CN106064648B - 自行车座垫制造方法 - Google Patents

自行车座垫制造方法 Download PDF

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CN106064648B
CN106064648B CN201510975127.XA CN201510975127A CN106064648B CN 106064648 B CN106064648 B CN 106064648B CN 201510975127 A CN201510975127 A CN 201510975127A CN 106064648 B CN106064648 B CN 106064648B
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mold
cushion
blank
seat cushion
forming
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CN106064648A (zh
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余彩云
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Velo Enterprise Co Ltd
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Velo Enterprise Co Ltd
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    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62J—CYCLE SADDLES OR SEATS; AUXILIARY DEVICES OR ACCESSORIES SPECIALLY ADAPTED TO CYCLES AND NOT OTHERWISE PROVIDED FOR, e.g. ARTICLE CARRIERS OR CYCLE PROTECTORS
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    • B62J1/26—Paddings involving other resilient material, e.g. sponge rubber with inflatable compartments
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Abstract

一种自行车座垫制造方法，是先将一可发泡材料发泡成型为一座垫粗胚，再将该座垫粗胚置入一成型模具中加热成型为一座垫；由此，本发明的自行车座垫制造方法可避免浪费材料及不环保的问题。

Description

自行车座垫制造方法
技术领域
本发明是与自行车座垫有关，特别是关于一种自行车座垫制造方法。
背景技术
一般自行车座垫主要包含有一弹性体，该弹性体是由发泡材质制成，例如经发泡的乙烯/醋酸乙烯酯共聚物(ethylene-vinyl acetate，简称EVA)或聚乙烯(polyethylene，简称PE)。该弹性体上通常覆盖有一层表布，该表布通常为网布、合成塑料皮或者其他布料。此外，该弹性体底部更会设置一硬质底壳，用以支撑座垫整体并通过其他构件而与自行车座杆连结。
德国编号第DE102013206727号发明专利揭露有一种自行车座垫的制造方法，是先将已经发泡成型的发泡块体利用机械加工(例如铣削、磨削等等)切削成类似座垫的形状，以形成一座垫粗胚，再将该座垫粗胚放入模具中加热，以将该座垫粗胚热塑成型为最终的座垫形状，更明确地说，是成型为自行车座垫的弹性体。
然而，前述专利所提供的制造方法中，在将发泡块体加工成座垫粗胚的过程中会切削掉许多不需要的发泡块体，此举不但相当浪费材料，且非常不环保。
发明内容
有鉴于上述缺点，本发明的主要目的在于提供一种自行车座垫制造方法，是能避免浪费材料及不环保的问题。
为达成上述目的，本发明所提供的自行车座垫制造方法包含有下列步骤：
a)将一可发泡材料发泡成型为一座垫粗胚；以及
b)将该座垫粗胚置入一成型模具中加热成型为一座垫。
由此，本发明的自行车座垫制造方法中，该座垫粗胚并非经由切削加工而成，因此不会造成材料浪费及不环保的问题。
较佳地，在该步骤b)中，可还将该座垫粗胚在加热成型的过程中与一织布结合，使得该座垫的底部具有该织布。由此，该织布可提升座垫的结构强度，尤其是抵抗侧向拉力的抗拉强度。
此外，在该步骤b)中，可还将该座垫粗胚在加热成型的过程中与一表布结合，使得该座垫的顶部具有该表布。通过此方式设置表布，不但相当简便，且可将表布设置得相当稳固。该座垫粗胚可在单一模具中同时与该织布及该表布结合，或者先一模具中与该织布结合，再于同一模具或另一模具中与该表布结合。
至于该步骤a)，是能以射出发泡的方式进行，更进一步地说，该步骤a)是将未发泡的可发泡射出材料射出至一粗胚模具内进行发泡成型。或者，该可发泡材料可为未发泡的可发泡片材，该步骤a)是将该可发泡材料放入一粗胚模具内进行发泡成型；该可发泡材料可利用射出成型制成，或者由大面积且未经发泡的可发泡板材裁切而成。
有关本发明所提供的自行车座垫制造方法的详细构造、特点、组装或使用方式，将于后续的实施方式详细说明中予以描述。然而，在本发明领域中具有通常知识者应能了解，所述详细说明以及实施本发明所列举的特定实施例，仅是用于说明本发明，并非用以限制本发明的专利申请范围。
附图说明
为进一步说明本发明的技术内容，以下结合实施例及附图详细说明如后，其中：
图1为利用本发明一第一较佳实施例所提供的自行车座垫制造方法所制成的座垫的立体示意图；
图2为图1沿剖线2-2的剖视图；
图3为本发明所提供的自行车座垫制造方法的流程图；
图4为一剖视示意图，是显示本发明该第一较佳实施例所提供的自行车座垫制造方法的步骤a)；
图5为一立体分解图，是显示本发明该第一较佳实施例所提供的自行车座垫制造方法的步骤b)；
图6为一剖视示意图，是显示本发明该第一较佳实施例所提供的自行车座垫制造方法的步骤b)中模具合模的态样；
图7为利用本发明一第二较佳实施例所提供的自行车座垫制造方法所制成的座垫的剖视示意图；
图8为一立体分解图，是显示本发明该第二较佳实施例所提供的自行车座垫制造方法的步骤b)；以及
图9为一剖视示意图，是显示本发明该第二较佳实施例所提供的自行车座垫制造方法的步骤b)中模具合模的态样。
具体实施方式
申请人首先在此说明，在以下将要介绍的实施例以及附图中，相同的参考号码，表示相同或类似的元件或其结构特征。
请先参阅图1及图2，本发明一第一较佳实施例所提供的自行车座垫制造方法，是用以制造一座垫10，该座垫10主要包含有一弹性体20，该弹性体20的材质为发泡材料，且通常为闭孔式发泡材料(closed cell foam)，例如EVA或PE材料等，以同时兼具缓冲性及支撑性。此外，本实施例的座垫10还包含有一表布30(例如网布、合成塑料皮等等)以及一织布40(例如纱布等等)，该表布30是位于该座垫10的顶部12，用以与骑乘者接触，该织布40是位于该座垫10的底部14，用以加强该座垫10的结构强度。
请参阅图3至图6，该座垫10的制造方法包含有下列步骤：
a)将一可发泡材料发泡成型为一座垫粗胚50。
详而言之，该座垫粗胚50是用以在下述的步骤b)中成型为该弹性体20，该可发泡材料是由塑料原料(例如EVA、PE等等)、发泡剂及其他添加物混合而制成，举例而言，该材料可(但不限于)制作成形状类似于该座垫10且大约仅有该座垫10一半尺寸的片材，然后，该材料(片材)是放入一粗胚模具60(如图4所示)内进行发泡成型，而成为一具有特定状的座垫粗胚50(如图5所示)。
前述的片材的制造方式，是可将前述的原料混合后经由机器制成大面积的板材，再将板材裁切成如前述的形状及尺寸的片材，由于该材料未经发泡，因此裁切后剩余的残料可再利用，不会造成材料浪费。或者，前述的原料混合后亦可制成射出材料(例如通过造粒程序制成颗粒状)，再利用射出成型制造出如前述的形状及尺寸的片材。或者，此步骤a)亦可直接以射出发泡的方式进行，亦即将前述的原料混合后制成射出材料，再将射出材料射出至该粗胚模具60内进行发泡成型。
发泡成型的程序是将该粗胚模具60设置于一发泡成型机(图中未示)内进行，该粗胚模具60包含有一上模62及一下模64，该上模62与该下模64相接合时形成一封闭空间，该材料在该封闭空间内受到加热而发泡膨胀，并受该粗胚模具60塑形而成为该座垫粗胚50。更具体地说，以EVA材料为例，将该材料在该粗胚模具60内加热至摄氏165度并持续15分钟，然后再冷却至室温，即可完成发泡成型的程序。
b)将该座垫粗胚50置入一成型模具中加热成型为该座垫10。
由于本实施例的座垫10除了包含有该弹性体20，还包含有该表布30及该织布40，因此，在本实施例的步骤b)中，还将该座垫粗胚50在加热成型的过程中与该表布30及该织布40结合，使得该座垫10的顶部12及底部14分别具有该表布30及该织布40。
如图5所示，本实施例的步骤b)是将该座垫粗胚50、该表布30及该织布40放入一成型模具70内进行加热成型。详而言之，该成型模具70包含有相互枢接的一上模72、一下模74及一压框76，该上模72具有一底面722，以及一凸出于该底面722的模台724，该下模74具有一顶面742，以及一自该顶面742凹陷的模穴744，该压框76隔着该表布30而压抵于该下模74的顶面742，该表布30受该压框76定位于该顶面742上且有一部分位于该模穴744内，该座垫粗胚50的顶面52是先涂上黏胶，然后，该座垫粗胚50以该顶面52朝向该模穴744而设置于该模穴744内，该织布40覆盖在该座垫粗胚50及该压框76上，最后，该上模72压抵于该压框76上(如图6所示)，以利用该模台724与该模穴744的形状使该座垫粗胚50加热成型为该座垫10。
加热成型的程序是将该成型模具70设置于一成型机(图中未示)内进行，具体而言，将该座垫粗胚50加热至其软化点(例如摄氏150度)并持续150-180秒，使座垫粗胚50进行二次发泡，并成型成特定的形状，然后再冷却至室温，即可完成加热成型的程序。该座垫粗胚50在受该成型模具70塑形的同时，亦与该表布30紧密黏结，且该座垫粗胚50软化时会渗入该织布40的细小孔隙内，因此加热成型的程序完成后，该织布40是牢固地与该弹性体20结合，进而提升该座垫10的结构强度，尤其是抵抗侧向拉力的抗拉强度。
请参阅图7至图9，本发明一第二较佳实施例是利用类同于前述的自行车座垫制造方法制造如图7所示的座垫80，该座垫80的顶部82无如前述的表布30，因此，该座垫80的制造方法的步骤b)中，该座垫粗胚50仅与该织布40结合，而不与表布30结合，因此该成型模具70内不需设置表布30，且该成型模具70亦不需设有如前述的压框76。
该座垫80制造完成后，可再利用传统方式设置表布于该座垫80的顶部82，或者利用图5所示的成型模具70，使表布结合于该座垫80的顶部82。
进一步言之，在第一较佳实施例中，该座垫粗胚50是在单一模具中同时与该织布40及该表布30结合。然而，该座垫粗胚50亦可先通过如图8所示的成型模具70而与该织布40结合，然后再通过类同于图5所示的成型模具70而与该表布30结合，亦即，前述的步骤b)可再拆成两个步骤，使得该座垫粗胚50进行两段式加热成型，以通过此两个步骤使该座垫粗胚50先后与该织布40及该表布30结合，此方式特别适用于形状较为复杂的座垫。
必需加以说明的是，本发明的自行车座垫制造方法的特点主要是在于，该弹性体20的粗胚50的成型过程中，不需利用机械加工的方式，将已经发泡成型的块状材料切削成特定形状，而是将未经发泡的材料直接发泡成型所需的粗胚形状，故可避免材料浪费及不环保的问题，因此本发明不限于在制造过程中设置表布及织布。
最后，必须再次说明，本发明于前揭实施例中所揭露的构成元件，仅为举例说明，并非用来限制本案的范围，其他等效元件的替代或变化，亦应为本案的权利要求范围所涵盖。

Claims (1)

1.一种自行车座垫制造方法，包含有下列步骤：
a)将一未经发泡的可发泡材料制作成一形状类似于自行车座垫且尺寸较该座垫为小的片材；
b)将该片材放入一粗胚模具内，该粗胚模具包含有一上模及一下模，该上模与该下模相结合时形成一封闭空间，该片材在该封闭空间内受到加热而发泡膨胀，并受该粗胚模具塑形而成为一具有特定形状的座垫粗胚；
以及
c)取用一成型模具，该成型模具包含有相互枢接的一上模、一下模以及一压框，该成型模具的上模具有一底面，以及一凸出于该底面的模台，该成型模具的下模具有一顶面，以及一自该顶面凹陷的模穴，该压框隔着一表布而压抵于该成型模具的下模的顶面，该表布受该压框定位于该顶面上且有一部分位于该模穴内，将该座垫粗胚以其顶面朝向该模穴而设置于该模穴内，以一织布覆盖在该座垫粗胚及该压框上，然后将该成型模具的上模压抵于该压框，对该座垫粗胚加热至其软化点，使该座垫粗胚进行二次发泡，以利用该模台与该模穴的形状成型为一自行车座垫。
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US10450023B2 (en) 2019-10-22
EP3085606A1 (en) 2016-10-26
US20160311486A1 (en) 2016-10-27
EP3085606B1 (en) 2019-07-03
TWI684543B (zh) 2020-02-11

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