间。这样通过该胶体7基本上确保了该垫子5对于碾压的反作用，如箭头所示，以便除去由于薄膜效应导致的弹性感觉，或者至少延迟该弹性感觉的出现。因此由该垫子提供的舒适度得到明显改进。
在上述的欧洲申请中描述的这样的垫子的生产方法总结在图3中。该方法需要预定一个热成型模具10，其底部具有一个或多个摺，例如与图2A的垫子5的摺9，9’相应的两个摺11，11’。该薄膜6通过热源而变软并且通过一个吸气系统12紧贴在该模具10的底部。然后通过用来在聚合作用后转变成胶体的液体制品7进行填充这样实施的垫子空腔，然后施加上述的支架薄板8并且当该液体制品7的聚合未结束时在该薄板8上对该薄膜进行边缘焊接以封闭该空腔。该聚合作用在封闭该垫子5以后继续进行并且可以完成该垫子的生产。
发明内容
本发明的一个目标是设计一种具有降低薄膜效应的垫子的生产方法，该方法能够构造一种刚刚描述过的垫子的可替换物。
事实上，尽管传统方法本身不具有任何缺点并且带来了完全的满意度，但是根据不同的方法可以生产类似的产品，以便能够选择这样的方法，该方法最适合可获得的生产工具组，工作人员的技能和所需的生产率等，在企业中这一直是有用的。
本发明的另一个目标是设计具有降低现有技术的薄膜效应的垫子的多种实施例。
通过设计一种凝胶垫子的生产方法可以实现这个目标。该生产方法包括：在一个薄膜中至少部分地包裹一种凝胶材料，包括如下步骤：在一个模具中该薄膜的热成型步骤；通过一种液体制品填充该垫子的步骤；通过将垫子支架焊接或粘和到该薄膜边缘上封闭该垫子的步骤；和该液体制品的聚合步骤，在该步骤期间该液体制品转变成一种凝胶材料，通过在该热成型薄膜的至少一个点上施加变形力将包含有该垫子薄膜的变形步骤的方法插入到该薄膜的热成型步骤之后，在生产过程中该薄膜的表面始终具有至少沟槽或波纹，同时该胶体与该薄膜的形状贴和。
根据一个实施例，该薄膜的变形步骤在向成型垫子中注入液体制品之前实施，当该热成型薄膜还在该模具中时，通过在该薄膜的至少一个点上施加一变形力以便该薄膜的一部分大致从该模具中脱开，剩余部分由吸气系统保持，在填充和封闭该垫子后并且在该液体制品完全聚合前放开该变形力。
根据一实施方式，变形步骤通过一包括至少一移动件的模具实施，该移动件朝向该模具的内部移动以便在该薄膜上施加该变形力。
根据一实施方式，该薄膜的变形步骤在向成型垫子注入液体制品之前实施，当热成型薄膜还在该模具中时，通过在该薄膜的至少一个点上施加一变形力以便使模具大致变形，该模具为柔韧或弹性材料，该模具的变形控制着薄膜的变形，在填充和封闭该垫子后并且在该液体制品完全聚合前放开该变形力。
根据一实施方式，该薄膜的变形步骤在垫子封闭后实施，在液体制品聚合期间通过在该薄膜的至少一个点上施加一变形力，通过该凝胶材料的记忆效应该液体制品聚合后的薄膜的变形是决定性的。
根据一实施方式，通过在该垫子表面上施加一物体获得该变形力，该物体的表面具有至少一个突起，在聚合过程中该突起的印痕留在该垫子的表面上。
根据一个实施方式，该垫子支架具有大于该薄膜厚度的厚度，该薄膜边缘沿相对于垫子支架的凝胶材料的侧表面成1-90°的角焊接在垫子支架上。
本发明还涉及根据上述的方法实施的凝胶垫子，它包括在一薄膜中至少部分地包裹一种凝胶材料，该薄膜的边缘焊接或粘和在垫子支架上，该薄膜具有至少一沟槽或波纹，该凝胶材料与薄膜形状贴和。
根据一实施方式，该薄膜具有一限定形状的印痕。
根据一实施方式，该薄膜的边缘沿相对于垫子支架的凝胶材料的侧表面成1-90°的角焊接在垫子支架上。
根据一实施方式，该薄膜为聚氨基甲酸脂的膜。
根据一实施方式，该薄膜包括并列放置的两个柔韧膜。
根据一实施方式，该凝胶材料为硅树脂膜。
根据一实施方式，该垫子包括在垫子支架的胶体的侧表面上实施一标记，通过封闭在该薄膜和垫子支架间的胶体的放大镜效应放大了该标记。
附图说明
本发明的这些目标以及其他特征和优势将参照附图，按照本发明的方法的两个实施方式和本发明实施的具有降低薄膜效应的垫子，在下面的说明书中具体描述。附图包括：
-图1A，1B，1C前面已经描述过，示出传统的软化的垫子；
-图2A和2B是传统类型的可降低薄膜效应的垫子的截面视图；
-图3示出传统的降低薄膜效应的垫子的生产方法；
-图4A-4D示出根据本发明的生产方法可降低薄膜效应的垫子的第一实施方式；
-图5A-5C示出根据本发明的生产方法可降低薄膜效应的垫子的第二实施方式；
-图6示出根据本发明的方法第二实施方式的变形；
-图7示出根据本发明的凝胶垫子的一实施方式；和
-图8A和8B示出根据本发明的垫子的特性。
具体实施方式
图4A-4D示出根据本发明可降低薄膜效应的凝胶垫子的生产方法的基本步骤。
在第一生产步骤中，柔韧膜20在传统形状的多孔模具30中热成型，该柔韧膜20成通常的弧形并且在这里它没有摺。该薄膜30例如为聚氨基甲酸乙脂膜，其厚度为几十多个微米。在一个变形中，该薄膜30构造有两个叠置的小厚度聚氨基甲酸乙脂膜(未示出)。该模具30与一底架31相连接，该底架31包括一与泵送系统33连接的吸气室32。该热成型通过引入一个热源如红外线辐射IR实施。当该泵送系统33被激活时，薄膜20被吸引贴和在该模具30的底部并形成与该模具形状贴和的垫子空腔40。
根据本发明，该薄膜20然后至少在其表面的一个点变形以便降低该垫子空腔40的体积。该模具30包括至少一个用于这个作用的变形区域。如图4B所示，在这里该变形区域为一在该底架31中可滑动安装的移动件34的形式，该移动件34的上表面通到该模具30中。
因此在图4B所示步骤中，在该模具的中心方向保持吸气并且推该滑动件34。该零件34的上部分形成一个突起，该突起推该薄膜20并且使该薄膜20局部与该模具30脱开，该薄膜的剩余部分通过吸气保持与该模具30贴和。当在垫子空腔40中填充一种可以聚合两种或三种组分的液体制品21最好为硅树脂为基的制品时，保持施加在该薄膜20上的变形力。
图4C的步骤中，在垫子空腔40用塑料材料薄板封闭期间，一直保持施加在该薄膜20上的变形力，以便形成未来的垫子40的支架薄板。该薄板22支架在该热成型空腔的边上，在这里该薄板22保持与该薄膜20的边缘相接触。以传统的方式确保该薄膜20的边缘在该薄板22上的焊接，即通过在该模具30中该热成型空腔边缘放置一个扁平环行电阻片35。该电阻片35连接到提供电流I的电源36上并且该电阻片35在短时间内具有一个能达到200°的温度。在焊接操作期间，在支架板22上施加相当大的压力，以便嵌入液体制品21，该液体制品21将能够位于该薄膜20和该薄板22之间。
根据本发明，由移动件34施加在该薄膜20上的变形力，在该垫子40闭和后，并且在该液体制品21完全聚合前，松开。在松开约束后出现的垫子形状40在图4D中以不指定或非限定的方式显示出。该形状具有随机特性并且不能描述清楚，因为它是施加在该薄膜20上的表面张力之间的多个力的平衡和该垫子40内部的凹陷的结果，该平衡倾向于再回到其最初的由热成型赋予的形状。事实上该液体制品21不能膨胀并且空气不能进入到该垫子40中，该垫子被密封封口。该垫子40的形状具有至少一个沟槽或波纹且随后在环境温度下，或者在使该垫子固定成最终形状的干燥箱中，通过液体制品的聚合而固定成形。
具有至少一个沟槽或者波纹的这样的垫子40与在EP96400277申请中所述的装备有至少一个形成裂缝的褶的垫子完成了同样的功能。事实上，在该垫子碾压的作用下该薄膜的表面展开并且同时延迟薄膜效应的出现。
对于所属技术领域普通技术人员来说，刚刚描述过的方法能够进行多种变型和实施。特别是该模具30可以包括多个形成突起的滑动件，例如两个设置在热成型空腔的边缘临近处的移动件。根据另一个变型，该模具30由柔韧或者弹性材料实施。在这种情况中，变形力直接施加在模具本身的底部，该模具可以变型并且同时使薄膜变形。当松开该变形力时，该模具恢复其最初形状。最后，如果该模具是可变形的，那么借助于设置在该模具中的至少一个喷嘴在薄膜上施加，或者在该模具自身上施加压缩空气的喷射，也可以获得变形力。
图5A-5C示出根据本发明方法的第二种实施方式。在这里，以传统的方式实现一种垫子50，它包括：一热成型薄膜51，一还未聚合的液体制品52和一支架薄板53。在该液体制品52完全聚合前，通过朝向成型件55的该垫子50的相对运动，在该成型件55上施加该垫子55的表面，如图5A所示。该结构件55包括一大致平的表面和至少一形成突起56的部分。
在图5B中，可以看到形成突起56的部分使垫子的薄膜51变形。在液体制品52聚合期间，该零件55保持靠在该垫子50上。当该聚合完成后，如图5C所示，该薄膜51具有至少一个适合于通过该形成突起56的部分留出印痕的沟槽或者波纹。由于该胶体52的记忆效应，该形状为最终的，该形状在随后的长时间的碾压后总是要恢复该形状。如上述的形状确保了降低通过在碾压作用下该薄膜51的展开导致的薄膜效应。
与本发明的方法的第一实施方式不同，这里，该薄膜以恒定尺寸变型，因为该变形力是在封闭该垫子50之后实施的。因为液体制品52是不可压缩的，所以不能减少该垫子的尺寸。刚刚描述过的两种方法因此具有这样的共同特征，即在该垫子热成型后和该液体制品完全聚合前，包括一个弹性变形步骤；同时该两种方法还具有这样的区别，即在第一种情况中是在注入液体制品之前确保变形，在第二种情况中是在注入液体制品和封闭该垫子之后确保变形。
根据本发明方法的第二种实施形式还可以进行不同的变型。例如该垫子通过前述的模具30的移动件34可以实施该垫子的变形。在这种情况中，变形步骤发生在图4C显示的步骤中，但是该移动件34仅仅在通过支架板封闭该垫子后才施加靠在该薄膜上。在这种情况中，在模具内部发生聚合。另外图5A，5B显示的该件5可以包括多个更大或更小尺寸的突起，并且具有例如圆齿状外型。如图6所示，包括未聚合的液体制品62的一垫子60的薄膜61的变形还可以通过网状件65实施，该网状件在聚合后在垫子60上留下其印痕。该垫子然后具有多个波纹的形状。
总体上说，另人满意地注意到刚刚描述的该生产方法非常适合于批量生产垫子，特别是由于设计了包括多个热成型空腔的模具。在这种情况中，通过大尺寸的支架板成组的生产该垫子，该大尺寸支架板然后切割成单个的支架板，例如通过冲压。
图7示出了根据本发明的一垫子70的特殊实施方式。该垫子70不同于前面的垫子，因为沿与相对于该支架平板71的胶体表面成0°的角度不同的角度“A”保持了该支架板71。因此，该薄膜72焊接在支架板71的边缘上，该支架板71沿角度“A”被斜切。该角度“A”事实上可以包括在1-90°(焊接在右侧)。等于0°的角度“A”相应于一平焊缝例如在现有技术中描述的和前面图中所示的。
再有申请人的另一个完美想法涉及了凝胶垫子的标记。这样的标记用于在该垫子上显示出一系列号，一生产标记，一装饰性首字母缩略词或者所有其他的标注，所希望的标志或者图画。一这样的标记可以通过一种非破坏性的方法如喷墨打印方法在该垫子的薄膜上实施。然而，这样的方法被证明实施昂贵调整困难。
如图8A所示根据本发明的方法，这样实施一这样的标记，即在焊接该支架板79到该薄膜上前，在一垫子的支架板79的内表面上实施例如字母标记“XYZ”。该支架板79在大多数情况下比该薄膜更薄强度更大，特别是一种鼻型板时，使用一种磨蚀方法，例如一种激光制的标记。一旦完成该垫子80，如图8B所示，该标记通过放大镜效应由困在支架板79和薄膜之间的胶体81被放大，该胶体为半透明的。该最初的标记看起来变大了，如图8B中所看到的那样。

Claims (7)

1.一种凝胶垫子(40，50，60，70)的生产方法，该凝胶垫子包括一至少部分包裹在一薄膜(20，51，61)中的凝胶材料(21，52，62，72)，该生产方法包括：一在模具(30)中该薄膜的热成型步骤，一用液体制品(21，52，62)填充该垫子的步骤，通过焊接或者粘和垫子支架(22，53，62，71)到该薄膜(20，51，65，72)的边缘从而进行封闭该垫子的步骤，液体制品的聚合步骤，在聚合期间该液体制品转换成凝胶材料，该方法的特征在于，其包括一该垫子的薄膜的变形步骤，通过在热成型薄膜的至少一个点上施加一变形力将该变形步骤插入在该薄膜的热成型步骤之后，以便该薄膜在生产过程中表面始终具有至少一沟槽或者波纹，该凝胶材料与该薄膜的形状贴和。
2.根据权利要求1所述的方法，其特征在于，该薄膜(20)的变形步骤在将该液体制品(21)插入到成型垫子(40)中之前实施，当热成型薄膜还在该模具(30)中时，通过在该薄膜的至少一个点上施加一变形力，以产生该薄膜的一部分大致从该模具中脱开的效果，该薄膜的剩余部分通过吸气被保持，在填充并封闭该垫子(40)之后并且在该液体制品(21)完全聚合之前，松开该变形力。
3.根据权利要求2所述的方法，其特征在于，变形步骤通过至少一包括至少一移动件(34)的模具(30)进行实施，该移动件(34)朝向该模具的内部移动以便在该薄膜(20)上施加变形力。
4.根据权利要求1所述的方法，其特征在于，该薄膜的变形步骤是在将该液体制品注入到成型垫子中之前实施的，当热成型薄膜还在模具中时，通过在该模具的至少一个点上施加一变形力，以便使该模具大致变形，该模具为柔韧性且具弹性的材料，该模具的变形控制了该薄膜的变形，该变形力在填充和封闭该垫子之后并且在该液体制品完全聚合之前松开。
5.根据权利要求1所述的方法，其特征在于，在封闭该垫子(50，60)之后，通过在液体制品(52，62)聚合期间在该薄膜的至少一个点上施加变形力，实施该薄膜(51，61)的变形步骤，在该液体制品聚合后通过该凝胶材料(52，62)的记忆效应，该薄膜的变形是最终的。
6.根据权利要求5所述的方法，其特征在于，该变形力通过在垫子表面施加一物体(55，65)而获得，该物体的表面具有至少一个突出物(56，65)使得在聚合过程中其印痕留在该垫子的表面上。
7.根据权利要求1-6任一项所述的方法，其特征在于，该垫子支架(71)具有大于该薄膜厚度的厚度，该薄膜(72)的边缘沿角度(“A”)焊接在垫子支架上，该角度(“A”)为相对于垫子支架的凝胶材料的表面成1°-90°的角度之间。
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JP2003531742A (ja) 2003-10-28
AU2000236633A1 (en) 2001-10-15

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