CN107297853A - 用于制造泡沫体的模具和方法以及泡沫材料体 - Google Patents

用于制造泡沫体的模具和方法以及泡沫材料体 Download PDF

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CN107297853A
CN107297853A CN201710234427.1A CN201710234427A CN107297853A CN 107297853 A CN107297853 A CN 107297853A CN 201710234427 A CN201710234427 A CN 201710234427A CN 107297853 A CN107297853 A CN 107297853A
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foam
die cavity
mould
core
foams
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D·哈默尔
P·克劳斯
H·库尔茨
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Grammer AG
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    • B29C44/08—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 using several expanding or moulding steps
    • B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
    • B29C44/086—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another and feeding more material into the enlarged cavity
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    • B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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    • B29C44/0469—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other provided with physical separators between the different materials, e.g. separating layers, mould walls
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • 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
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    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明特别涉及一种用于制造泡沫体的模具和方法以及泡沫材料体，用于制造泡沫材料体的装置，其包括具有至少两个模具半部(12、13、30)的模具(11)、通至第一模腔(20)的第一浇注开口(27)以及通至单独的第二模腔(22)的第二浇注开口(27)。

Description

用于制造泡沫体的模具和方法以及泡沫材料体
技术领域
本发明首先涉及一种用于制造泡沫体的工具。
背景技术
这样的泡沫体例如作为用作为车辆座椅的头靠部的垫。头靠部具有包括头贴靠面的头箱，所述头贴靠面直接或间接设置在头箱上。所述头箱例如借助至少一个支承杆支承在座椅上。头箱设有通常由泡沫体形成的垫。
在现有技术中已经组合不同的泡沫，例如借此头靠部的垫例如具有硬的核心，但具有软的外罩。
由DE 101 36 523 B4已知一种头靠部，所述头靠部的头箱具有垫，所述垫具有聚氨酯制成的软泡沫材料的元件和聚氨酯制成的硬泡沫材料的置入件。
在US 7,926,871 B2中说明一种头靠部，所述头靠部在垂直相叠的区域中包括具有不同的动态特性的泡沫。
DE 101 23 704 A1说明一种用于制造用于机动车垫部件的多层的泡沫材料垫体的装置。型芯导入配合成形元件中并且以第一泡沫注塑包封。此后型芯设置在附加配合成形元件中并且以第二泡沫注塑包封。第二泡沫具有不同于第一泡沫的特性。
发明内容
本发明的任务是提供一种装置，其在制造的时间耗费方面改善具有不同的泡沫的泡沫体的制造。
该任务通过具有权利要求1的特征的装置解决。
所述装置具有包括至少两个模具部件的模具(Form)。所述模具部件可以在打开的和关闭的位置之间运动。所述模具具有通至第一模腔的第一浇注开口和至少一个通至至少一个单独的第二模腔的第二浇注开口。泡沫可以通过相应的浇注开口引向第一或第二模具空腔。例如通道将浇注开口与模腔连接。即所述模具具有至少两个单独的模腔，所述模腔分别具有单独的浇注开口。第一模腔和第二模腔在模具的关闭的位置中通过壁彼此分开。
按照本发明的装置的优点在于，同时或短暂相隔地依次可实现第一泡沫注入和硬化到第一模具空腔中并且第二泡沫注入和硬化到第二模具空腔中。第一泡沫和第二泡沫例如具有不同的特性。例如第一泡沫具有比第二泡沫大的硬度。以这种方式，可以显著减少泡沫体的制造时间，这导致制造成本的节省。在第一模具空腔和第二模具空腔中成形的模具部件例如是成品的部件。
利用所述装置例如可制造用于给头靠部的头箱装垫的泡沫体，其形成用于车辆座椅的头靠部的头箱，其中，泡沫体在第一区域中包括具有第一特性的泡沫并且在至少一个第二区域中包括具有第二特性的泡沫。例如头箱可以在头贴靠区域中设有软的泡沫并且在其余的区域中设有硬的泡沫。
模具例如具有型芯，所述型芯可以设置在模具中。所述型芯构成至少一个模腔的至少一个壁区域。所述型芯可以例如构成泡沫体中的袋状的空隙。例如型芯构成用于座椅的头靠部的头部件的泡沫体中的空隙。所述空隙可以例如设置用于，将头靠部的与至少一个支承杆连接的基本部件设置在所述空隙中。
按照本发明的一种特别的设计，型芯将第一模腔与第二模腔分开。型芯在该情况下构成第一模腔的至少一个面和所述至少一个第二模腔的至少一个面。以这种方式，按照本发明，例如泡沫体可以具有用于头靠部的基本部件的空隙，其中，泡沫体这样构成，使得具有不同的特性的至少两个不同的泡沫邻接在所述空隙上。
按照一种实施形式，型芯可运动地支承在模具上并且在脱模位置和工作位置之间可运动。在脱模位置中，制造的模具部件可以从模具取出，并且在工作位置中，将泡沫注入模具开口中是可能的。例如型芯在脱模位置和工作位置之间可偏转地支承在模具上。
在两个模腔之间例如构成至少一个开口。借助所述开口，在第一模腔中制造的泡沫部件和在第二开口中制造的泡沫部件可以相互连接。所述连接可以例如由此进行，即，泡沫在否则分开的模腔中通过开口可以进行接触并且以这种方式连接。
泡沫的连接可以例如材料锁合地进行。在该情况下，泡沫材料必须允许连接。
按照一种特别的实施形式，至少一个连接元件这样设置在开口中，使得所述连接元件为了连接在模腔中要制造的泡沫部件伸出到第一模腔中并且伸出到第二模腔中。连接元件例如由如下材料构成，在第一模腔和第二模腔中制造的模具部件可成形在所述材料上。即在成形过程之后，连接元件以及在第一模腔中生产的泡沫部件和在第二模腔中生产的泡沫部件材料锁合和/或形锁合地连接。
所述开口可以例如在型芯和模具之间构成。
按照第二方面，本发明涉及一种用于制造泡沫体的方法。
例如应用所述方法，以便制造车辆头靠部的垫。这样的头靠部通常以泡沫体加垫。
以上提到的DE 101 23 704A1例如说明现有技术的这样的方法。
本发明的任务是提供一种方法，利用所述方法在小的时间消耗情况下可制造具有不同的泡沫的泡沫体。
本发明通过具有权利要求7的特征的方法解决。
在用于制造泡沫材料体的按照本发明的方法中，连接元件放入连接模具的两个模腔的开口中。在此，连接元件伸出到第一模腔和第二模腔中。同时或短暂相隔地依次通过第一浇注通道将第一泡沫填充到第一模腔中并且通过第二浇注通道将第二泡沫填充到第二模腔中。随后泡沫在第一模腔和第二模腔中硬化。处于第一模腔和第二模腔中的泡沫材料锁合和/或形锁合地与连接元件连接。在硬化之后，具有不同的泡沫的泡沫体从模具中被取出。
关于所述方法的优点，为了避免重复，参阅本发明的第一方面的实施方式。
按照本发明的一种设计，在连接元件放入模具中之后，型芯这样设置在模具中，使得所述型芯将第一模腔与第二模腔分开。也关于该特征的优点和实施方式参阅本发明的第一方面。
最后本发明还涉及一种用于座椅、尤其是车辆座椅的头靠部的泡沫体。
对于现有技术参阅本发明的第一方面。
本发明的任务是提供一种泡沫体，其具有至少两个不同的泡沫并且在其操作方面被改善。
该任务通过具有权利要求8的特征的泡沫体解决。
所述泡沫体具有至少一个第一泡沫和第二泡沫，其中，第二泡沫在至少一个特性方面与第一泡沫不同。泡沫体具有例如至少一个硬泡沫区域和至少一个软泡沫区域。第一泡沫和第二泡沫通过一种连接相互连接。
所述连接可以例如由在第一泡沫和第二泡沫之间的材料锁合形成。
按照一种备选方案，所述连接例如由连接元件构成。所述连接元件与第一泡沫和第二泡沫连接。所述连接可以例如通过材料锁合和/或通过形锁合实现。所述连接元件可以例如构成为连接垫。在该情况下提供用于与相应的泡沫连接的相对大的面。
附图说明
本发明其他的优点和特征借助示意性在图中示出的实施例得出。其中：
图1示出按照本发明的装置的剖面图，其中，所述装置的模具的模具部件打开并且型芯设置在取出位置中；
图2示出根据图1的示图，其中，连接垫设置在模具的型芯上；
图3示出根据图2的示图，其中，型芯设置在工作位置中；
图4示出根据图3的模具的示图，其中，第一模具部件和第二模具部件处于预关闭位置中；
图5示出根据图4的示图，其中，第一模具部件和第二模具部件处于关闭位置中，并且其中，第一泡沫注入第一模腔中并且第二泡沫注入第二模腔中；
图6示出根据图5的示图，其中，用于硬化泡沫体的浇注开口由第三模具部件遮盖；
图7示出根据图3的打开的模具的示图，其包括硬化的泡沫体；
图8示出根据图1的型芯的示图，其包括在取出位置中的泡沫体；
图9示出在从型芯脱模并且在头靠部的基体上装配之后的泡沫体。
具体实施方式
用于制造泡沫体的装置总体上以附图标记10表示。相同的附图标记在不同的图中表示对应的部件，即使后面设置或省略小的字母。
装置10具有模具11，所述模具在图1中示出。所述模具11具有模具部件12、13和30以及型芯14。模具部件13和30在图1中出于概观原因未示出。型芯14以臂15围绕偏转轴线a可偏转地保持在模具部件12上。臂15与模具部件12的端部区域16一起形成偏转铰链G1。型芯14可以以这种方式在图1中示出的取出位置和例如图3中示出的工作位置之间偏转。
在图3中示出的模具部件13可以相对于模具部件12在打开的位置和关闭的位置之间运动。按照图1，模具部件13处于打开的位置中并且型芯14设置在取出位置中。在图4中，模具部件13在预关闭位置中示出。按照图5，在关闭的位置中示出模具部件13。
模具部件12设有空隙19，所述空隙构成第一模腔20的一部分。模腔20的另一个部分由在模具部件13中的空隙21构成。换句话说，空隙19和21共同构成模腔20。模具部件12和13的内表面与型芯14的外表面18一起限定第一模腔20。
第一模腔20由模具部件12的邻接到空隙19上的内表面32、由型芯14的外表面18以及由接片25的外表面40限定。第一模腔20设置用于，构成头靠部的泡沫体的后面的区域以及侧向区域。设置为，将第一模腔20以泡沫填充，所述泡沫在硬化之后构成相对硬的垫。
在模具部件13中的空隙31构成第二模腔22的一部分。第二模腔22在模具部件12和13的关闭的位置中由接片25的内表面23、型芯14的外表面18以及第三模具部件36的成型面37和38(参看图6)限定。空隙31构成为在模具部件13中的通孔，从而第二模腔22通过开口24可填充，所述开口构成浇注开口。第二模腔22设置用于成形头靠部的泡沫体的头贴靠区域。为此设置为，第二模腔以在硬化之后形成相对软的垫的泡沫填充。
接着应说明用于制造泡沫体的方法。在按照图1的装置的位置中，型芯14以及模腔20和22由分离介质润湿。随后由聚氨酯(PUR)制成的连接垫26在模具11中、例如在型芯14上这样设置(参看图2)，使得连接垫26在型芯14运动到工作位置中之后伸入两个模腔20和22中。在如下情况下是这样，即，连接垫26这样大，使得其在模具部件12和13的关闭的状态中超过接片25的两个对置的面23和40伸出。
在下一个方法步骤中，型芯14沿方向u1运动到工作位置中。在图3中在工作位置中示出型芯14。
当型芯14处于工作位置中时，首先第二模具部件13运动到按照图4的预关闭位置中并且随后运动到按照图5的关闭的位置中。此后通过在模具部件13中构成的第一浇注开口27(参看图5)借助第一泡沫输入管路29将第一泡沫喷射到第一模腔20中并且通过开口24借助第二泡沫输入管路28将第二泡沫喷射到第二模腔22中。在模具部件13中构成一通道39，所述通道从浇注开口27通至第二模腔22，从而第二模腔22通过浇注开口27能够以泡沫填充。
在两个模腔20和22被填充之后，模具11以盖状的第三模具部件30闭锁(参看图6)。第三模具部件30具有成型面37，所述成型面关于开口24限定第二模腔22。此外，第三模具部件具有成型面38，所述成型面关于开口27限定第一模腔20。模具11保留在该位置中，直至泡沫在模腔20和22中硬化。
在硬化之后，模具再次运动到打开的位置中，其中，模具部件30和模具部件13从模具部件12移去除(参看图7)并且然后型芯14沿方向u2偏转到取出位置中(参看图8)。按照图8，完成硬化的泡沫体33处于型芯14上。泡沫体33可以然后从型芯14被取出。最后模具11被清洗并且然后再次准备用于其他的制造过程。
在图9中，头靠部45完成装配地连同泡沫体33示出。在泡沫体33的空隙17中，装配头靠部45的基本部件42，所述基本元件在图9中仅通过虚线表示。借助虚线示出支承杆44，所述支承杆穿过泡沫体33的开口43从所述开口伸出。支承杆紧固在基本部件42上。通过开口43，头箱42可以装配在空隙17中。
泡沫体33具有软泡沫区域34以及硬泡沫区域35。软泡沫区域34在泡沫体33在基本部件42上的完全的装配之后至少部分地构成头靠部45的头贴靠区域41。硬泡沫区域35形成头靠部的泡沫体的一个后面的区域、侧向区域以及一个上面的和一个下面的区域。软泡沫区域34材料锁合地与连接垫26连接并且硬泡沫区域35同样材料锁合地与连接垫26连接。亦即通过连接垫26，软泡沫区域34和硬泡沫区域35彼此连接。

Claims (11)

1.用于制造泡沫材料体的装置，所述装置具有包括至少两个模具半部(12、13、30)的模具(11)，具有通至第一模腔(20)的第一浇注开口(27)以及具有通至单独的第二模腔(22)的第二浇注开口(27)。
2.按照权利要求1所述的装置，其特征在于，型芯(14)能够被设置在模具(11)中。
3.按照上述权利要求之一所述的装置，其特征在于，型芯(14)将第一模腔(20)与第二模腔(22)彼此分开。
4.按照上述权利要求之一所述的装置，其特征在于，型芯(14)能够运动地支承在模具(11)上。
5.按照上述权利要求之一所述的装置，其特征在于，型芯(14)构成为，使得连接元件(26)能够设置在模具(11)中，使得所述连接元件为了连接在模腔(29、22)中要制造的泡沫部件伸出到第一模腔(20)中并且伸出到第二模腔(22)中。
6.用于制造泡沫材料体的方法，其中，
将连接元件(26)放入模具中，使得连接元件(26)伸入模具(11)的第一模腔(20)和第二模腔(22)中，
关闭模具(11)，
同时或短暂相隔地依次通过第一浇注开口(27)将第一泡沫填充到第一模腔(20)中并且通过第二浇注开口(24)将第二泡沫填充到第二模腔(22)中，
使在第一模腔(20)和第二模腔(22)中的泡沫经历一段硬化时间，
打开模具(11)，
并且将模具部件从模具(11)中取出。
7.按照权利要求6所述的方法，其特征在于，型芯(14)设置在模具(11)中，使得所述型芯将第一模腔(20)与第二模腔(22)分开。
8.泡沫材料体，其包括至少一个软泡沫区域(34)和至少一个硬泡沫区域(35)，其特征在于，软泡沫区域(34)和硬泡沫区域(35)间接或直接地以连接部材料锁合和/或形锁合地相互连接。
9.按照权利要求8所述的泡沫材料体，其特征在于，所述连接部具有连接垫(26)，软泡沫区域(34)材料锁合和/或形锁合地与连接垫(26)连接并且硬泡沫区域(35)材料锁合和/或形锁合地与连接垫(26)连接。
10.按照权利要求8或权利要求9所述的泡沫材料体，其特征在于，泡沫体(33)构成有空隙(17)，头靠部(45)的头箱(42)可装配在所述空隙中。
11.按照权利要求8至10之一所述的泡沫材料体，其特征在于，软泡沫区域(34)和/或硬泡沫区域(35)由聚氨酯泡沫形成。
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