CN104842840A - 一种改进型层状航空椅垫及其制造方法 - Google Patents
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Abstract
本发明涉及一种改进型层状航空椅垫，其包括由上到下的有机耐高温纤维层、混合再生层和毛毡层；所述混合再生层由植物纤维、航空椅垫制作产生的填充物废料和天然乳胶粘合剂混合组成，所述航空椅垫制作产生的填充物废料为人造PU、纺织纤维、聚酯纤维、木质纤维素纤维和发泡塑料中的一种或两种以上。该椅垫具备良好的透气散热性能，能够有效的阻止坐垫在使用期间产生的细菌数量，该航空椅垫耐热等级在F155℃左右，绝缘和抗张强度及耐磨耗强度均高出同类产品15－25倍以上，同时本发明在耐高压荷重、耐化学腐蚀、耐油性、耐水解、耐臭氧、耐辐射、耐老化方面都有显著的效果和良好的性能表现。
Description
技术领域
本发明属于航空椅垫制造技术领域，具体涉及一种改进型层状航空椅垫及其制备方法。
背景技术
现有的航空椅垫及制作方法是将由木纤维素纤维或塑料聚合物制成的填充物包括低密度聚醚（不吸水海绵）、聚乙烯醇（高吸水材料，无明显气孔）和聚酯等其它材料制成的弹性发泡海绵物，通过缝合填装入由动物皮革或是织物制成的表面袋状内，合并封口形成航空椅垫。例如：可以将低密度聚醚或其它弹性发泡海绵材料切碎与动物毛发混合作为基础填充材料，填充入带有内部钢架结构或无结构预先缝合形成的袋状内，合并封口形成航空椅垫。或者，可以将整块聚乙烯醇或聚酯材料，按照人为的需求进行表面造型切割后，直接填充进带有内部钢架结构或无结构预先缝合形成的袋状内，合并封口形成航空椅垫。很显然，这些传统航空椅垫及制作方法经不起使用者的长期使用，低密度聚醚（不吸水海绵）、聚乙烯醇（高吸水材料，无明显气孔）和聚酯等其它材料的弹性和抗压性都非常的弱，承载过一段时间人体给予的体重压力后，材料原有的记忆性出现丢失，外形溃散不再具备继续使用的价值。除了抗压性弱之外，由这些材料制造的航空椅垫的阻燃性、导热性、绝缘性和抗张强度及耐磨耗强度等都非常的弱，同时这些材料的大范围使用，以及在制造航空椅垫时产生的废料非常不利于环保，须以掩埋或其它方式进行处理。在此前提下增加航空椅垫的使用寿命，赋予它更多的使用性能，已经成为了目前航空椅垫的重点研究方向。
现有的航空座椅在椅垫臀部部位及座椅后背依靠部位，均设有不锈钢或其他金属材料制成的弹簧内衬椅垫，这种弹簧椅垫的寿命一般是1-2年，在经历100000-140000次弹压后，就基本丧失了弹簧椅垫的特性，另外由于原有椅垫内部的弹簧材料的金属特性，以及制作时金属面积的限制，原有一些航空座椅在椅子扶手、臂靠、颈靠、头靠这些小面积部位无法植入弹簧材料椅垫，所以这些部位常常显现出舒适度差，长时间靠扶不能缓解疲劳的缺点，而单一的聚氨酯发泡塑料更是在使用超过千次左右，就开始严重降低材料本身的减震性和透气性。在由于飞机自身安检程序及零部件更换要求的特殊性，许多飞行器椅垫在达到临界点后仍继续使用，这给飞行器乘员带来了长时间使用时的安全隐患。
发明内容
本发明目的在于克服现有技术缺陷，提供一种改进型层状航空椅垫及其制备方法。
为实现上述目的，本发明采用如下技术方案：
一种改进型层状航空椅垫，其包括由上到下的有机耐高温纤维层、混合再生层和毛毡层；所述混合再生层由植物纤维、航空椅垫制作产生的填充物废料和天然乳胶粘合剂混合组成，所述航空椅垫制作产生的填充物废料为人造PU、纺织纤维、聚酯纤维、木质纤维素纤维和发泡塑料中的一种或两种以上。发泡塑料可以是低密度聚醚、聚乙烯醇和聚酯等聚合物中的一种或组合物制成。航空椅垫制作产生的填充物废料不包括航空椅垫内部用以固定的钢架结构废料。
具体的，所述有机耐高温纤维优选为国产芳砜纶等。
所述毛毡表面设有若干通孔，用以增加毛毡的透气性。
所述混合再生层中植物纤维的用量不低于植物纤维和航空椅垫制作产生的填充物废料两者总重量的50%（优选50－70%），所述植物纤维优选为棕榈纤维等。
上述改进型层状航空椅垫的制造方法，其包括如下步骤：
1）根据人体工学要求制造表面蜡质、上下双层的凹凸航空椅垫模具；
2）将航空椅垫制作产生的填充物废料粉碎成颗粒，并与植物纤维搅拌混匀获得混合物料，按每公斤混合物料添加150－250g粘合剂的比例加入天然乳胶粘合剂，搅拌混匀，备用；
3）将按照航空椅垫模具单层大小进行裁剪后的毛毡层平铺于位于下层的凸航空椅垫模具上表面；将按照航空椅垫模具单层大小进行裁剪后的有机耐高温纤维层平铺于位于上层的凹航空椅垫模具下表面；
4）在毛毡层和有机耐高温纤维层之间加入步骤2）所得产物，闭合航空椅垫模具以对模具内填充的航空椅垫原料进行挤压成型，
5）将闭合后的航空椅垫模具放入温度40－43℃的干燥房内2－4小时，取出；
6）对航空椅垫模具边缘的溺出原料进行裁剪处理，即得。裁剪处理所得的溺出原料粉碎成颗粒后可作为航空椅垫制作产生的填充物废料循环利用。
7）将制造脱模后得到的椅垫，装入由不少于5层直径0.2cm锦纶纱线织造而成的蜂巢状减震袋中，以增加产品的弹性和阻尼特性。
一种航空座椅，该航空座椅包含上述的改进型层状航空椅垫。
可依据航空椅垫厚度要求，调节上下双层的凹凸航空椅垫模具中间的空隙大小，以使挤压成型后的航空椅垫最大厚度不超过5cm，最小厚度不低于2cm。
本发明中，毛毡的表面可进行表面周长不超过3cm的六棱形打孔，单层厚度在2mm左右。通过天然乳胶粘合剂的粘合作用将植物纤维和航空椅垫制作产生的填充物废料粘合在一起，并在混合再生层凝固前，将其粘合到有机耐高温纤维层与作为底面的带孔毛毡层之间。
本发明中，用于制造航空椅垫的模具材料包括：用于制造航空椅垫符合人体工程学表面涂蜡的上下双层的凹凸塑料PBT（聚对苯二甲酸丁二醇酯，英文名polybutylene terephthalate，属于聚酯系列，是由1.4-pbt丁二醇与对苯二甲酸PTA或对苯二甲酸二甲酯DMT聚缩合而成，并经混炼程序制成的乳白色半透明到不透明、结晶型热塑性聚酯树脂）航空椅垫模具和/或钢材8407航空椅垫模具。
就保护现有的生态环境和生产资源而言，作为一个生产加工型企业，降低生产成本促使材料再循环，尤其是在生产过程中产生的废弃材料再循环使用，并且通过材料的再循环可以促进企业改进自我的生产工艺，在此点上维持或提高材料的必要性能，日趋变得越发重要。本发明中，提供了凹凸PBT材质的航空椅垫模具以及模具覆盖层，覆盖层凸起层面上为带孔毛毡层，该层作为固定型航空椅垫的底层材料，使中层的混合再生层平铺在上面，同时可以呈现包覆形以保持中间混合再生层的形体状态，以及允许上层有机耐高温纤维层的延长边缘处包裹覆盖中间的混合再生层以及下层的毛毡层。
和现有技术相比，本发明在工艺上为特殊行业如大型吊车、小型飞机及特殊机车的人体承载工具提供了新的坐垫及靠垫设计方案，本发明经测试还可生产成靠垫，所生产的靠垫及坐垫产品在对人身颈椎，腰椎及臀部的塑形和健康保护上可以达到其它座椅不能达到的效果，而且长期乘坐不变形。综合本发明的特点，其具备良好的透气散热性能，能够有效的阻止坐垫在使用期间产生的细菌数量，该航空椅垫耐热等级在F155℃左右，绝缘和抗张强度及耐磨耗强度均高出同类产品15-25倍以上，同时本发明在耐高压荷重、耐化学腐蚀、耐油性、耐水解、耐臭氧、耐辐射、耐老化方面都有显著的效果和良好的性能表现。
另外本坐垫可以满足小型飞机坐垫对高弹性、吸震性、抗撕裂、抗静电，高承载和减震缓冲等方面的需求，可有效对抗时速约在250-400千米/小时，在机体座椅弹射中加速度平均为40米/秒，人体过载达到4.1g，也就是作用于飞行员身体上的平均力量比他的体重大4.1倍的情况下，由于过载时间在1.65-1.85秒内在此情况下，此坐垫可在一定的使用期内（15000个小时内）帮助飞行员降低这种过载2倍。
同时产品的检验检测亦是对产品制作方法的一种价值肯定。同时本产品按照国标MIL-STD-105E随机抽样实施检查，检查结果如下。
本产品外观检查要求：
本产品按照GB17927-1999，软体家具弹簧软床垫和沙发抗引燃特性评价，以及DA136-1996，中华人民共和国公安安全行业标准软体家具易燃性的实验和分级方法，进行设计，经检测本品符合要求。
其它试验品包含但不限于以下内容：复合材料碎片，PVC+毛毡+国产芳砜纶，褐色涤纶网格布料，厚度20.0mm的块状乳胶植物棕材料，燃烧性能符合要求。
推背测试：推背测试是通过推背测试机对椅子靠背向后施加一定的力，是椅子向后倾仰产生挤压。其目的主要是检测椅子各部件承受挤压的能力。
推背测试根据施力大小可分为：功能性测试和破坏性测试两种。
1.功能测试试施力为91kg,持续时间为1分钟，测试后椅子各部件如果有变形、损坏或断裂现象，为测试不通过。经测试本品试施力为91kg, 持续时间为11分10秒钟，航空椅垫开始出现变形、损坏现象。
2.破坏性测试施力为136kg,持续时间为1分钟，测试后椅子各部件如果有严重变形、损坏或断裂现象，为测试不通过。经测试本品试施力为136kg, 持续时间为14分45秒钟，航空椅垫开始出现严重变形、断裂现象。
经测试本发明材料超过现有市场航空椅垫产品特性10倍以上。
附图说明
图1为本发明所述层状航空椅垫的结构示意图；
图2为本发明所述层状航空椅垫填压在模具内的侧面剖视图.，
图3为本发明所述层状椅垫人体工学图。
具体实施方式
以下通过实施例对本发明做进一步的说明，但本发明的保护范围不限于此。
实施例1
如图1所示，一种改进型层状航空椅垫，其包括由上到下的有机耐高温纤维层（国产芳砜纶层）1、混合再生层2和表面设有若干通孔的毛毡层3（所述通孔为表面周长不超过3cm的六棱形）；所述混合再生层2由棕榈纤维、航空椅垫制作产生的填充物废料和天然乳胶粘合剂混合组成，所述航空椅垫制作产生的填充物废料由纺织纤维、聚酯纤维和发泡塑料混合而得。所述混合再生层2中棕榈纤维的用量不为棕榈纤维和航空椅垫制作产生的填充物废料两者总重量的60%。可用作航空椅垫的臀部椅垫。
如图2所示，上述改进型层状航空椅垫的制造方法，其包括如下步骤：
1）根据人体工学要求制造表面蜡质的上层凹航空椅垫模具5、下层凸航空椅垫模具4；
2）将航空椅垫制作产生的填充物废料粉碎成颗粒，并与植物纤维搅拌混匀获得混合物料，按每公斤混合物料添加200g粘合剂的比例加入天然乳胶粘合剂，搅拌混匀，备用；
3）将按照航空椅垫模具单层大小进行裁剪后的毛毡层3平铺于位于下层的凸航空椅垫模具4上表面；将按照航空椅垫模具单层大小进行裁剪后的有机耐高温纤维层（国产芳砜纶层）1平铺于位于上层的凹航空椅垫模具5下表面；
4）在毛毡层3和有机耐高温纤维层（国产芳砜纶层）1之间加入步骤2）所得产物，闭合航空椅垫模具以对模具内的填充物进行挤压成型，挤压成型后的填充物最大厚度不超过5cm，最小厚度不低于2cm；其中，毛毡层3折叠呈包覆形承载住中间的混合再生层，有机耐高温纤维层1的边缘包裹了毛毡层3；
5）将合并后的航空椅垫模具放入温度42℃的干燥房内3小时，取出；
6）对航空椅垫模具边缘的溺出原料进行裁剪处理（图中的虚线6为切割示意点），即得。裁剪处理所得的溺出原料粉碎成颗粒后可循环利用。图中的标示7可以是交叉四钢架条状钢材植入点及固定型座椅成型后的螺丝插入点，该部分可在制造塑模前，按实际座椅类型及大小调整位置及植入点数量。
综上所述，本发明的层状航空椅垫必须达到必要的使用特性，而且还能够在模具的其中一边，在保持固定型座椅性能与美观的前提下，切割出溺出的原料。切割剩下来的材料可用于二次再循环使用。
本发明的实施方案是提供一种改进型层状航空椅垫及其制造方法，该航空椅垫基本上由相同的几种材料类型组成，该材料的主要类型是掺入植物纤维的制椅废料（大多由聚酯类纤维组成），而形成航空椅垫的表层和底层材料在不违背本发明航空椅垫所达到的性能的前提下，也可根据实际生产情况对其进行调整或更换。对采用本发明方法生产出的航空椅垫，也可在外层添加相应的PU或其它纺织材料所缝制的座椅外套，并将套好椅套的航空椅垫安装固定在椅架上即可。
本发明改进型层状航空椅垫，可依据需要调整外观形状（如图3所示）。仅从本发明的材料特性上（使用期15000个小时内）对人体的颈椎、腰椎及臀部压迫面积上给予其它材料不能赋予的按压受力处穴位，避免颈肩的劳损、促进腰背部血液循环、够减少臀部压迫面积。
1）本发明复合材料制成的颈部按压垫，复合材料制作方法可延用图1和图2所示内容，但由于复合材料所体现出的强度特性，在制作颈部按压垫8时，需要增加混合再生层2中天然乳胶粘合剂用量的40－50%，同时降低有机耐高温纤维层1和毛毡层3用量的各40－50%，以使颈部按压垫的柔软特质变大。
2）颈部按压垫的厚度和外观可根据人体颈部的体量，在制作初期按压材料特性引起颈部按压垫变化并加热定型，能让使用者的颈椎完美贴合颈部按压垫，避免颈椎生理弯曲变直，这在目前的一般制椅工艺中还从未用到。
3）腰背部航空椅垫9的厚度和外观可根据人体脊椎生理特征，在制作时增加混合再生层2中天然乳胶粘合剂用量的50－60%，同时降低有机耐高温纤维层1和毛毡层3用量的各40－50%，使整个腰背部航空椅垫在制作时使材料堆积定型到适当高度，并依据材料特性改变腰背部航空椅垫造型变化并加热定型。
4）腰部的最佳支撑点在人体的第三和第四脊椎，在此部位通过本发明所生产的腰背部航空椅垫可以轻松降低第三和第四节脊椎的承压，减轻腰椎骨承受的人体上半身重量，促进腰背部血液循环，让背脊椎骨得到放松，从而解除背脊椎骨的疲劳度，达到减缓疲劳的需求。
5）臀部航空椅垫的厚度和外观可根据乘坐者的臀型或大众臀型，在制作时沿用图1的复合材料标准用量，在确定好臀部航空椅垫的凹凸面的外形设计时加热定型。
6）人体臀部的塑形受到人体大部分重量的影响，定型后的臀部航空椅垫拥有的持久回弹特性以及紧贴的外观造型，帮助使用者调节身体重力给予臀部压迫面积的大小。
本发明椅垫打破了原有由聚氨酯发泡塑料、金属弹簧软垫组合构成的常规航空座椅椅垫材料结构。并且由于本发明的层状椅垫内部材料在制造时天然所产生的气泡具有一定的减震作用，加上整体块状材料在脱模时所装入的由锦纶制成的多层蜂巢状减震袋，充分发挥了多层蜂巢状减震袋在使用时受压而产生的弹性和阻尼特性，加上改进型层状材料本身的透气性及减震性、阻尼性的优点，在没有载荷时整个材料几乎不施加张力，因此在静态中本产品的伸长率为1%甚至更低，所以本发明经疲劳测试验证可经历重量在75KG质量的物体使用次数达300.000次无缝痕、无断裂。
依据此内容所制造的航空座椅，可应对飞行器在空中飞行时前后上下振动航空座椅带给人体臀部的滑移，以及当乘坐者向本椅垫施加较大的激发力时椅垫本身给予的回弹，这种椅垫给予乘坐者的回弹在飞行中很可能带来致命的伤害。
本发明依据以上特点，根据这种改进型层状椅垫的制备方法，设计了新型航空座椅它具有以下特征：
1）新的层状产品特性取代了原有航空座椅内部的金属弹簧椅垫。
2）使用0.2cm直径锦纶纱线织造的多层蜂巢状减震袋，增加了弹性和阻尼性。
3）增加了航空座椅小面积椅垫部位的抗压性及舒适性，如扶手、臂靠、颈靠、头靠。
4）产品的柔软性及吸附性增加了产品的摩擦力，使本发明有效的抵抗了乘坐者臀部的滑移。
5）本发明在保证座椅舒适性的基础上有效的降低了原有航空座椅的挤压回弹率约3-5倍。
6）产品具有独特的透气性与防水性能，并可与其它类型的座椅进行升级设计与换代设计。
Claims (7)
1.一种改进型层状航空椅垫，其特征在于，包括由上到下的有机耐高温纤维层、混合再生层和毛毡层；所述混合再生层由植物纤维、航空椅垫制作产生的填充物废料和天然乳胶粘合剂混合组成，所述航空椅垫制作产生的填充物废料为人造PU、纺织纤维、聚酯纤维、木质纤维素纤维和聚氨酯发泡塑料中的一种或两种以上。
2.如权利要求1所述的改进型层状航空椅垫，其特征在于，所述有机耐高温纤维为国产芳砜纶。
3.如权利要求1所述的改进型层状航空椅垫，其特征在于，所述毛毡表面设有若干通孔。
4.如权利要求1所述的改进型层状航空椅垫，其特征在于，所述混合再生层中植物纤维的用量不低于植物纤维和航空椅垫制作产生的填充物废料两者总重量的50%，所述植物纤维为棕榈纤维。
5.权利要求1至4任一所述改进型层状航空椅垫的制造方法，其特征在于，包括如下步骤：
1）根据人体工学要求制造表面蜡质、上下双层的凹凸航空椅垫模具；
2）将航空椅垫制作产生的填充物废料粉碎成颗粒，并与植物纤维搅拌混匀获得混合物料，按每公斤混合物料添加150－250g粘合剂的比例加入天然乳胶粘合剂，搅拌混匀，备用；
3）将按照航空椅垫模具单层大小进行裁剪后的毛毡层平铺于位于下层的凸航空椅垫模具上表面；将按照航空椅垫模具单层大小进行裁剪后的有机耐高温纤维层平铺于位于上层的凹航空椅垫模具下表面；
4）在毛毡层和有机耐高温纤维层之间加入步骤2）所得产物，闭合航空椅垫模具以对模具内填充的航空椅垫原料进行挤压成型；
5）将闭合后的航空椅垫模具放入温度40－43℃的干燥房内2－4小时，取出；
6）对航空椅垫模具边缘的溺出原料进行裁剪处理，即得。
6.如权利要求5所述改进型层状航空椅垫的制造方法，其特征在于，步骤6）中裁剪处理所得的溺出原料作为航空椅垫制作产生的填充物废料循环利用。
7.一种航空座椅，其特征在于，该航空座椅包含权利要求1所述的改进型层状航空椅垫。
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| CN114450247A (zh) * | 2019-09-24 | 2022-05-06 | 宜家供应有限公司 | 包含木质纤维素纤维的软垫舒适构件 |
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