CN104832654B - 充气垫圈 - Google Patents

充气垫圈 Download PDF

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CN104832654B
CN104832654B CN201410680090.3A CN201410680090A CN104832654B CN 104832654 B CN104832654 B CN 104832654B CN 201410680090 A CN201410680090 A CN 201410680090A CN 104832654 B CN104832654 B CN 104832654B
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foam sheet
washer
foam
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frame
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CN104832654A (zh
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丹尼尔·比安基
布拉德利·J·黑曾
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Exclusive Manufacturing Co
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/006—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor for making articles having hollow walls
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/02—Sealings between relatively-stationary surfaces
    • F16J15/021—Sealings between relatively-stationary surfaces with elastic packing
    • F16J15/022—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material
    • F16J15/024—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material the packing being locally weakened in order to increase elasticity
    • F16J15/027—Sealings between relatively-stationary surfaces with elastic packing characterised by structure or material the packing being locally weakened in order to increase elasticity and with a hollow profile
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J15/00—Sealings
    • F16J15/46—Sealings with packing ring expanded or pressed into place by fluid pressure, e.g. inflatable packings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B29C51/105—Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B29C66/71—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B29C66/72—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
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B29K2023/0691—PEX, i.e. crosslinked polyethylene
    • 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
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • 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
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/26—Sealing devices, e.g. packaging for pistons or pipe joints
    • B29L2031/265—Packings, Gaskets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material

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Abstract

本发明提供一种泡沫双薄片成形的充气垫圈。所述泡沫薄片在双薄片成形工艺之前、期间或之后不需要用不透气材料的一或多个层覆盖。还公开用于制造所述充气垫圈的方法。

Description

充气垫圈
技术领域
本发明涉及双薄片成形的充气垫圈，和其制造方法。
背景技术
在许多应用中使用垫圈来形成机械密封。在汽车应用中，许多垫圈由一或多个泡沫薄片形成。所述泡沫垫圈可以弯曲到多种汽车结构中的任一者中的各种不规则形状的间隙和/或空隙中的凹处和裂缝中。
历史上，汽车应用中的泡沫垫圈是实心的而非中空的。如本文中所用，“实心的”包括泡沫材料的薄片，纵使空气陷留于泡孔结构中。举例来说，泡沫聚氨基甲酸酯的薄片是“实心的”。“实心”泡沫薄片包括具有恒定或实质上恒定的密度、变化的密度或其组合的薄片。泡沫材料的泡孔中的空气超出如本文中所用的“囊封空气”或“充气囊袋”的定义的范围。
应理解，实心泡沫薄片作为垫圈的使用可能会增加材料成本并且可能会增加可能不期望额外重量的结构的重量。因此，具有至少一个中空区段的垫圈可以是适用的。
各种材料的中空垫圈已经通过使一个预先形成的垫圈部分粘附到另一个预先形成的垫圈部分而形成。这个粘附加工已经传统地包括例如模切和/或熔接模制的制造步骤。所述额外制造步骤可能会增加具有至少一个中空区段的垫圈的制造的成本和时间。
因此，需要重量轻的垫圈，其使用较少材料并且使向组件增加的重量减到最少。还需要维持相对简单和/或流线型的制造工艺，例如使用现有设备的工艺。
发明内容
本申请公开一种充气泡沫垫圈，其可以解决本领域中的一或多种需要。如本文中所用，“充气的”并不指泡沫中的泡孔中所包覆的空气；实际上，“充气的”是指泡沫层之间所囊封的空气囊袋。所述空气囊袋可以通过双薄片热成形工艺而变得囊封于泡沫层之间，所述工艺向所述垫圈提供其形状。“充气的”可能但并非必需所述垫圈的整体都填充有空气；实际上，预期垫圈的多个区域可以包括一或多个充气囊袋以及扁平区域。
附图说明
图1是泡沫薄片的透视图。
图2是具有充气囊袋的例示性垫圈的剖示透视图。
图3是具有充气囊袋的例示性垫圈的透视图。
图4是具有充气囊袋的另一个例示性垫圈的透视图。
图4A是图4的例示性垫圈的剖示图。
图5是制造充气泡沫垫圈的例示性方法。
具体实施方式
本发明涉及未预期的现象。已经理解，如果充气囊袋将在用以向囊袋提供初始形状的热量密集工艺期间在两个泡沫薄片之间成形，那么后续冷却将导致一个泡沫薄片塌陷到另一个上。预期这种塌陷将会实质上破坏充气囊袋的最初成形的形状。这个预期至少部分基于理想气体定律(Ideal Gas Law)、泡沫材料的多孔状/多孔性性质、泡沫薄片中或周围不存在额外结构材料以便维持最初成形的形状、和/或泡沫薄片的外表面上和/或薄片之间的接缝处不存在额外不透气材料层。
然而，出人意料地发现，双成片泡沫成片在一起以在垫圈中形成充气囊袋，在两层的泡沫垫圈中产生充气囊袋，所述充气囊袋即使在冷却之后也实质上维持其初始形状。
参看图1，各自具有多个泡孔11的泡沫薄片10和20是起始材料，其最终变成充气垫圈中的泡沫层。泡沫薄片10和20可以具有相同或不同泡沫材料并且可以具有相同或不同密度。泡沫薄片10和20可以由闭孔泡沫形成。举例来说，泡沫薄片10和20中的一或两者可以是交联聚烯烃泡沫。许多材料可以是合适的，包括聚丙烯泡沫、聚乙烯泡沫和其掺合物。预期不透气材料层不需要包括于泡沫薄片10和12的外表面上或添加到其。所选择的材料可以具有横越多个范围的密度，包括2 lb/ft3到4.31 lb/ft3，但也预期超出这个例示性范围的范围的密度。
参看图2，展示例示性充气泡沫垫圈30的剖示透视图。泡沫薄片10和20在暴露于热成形工艺之后变得成形为预定形状并且在封口22处密封。剖示图展示了在其间具有充气囊袋17的泡沫薄片10和泡沫薄片20，其还可观测为凸起的区域15。
参看图3，展示例示性充气泡沫垫圈30的透视图。充气囊袋17除通过凸起的区域15外不可观测。预期充气囊袋17沿着其外围从在热成形工艺(例如双成片)期间成形的封口22囊封。由熔接模制和模切形成的额外封口以及额外不透气材料可以在形成成形的充气泡沫垫圈30之后添加，但其不是必需的。实际上，特别预期不存在额外不透气材料的实施例。此外，特别预期不存在熔接模制的封口或除在热成形工艺期间成形的封口以外的其它类型的封口的实施例。
参看图4，展示另一个例示性充气垫圈。例示性垫圈由泡沫薄片10和20形成。例示性垫圈在泡沫薄片10与20之间的接头处具有封口22。例示性垫圈具有充气囊袋17，如图4A提供的剖示图中所见。
参看图5，公开例示性热成形制造方法；即双成片。在操作中，第一泡沫薄片10和第二泡沫薄片20经恰当地尺寸化，参看框40。这些薄片最终变成充气垫圈30中的泡沫层。这可能需要第一泡沫薄片10和第二泡沫薄片20被切割或修剪成具体长度和/或宽度。第一泡沫薄片10和第二泡沫薄片20的大小可以通过将以垫圈30填充的空隙的大小和形状来确定。在某些应用中，第一泡沫薄片10和第二泡沫薄片20的大小还可以通过双成片中所用的压机的大小以及对应于所成形的充气泡沫垫圈30的设计的上模具工具和下模具工具的尺寸来确定。
在形成产生垫圈30的复合材料之前，在双成片设备上使第一泡沫薄片10与第一框架啮合并且第二泡沫薄片20与第二框架啮合，参看框45。泡沫薄片10和20可以使用液压操作的机械夹钳或用于在加热操作期间保持泡沫薄片就位的任何其它合适机构与框架啮合或可移除式固定。通过将泡沫薄片夹持到框架，泡沫薄片还可以在加热操作期间保持处于张力中。
第一泡沫薄片10和第一框架可以引入加热操作中。所述工艺可以在烘箱或能够将第一泡沫薄片10加热到预定温度后持续特定时间段的任何结构中进行。第二泡沫薄片20和第二框架可以与第一泡沫薄片10在相同时间或紧接近于第一泡沫薄片10引入加热工艺中，参看框50。第二泡沫薄片20和第二框架可以引入与第一泡沫薄片10相同的烘箱或加热结构中，或第二泡沫薄片20和第二框架可以引入替代性烘箱或加热结构中。
加热工艺的温度和时间段取决于所用以形成垫圈的泡沫薄片的密度和厚度。在一个实例中，第一泡沫薄片10和第二泡沫薄片20可以被加热到约280°F到360°F范围内的温度。更具体来说，第一泡沫薄片10和第二泡沫薄片20可以被加热到约300°F的温度。当在这个温度范围内加热第一泡沫薄片10和第二泡沫薄片20时，薄片可以同时或相继地(在温的或热的时)使用压机、上模具工具和下模具工具模制成所要垫圈30的形状，参看框55。这个工艺在第一泡沫层与第二泡沫层之间留下具有初始形状的充气囊袋，所述泡沫层一起形成复合材料或垫圈30。
成形工艺可以包括上部工具模具和下部工具模具。成形工艺中所用的上部工具模具和下部工具模具基于将以垫圈30填充的车辆空隙的设计进行选择。
在一个例示性操作中，第一泡沫薄片10可以与上工部具模具的内表面相邻地定位，并且第二泡沫薄片20可以与下部工具模具的内表面相邻地定位。上部工具模具和下部工具模具可以包括通道或能够去除空气的任何其它合适结构。因此，真空泵或任何其它合适装置可以应用于上部工具模具，导致第一泡沫薄片呈上部工具模具的内表面形式。这可以产生复合材料或垫圈30的第一部分。类似地，真空泵或任何其它合适装置可以应用于下部工具模具，导致第二泡沫薄片呈下部工具模具的内表面形式。这可以产生复合材料或垫圈30的第二部分。
上部工具模具和下部工具模具可以随后压缩在一起。经加热的薄片和来自压缩的压力的作用使复合材料或垫圈的第一部分与复合材料或垫圈的第二部分粘结，形成一体的复合材料或垫圈。
可以冷却复合材料或垫圈，参看框60。预期许多冷却方法，包括简单地将垫圈从双成片设备移出并且使垫圈在室内制造环境中在室温下冷却直到垫圈本身到达平衡。其它冷却方法可以是可能的，例如使用制冷或风扇以加快冷却，或用以减缓冷却的方法。必要时，可以从复合材料修剪掉任何存在的过量材料以形成垫圈30，参看框65。如果没有必要，那么复合材料本身是垫圈30。
出人意料地，经冷却的垫圈实质上维持充气囊袋的初始形状而非塌陷。此处，“实质上”相同形状意指最终形状可能并不与初始形状一致，但最终形状使泡沫垫圈功能上可操作，此部分归因于垫圈中的充气囊袋的尺寸。
关于本文中所述的工艺、系统、方法等，应理解，尽管所述工艺等的步骤已经描述为根据某一排序的顺序进行，但所述工艺可以不同于本文中所述的次序的次序实施的所述步骤来实践。此外应理解，某些步骤可以同时进行，可以添加其它步骤，或可以省略本文中所述的某些步骤。换句话说，本文中工艺的描述出于说明某些实施例的目的而提供，并且决不应视为限制所主张的发明。
因此，应理解，以上描述旨在是说明性并且非限制性的。在阅读以上描述后，不同于所提供的实例的许多实施例和应用将显而易见。本发明的范围不应参考以上描述来确定，而应参考所附权利要求书以及所述权利要求书所授权的等效物的全部范围来确定。预期并且期望，未来的开发将发生于本文中所论述的技术中，并且所公开的系统和方法将并入到所述未来的实施例中。总之，应理解，本发明能够进行修改和改变。
除非本文中相反地明确指示，否则权利要求书中所用的所有术语都旨在被给出如对于如本文中所述的技术博学的人员所理解的其最广泛的合理构造和其普通含义。具体来说，除非权利要求相反地叙述了明确限制，否则例如“一个(a)”、“所述(the)”、“所述(said)”等的单数冠词的使用应理解为列举一或多个所指示要素。

Claims (8)

1.一种制造充气泡沫垫圈的方法，其包含:
使第一泡沫薄片与第一框架部件啮合以及第二泡沫薄片与第二框架部件啮合；
分别在所述第一框架和所述第二框架中加热所述第一泡沫薄片和所述第二泡沫薄片；
使第一泡沫薄片热成形到第二泡沫薄片,囊封所述第一与所述第二薄片之间的空气以形成具有具备在热成形期间成形的初始形状的充气囊袋的垫圈；和
在热成形之后冷却所述垫圈，使得所述充气囊袋实质上维持所述初始形状，
其中所述第一泡沫薄片或所述第二泡沫薄片中的至少一者包含闭孔交联聚烯烃泡沫。
2.根据权利要求1所述的方法，其中热成形包含双薄片加工。
3.根据权利要求1所述的方法，其中所述第一泡沫薄片包含与所述第二泡沫薄片相同的材料。
4.根据权利要求1所述的方法，其中所述第一泡沫薄片包含与所述第二泡沫薄片不同的材料。
5.根据权利要求1所述的方法，其中所述第一泡沫薄片和所述第二泡沫薄片中的至少一者包含选自由以下组成的群组的薄片：聚丙烯、聚乙烯和其掺合物。
6.根据权利要求1所述的方法，其中冷却包含在无风扇或制冷的情况下使所述垫圈从在热成形期间所用的温度冷却到室温。
7.根据权利要求1所述的方法，其中冷却包含将所述垫圈从热成形设备移出并且使所述垫圈暴露于室内制造环境的温度和压力至少约一小时。
8.一种泡沫充气垫圈，其通过根据权利要求1-7中任一种所述的方法制造。
CN201410680090.3A 2013-12-06 2014-11-24 充气垫圈 Expired - Fee Related CN104832654B (zh)

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