CN102316763A - 由可膨胀和可网状化的聚烯烃材料模制的座椅部件 - Google Patents

由可膨胀和可网状化的聚烯烃材料模制的座椅部件 Download PDF

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CN102316763A
CN102316763A CN2010800077380A CN201080007738A CN102316763A CN 102316763 A CN102316763 A CN 102316763A CN 2010800077380 A CN2010800077380 A CN 2010800077380A CN 201080007738 A CN201080007738 A CN 201080007738A CN 102316763 A CN102316763 A CN 102316763A
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mould
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seat
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M·韦基奥拉
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/18—Seat parts having foamed material included in cushioning part
    • A47C7/20—Seat parts having foamed material included in cushioning part with reinforcement in the foam layer
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/18—Seat parts having foamed material included in cushioning part
    • A47C7/185—Seat parts having foamed material included in cushioning part with a stiff, rigid support
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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    • B29C44/027—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles the foaming continuing or beginning when the mould is opened
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7371—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable
    • B29C66/73715—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable heat-shrinkable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明公开了一种座椅部件(1，101)的制造方法，该座椅包括主体(2)，其通过对可膨胀和可网状化类型的聚烯烃塑料材料进行模制而获得，以及由刚性材料制成的模板(3，103)，该模板在主体(2)还处于热的状态时与其相连接，这样就能在冷却期间控制主体的材料的收缩。

Description

由可膨胀和可网状化的聚烯烃材料模制的座椅部件
技术领域
本专利申请用于工业发明，涉及一种由可膨胀和可网状化的聚烯烃材料制成的，特别用于车辆的座椅部件的制造方法。
背景技术
术语“座椅部件”表示座椅、靠背和头枕。本发明并不专门限于车辆的座椅，其还延伸至室内装饰座椅，例如工具、扶手椅、沙发和类似的物品。
众所周知，可膨胀和可网状化的聚烯烃材料的特点是质轻、柔软、耐磨和耐水，因此特别适合用于制造各种座椅。
然而，可膨胀和可网状化的聚烯烃材料并没有广泛用于制造座椅部件，这是由于在制备和实现过程期间，其由于存在的一些缺陷而削弱。
实际上，这些物品通过向模具注入塑料材料来制造，该塑料材料在模具中膨胀并形成网状。模具保持在特定温度，这样就能够保证材料密封在模具内的制造周期中，实施材料的网状化和膨胀负载的分解。
当打开模具时，由于剧烈地膨胀，产品自发地从模具中释放出来，继续膨胀，然后在冷却期间开始收缩。膨胀和收缩过程无法精确地控制，因此在工业生产中产生了很高的废品率。
因此，其结果是座椅部件不符合建立在设计水平上的尺寸要求，并且难以与其它部件进行模块化组装。
而且，必须要考虑的是膨胀的材料大都是柔软的材料。因此，为了使其更硬并能使用，使用这些材料的座椅部件应该与支撑框架相连。由于座椅模件在模制、膨胀和网状化之后尺寸的变化，因此与支撑框架的连接并不简单。实际上，如果座椅部件设有接纳固定装置的孔，则这些孔有可能与框架的孔不匹配。
因此，座椅部件与框架的连接比较复杂而且昂贵，需要对座椅部件和/或框架进行特殊的调整。
DE 27 17 268号专利申请公开了由膨胀的聚氨酯制成的座椅部件。虽然膨胀的聚氨酯与膨胀的聚烯烃在外观上相似，但是必须注意的是这两种技术的制备过程是有区别的。因此，众所周知，在聚氨酯技术中，座椅部件通过模制并在模具中冷却而得到。
DE 20 2006 013633号专利申请公开了一种座椅部件，其包括由刚性材料制成的支撑部和与该支撑部连接的外壳，这样在支撑部和外壳之间就形成了空腔。该空腔通过注入填充材料进行填充。外壳由聚氨酯、聚烯烃或其它防水材料制成，是一个预模制的外壳。因此，膨胀的外壳(也能够具有聚烯烃基质)是一种稳定的材料，其已经被网状化，并且接下来也不再会有尺寸上的变化。
支撑部和预模制的外壳设置在模具中，其中注入填充材料。(也)由聚烯烃材料制成的外壳进行热成形，但是在外壳内部的聚烯烃并不网状化或者改变尺寸。
发明内容
本发明的目的在于，通过发明一种座椅部件的制造方法来消除现有技术中的缺陷，所述座椅部件由膨胀材料制成，该膨胀材料很好地符合原始设计的尺寸特征，同时所述座椅部件价格低廉并易于生产和安装。
由于后附的独立权利要求1所阐述的特征，根据本发明，这个目的已经实现。
从属权利要求公开了优选的实施例。
根据本发明的座椅部件的制造方法包括下面的阶段：
-向模具中注入具有可膨胀和可网状化的聚烯烃基质的材料，
-模具内的所述聚烯烃材料的网状化，这样就可以得到具有模具形状的主体，
-由于材料中包含的膨胀剂引起的尺寸的增加，当打开模具时，座椅自发的释放出来，
-在模具外主体进行膨胀，直到膨胀结束，和
-当主体结束膨胀，并且在冷却期间主体的材料开始收缩之前，将所述主体与由刚性材料制成的模板连接，和
-通过模板控制主体的冷却和热缩，这样主体就能符合座椅的原始规格。
新的制造过程在打开模具之后提供了座椅的第一膨胀阶段，以及一个热缩阶段，在该热缩阶段座椅在冷却期间减小(热缩)到期望的尺寸。
模板的使用具有一系列优点：
-使得很好地控制了座椅部件的主体的最终尺寸；
-提供了座椅部件的加强系统；
-提供具有稳定和耐久的固定装置以将座椅锚固到框架上。
附图说明
本发明的附加技术特征根据下面附图中图解的详细描述将会变得清楚，该描述仅用于解释说明，而并不限于这些实施例，其中：
图1为座椅部件的第一实施例的立体图，其中膨胀材料的主体刚从模具中出来；
图2为图1中的座椅部件在组装之后以及膨胀材料的主体热缩之前的横截面图；
图3为图2中的座椅部件在组装以及膨胀材料的主体热缩之后的横截面图；
图4为安装到框架上的图3中的座椅部件的横截面图；
图5与图2相同，除了其示出了本发明的座椅部件的第二实施例；以及
图6为安装到框架上的图5中的座椅部件的横截面图。
具体实施方式
参考图1-4，公开了座椅部件的第一实施例，座椅部件一般用数字(1)来表示。
座椅部件(1)包括柔软材料的主体(2)和刚性材料的模板(3)。
主体(2)由可膨胀的和可网状化的聚烯烃材料通过注模的方法制成。将聚烯烃材料注入到模具中，加热并进行网状化处理。在网状化处理期间，聚烯烃材料膨胀，变成模具的形状，聚烯烃材料的膨胀继续进行，然后主体从模具中自发地释放出来。
必须要考虑的是，与将要制造的座椅比较，模具是小尺寸的(例如，模具的空腔比需要制作的座椅的空腔小50％)。
主体(2)设置在后表面上，具有边框(20)，其限定出一个凹入的用于接纳模板的底座(21)。边框(20)的内边缘限定了具有倒转的U形形状的底部侧凹部(22)中的容纳部，用于接纳模板(3)的边缘。
图1示出了具有基本上呈平行六面体形状的座椅部件的主体(2)，其具有矩形的后框(20)；然而，主体(2)能够是任何形状，如圆形或多边形边缘。
优选地，底部侧凹部(22)中的容纳部可以沿着整个框(20)的内边缘得到；然而，只有两个在底部侧凹部中的容纳部能够设置在框(20)的相对侧。盲孔(23)位于主体(2)后面的底座(21)中，用于接纳固定部件，例如螺帽或螺栓。
模板(3)由刚性材料制成的板构成，例如金属、PVC或聚酰胺纤维(尼龙)。在本发明的第一实施例中显示了平的矩形模板；然而，模板也可以是弯曲的。
模板(3)设有通孔(33)，以接纳固定部件，例如螺丝或螺栓。孔(33)也能够刻有螺纹。在任何情况下，模板的孔(33)与主体(2)的盲孔(23)相对应设置。主体的孔(23)具有比模板的孔(33)大一些的直径，这是因为它们必须接纳螺帽和必须抵消可能出现的没有对齐的错误。
模板(3)根据将要制造的座椅部件的特殊规格来制定尺寸。
实际上，当主体(2)自发地从模具中释放时，主体的材料继续其膨胀过程。一旦膨胀过程结束，模板3插入到主体(2)的凹入的底座(21)中。如图2所示，模板(3)的边缘有间隙地接纳到主体的底部侧凹部(22)的接纳部中。
在冷却期间，主体(2)收缩。相应地，如图3所示，主体的底部侧凹部(22)中的接纳部压在模板(3)的边缘上，消除了所有间隙并且中断热缩。
这样，模板牢固地固定在主体(2)上，并且同时阻止了主体(2)的多余的热缩。因此，主体(2)很好地符合模板(3)的尺寸规格，而不用去考虑主体(2)的材料经受的自由的热缩。
除了作为主体(2)的尺寸的控制部件以外，模板(3)还可用作主体(2)的加强部件，不需要对主体(2)设置加强肋，该加强肋增加了模具的复杂性，也不需要使用加强插入物，其难以与主体(2)匹配。
此外，如图4所示，模板(3)还可以与框(4)一起作为固定部件，将座椅(1)固定到框(4)上。
实际上，框(4)能够设有与模板的孔(33)对准设置的螺栓(40)。
在这种情况下，主体(2)从模板(3)上拆卸下来；然后，将螺栓(40)插入到模板的孔(33)中并将螺帽(41)拧在螺栓(40)上，从而将模板(3)固定到框(4)上；最后，主体(2)再与模板(3)组装在一起，这样螺帽(41)就收纳在主体(2)的盲孔(23)中。
必须要注意的是，组装能够进行的原因在于，一旦冷却结束，即使在没有模板时，膨胀并网状化的材料依然能够保持原始的尺寸。
在下文中，相同的部件或与已经描述的部件相对应的部件使用相同的附图标记表示，省略其详细的描述。
图5和6所示为根据本发明的第二实施例的座椅部件(101)，其中模板(103)设有螺丝固定部件(133)，而不是孔。相应地，框(104)设有孔(140)，以接纳模板的螺栓(133)。螺帽(141)拧到模板的螺栓(133)上以固定框。在这种情况下，没有必要将主体(2)从模板(103)上拆卸下来，并在将模板固定到框(104)之后将主体再组装到模板上。
图5和6示出了在相对的边缘设有两个平的部分(130)的凹形的模板(103)，其插入到主体(2)的底部侧凹部(22)的接纳部中。因此，框(104)也必须具有凹形的底座以接纳模板(103)。
本领域的专业人员可以对本发明的这些实施例进行变形和修改，但其还是在所附的权利要求所声明的本发明的范围之内。

Claims (7)

1.座椅部件(1，101)的制作方法，其包括下述阶段：
-向模具中注入可膨胀和可网状化的聚烯烃材料，
-将模具内的所述聚烯烃材料网状化和膨胀，这样就能获得具有模具形状的主体(2)，
-主体(2)由于膨胀从所述模具中自发地释放，
-在所述模具外，主体(2)进行膨胀，直到膨胀结束，
-当主体(2)已经结束膨胀，并在冷却期间主体材料收缩之前，将所述主体(2)与由刚性材料制成的模板(3，103)相连接，和
-通过模板(3，103)控制主体(2)的冷却和热缩，从而主体与模板的原始规格相符合。
2.如权利要求1所述的方法，其特征在于，与要得到的座椅相比，模具具有小的尺寸。
3.如权利要求1或2所述的方法，其特征在于，塑造模具的形状，以使得主体(2)设置在具有凹入的底座(21)的后表面，该凹入的底座具有比主体的表面稍小一些的区域，并且，所述模板(3，103)插入到凹入的底座中。
4.如权利要求3所述的方法，其特征在于，塑造模具的形状，以使得主体(2)具有边框(20)，其限定出凹入的底座(21)，底部侧凹部(22)中的接纳部位于边框(20)的内部边缘，并且模板(3，103)的边缘插入到底部侧凹部(22)的接纳部中。
5.如上述权利要求中任意一项所述的方法，其特征在于，固定部件(33，133)设置在模板(3，103)上，并且模板固定到支撑框(4，104)上。
6.如权利要求5所述的方法，其特征在于，模板通过框上的螺栓部件(40)固定到框上，该螺栓部件穿过模板上的通孔(33)。
7.如权利要求5所述的方法，其特征在于，模板通过模板上的螺栓部件(133)固定到框上，该螺栓部件插入到框的孔(140)中。
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