CN109152485A - 软垫弹簧和用于制造软垫弹簧、床垫和软垫家具的方法 - Google Patents
软垫弹簧和用于制造软垫弹簧、床垫和软垫家具的方法 Download PDFInfo
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- 150000003609 titanium compounds Chemical class 0.000 claims description 4
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Abstract
软垫弹簧包括由微合金钢制成的弹簧钢丝和至少设置在其上某些区域内的颜色指示剂,所述微合金钢含有重量比为0.004‑0.015%的一种或多种合金元素。本发明还涉及一种用于制造软垫弹簧、床垫或具有所述软垫弹簧的软垫家具的方法。
Description
本发明涉及一种软垫弹簧,一种用于制造软垫弹簧的方法,特别是用于制造软垫家具或床垫的方法,以及一种床垫和一种软垫家具。
DE 10 2013 103 644公开了一种弹簧芯弹簧,其由金属丝构成,可用于例如床垫或软垫家具。该弹簧由缠绕成螺旋形的弹簧钢丝组成,其在载荷时变形。该弹簧已经在软垫家具和床垫的制造中得到证明,其中在制造过程中对该弹簧进行热处理以使其更加坚韧。通过这种热处理防止了各个弹簧的下垂和由此产生的凹陷,例如垫衬物或床垫中的凹陷。但是,只有耗费巨大精力才能确定热处理是否充分。最终客户通常无法进行检查。
随后公开的DE 10 2015 102 539 A1公开了一种用于制造软垫弹簧的方法。该软垫弹簧由弹簧钢丝构成并具有颜色指示剂,该颜色指示剂指示是否已经对软垫弹簧进行了足够的热处理以进行退火。
从该现有技术出发,本发明的目的是改进所述软垫弹簧,从而提高弹簧的延展性,同时确保所述颜色指示剂的粘附,并且提供制造所述软垫弹簧的方法。
本发明通过具有权利要求1的特征的软垫弹簧和具有权利要求6的特征的方法来实现这一目的。
根据本发明的软垫弹簧包括由微合金钢制成的弹簧钢丝和至少设置在其上某些区域中的颜色指示剂,其中微合金钢含有重量比为0.004-0.015%的一种或多种合金元素。
因此,在一个优选实施例中,所述颜色指示剂不是所述弹簧钢丝材料的组成部分,而是涂覆于所述弹簧钢丝。
微合金钢通常包含低重量比的合金元素,例如铝、钛、钒或铌。这些合金元素中的一部分可以形成碳化物或氮化物。特别优选地也可以发生所谓的晶粒细化,其中在微观结构中产生更小和更细的晶粒。伴随着热处理,由于晶粒细化,在微观结构中形成更细的晶粒。
这种微观结构的晶粒细化反过来可以对弹簧钢丝的韧性和延展性产生积极影响,这与改善的变形性能有关。
此外,由于氮与钛的牢固结合,可以优化强度并且可以改善拉伸性能。
此外,已经表明所述颜色指示剂,特别是含铜涂层与微合金钢的良好结合是可能的。
根据本发明的软垫弹簧的有利实施例变型是从属权利要求的标的。
如果所述弹簧钢由钛重量比为0.004-0.01%之间的钛-微合金钢组成,则比较有利。钛的加入对所述弹簧钢丝的微观结构和最终产品的微观结构有影响。通过添加钛作为合金元素,可以形成比其它已知的弹簧钢丝更细晶粒的微观结构,特别是由于晶粒细化,优选在弹簧钢丝制造过程中的热处理范围内。
当钛-微合金钢中钛的重量比为0.005-0.008%之间,就可以获得最佳结果。
该颜色指示剂可以有利地作为含铜涂层,特别是作为由铜构成的涂层涂覆于所述弹簧钢丝。一种含铜涂层被理解为具有一定铜比例和一定质量比例的涂层。此外,例如,粘合剂可以构成涂层的一部分。在涂层合金的情况下,可以是漆或金属基体。含铜涂层应该有利地不影响所述软垫弹簧的机械性能。含铜涂层还可以基本上完全由铜构成,薄薄地涂覆至所述弹簧钢丝。也可以使用合适的铜合金,以设定一定的转换温度。在颜色变化期间,根据达到的温度,所述铜色涂层变深或变浅,在视觉上容易辨别。
所述弹簧钢丝可基于C38(D)至C70(D)类型的根据DIN EN ISO 16120的拉拔用盘条用钢而形成,该钢还与钛合金化,特别是在上述优选浓度范围内。
根据本发明的用于制造软垫弹簧的方法,特别是用于制造软垫家具或床垫的方法,尤其包括制造由微合金钢制成的弯曲或未弯曲的弹簧钢丝的步骤,其中所述微合金钢具有至少一种或多种重量比为0.001-0.015%的合金元素。
此外,根据本发明,所述方法还包括在弹簧钢丝弯曲之前、期间或之后,在弹簧钢丝的至少某些区域内涂覆一种热敏颜色指示剂,然后在所述软垫弹簧制造完成之前,将所述弹簧钢丝到所述颜色指示剂的最低转换温度。一些机器在所述弹簧卷绕之前在拉丝过程中进行加热,因此所述弹簧是热卷的。然而,也有一些机器通过在第二步中引入电流进行加热,借此,弹簧早已被卷绕。
通过涂覆所述热敏颜色指示剂,确保了所述弹簧钢丝的热处理视觉可见。通过相应的颜色变化,无论是软垫家具和床垫的制造者,还是最终客户,都能够看出弹簧钢丝是否进行了热处理,这使得所述弹簧钢丝更加坚韧。因此,可以从视觉上强调所述软垫弹簧的重要质量标准。
所述弹簧钢丝的制造可以有利地包括在热轧过程中将弹簧钢与钛和/或钛化合物微合金化,以便在随后的冷却过程中,由于添加的钛和/或添加的钛化合物的数量,钢的细晶粒结构发生变化,形成弹簧钢体。在这种情况下,钢的细晶粒结构的变化与未与钛或钛化合物微合金化的钢的比较有关。在这种情况下,钛被理解为基本金属。金属化合物可以是如钛盐、碳化物或氮化物或钛合金。
此外,制造所述弹簧钢丝包括优选在低于50℃的温度下通过拉伸所述弹簧钢体来形成所述弹簧钢丝。这种成形加工也称为冷拔法。
现在可以在拉拔工序后涂覆所述颜色指示剂。
可以在涂覆所述颜色指示剂之前或之后将所述弹簧钢丝弯曲和/或卷绕成所述软垫弹簧的形状。
在热处理期间,所述弹簧钢丝优选被加热到高于280℃的温度。对于热处理,所述弹簧钢丝可以加热到,例如,290℃至310℃之间的温度,其中热处理的持续时间可以取决于所使用的弹簧钢丝,但温度必须至少短暂地达到290℃以上。因此,所述颜色指示剂的转换温度优选地至少为250℃,特别是在290℃至310℃之间。在这些温度下,热处理产生积极效果。
为了有效地制造所述软垫弹簧,可以通过浸浴来涂覆所述颜色指示剂。在这种情况下,所述涂层可以仅用电化学或电镀的方式施加电压。所述颜色指示剂优选地具有0.05至1微米之间的厚度,特别是0.10至0.80微米,因此所述颜色指示器仅少量地涂覆至所述弹簧钢丝。
在本发明的另一实施例中,所述颜色指示剂仅涂覆于所述弹簧钢丝的某些区域,这特别节省材料。例如,所述颜色指示剂可以仅涂覆于所述软垫弹簧的中间区域,其在负载时变形,因此至少通过所述颜色指示剂可以看出所述变形区域是否进行过热处理。然后,设置在软垫弹簧相对侧上的端环可以保持不加涂层。当然,也可以用所述颜色指示剂完全涂覆所述软垫弹簧。
根据本发明还提供了一种软垫弹簧,其特别用于床垫或软垫家具中。在床垫或软垫家具中,可以将观察窗设置在用于软垫弹簧的垫套上或设置在由多个软垫弹簧制成的单元上,因此最终客户也可以看出所述软垫弹簧是否经过适当热处理。
下面将参照附图根据示例性实施例来更详细地解释本发明。图中:
图1示出了在热处理之前和之后具有根据本发明的颜色指示剂涂层的软垫弹簧的摄影视图,
图2示出了不具有颜色指示剂的传统软垫弹簧。
图2示出了未涂覆有由热敏颜色指示剂制成的涂层的软垫弹簧。可以看到制造软垫弹簧的所述弹簧钢丝各处颜色都相同,并且在视觉上不能看出是否对该软垫弹簧进行了热处理以使所述弹簧钢丝更坚韧。
根据本发明的软垫弹簧在图1的左侧示出。
所述软垫弹簧具有弹簧钢丝,所述弹簧钢丝由微合金钢制成,所述微合金钢含有重量比为0.004-0.015%的合金元素。
已经证明钛是特别优选的合金元素。钛重量比可以优选为0.004-0.01%,最优选为0.005-0.008%。
在这种情况下,所述弹簧钢丝优选地由钢制成,该钢基本上是碳钢,并且特别优选地基于C38(D)至C70(D)钢本色。
可以通过微合金化和热轧后的特殊冷却工艺来制造所述钢丝,使得钢的细晶粒结构在钢厂时已经受到影响。与非微合金化弹簧钢丝相比,形成了晶粒细化。首先,例如在冷成形的范围内,形成弹簧钢体,该弹簧钢体随后可以通过拉拔而形成弹簧钢丝。
随后可以制备具有颜色指示剂的涂层,下文将对此进行详细描述。
所述软垫弹簧在平行布置的两个端环之间的中间区域中卷绕成螺旋状,并且在这一中间区域内涂覆有热敏颜色指示剂。从视图可以推断,中间区域的颜色与所述软垫弹簧的两个未涂覆的端环不同。中间区域明显较暗,这是因为由于热处理导致所述热敏颜色指示剂的颜色发生变化。在右侧示出了一个未经热处理的带有颜色指示剂的软垫弹簧,可以清楚地看出颜色是均匀的。将厚度在0.15至0.75微米之间的含铜涂层作为中间区域的热敏颜色指示剂通过电化学方式涂覆到所述钢丝上。为此,所述钢丝被引导通过浸浴,同时向所述弹簧钢丝施加电压,从而在表面沉积所述含铜涂层。通过这种方法可以比较精确地设置所述涂层的厚度和涂覆区域。
在这种情况下,所述颜色指示剂可以一直涂覆于仍未成形的弹簧钢丝,因此在涂覆之后它仅成形为所述软垫弹簧的形状。然后优选进行完全涂覆。然而,也可以首先将所述弹簧钢丝成形为软垫弹簧并至少部分地涂覆已成形的弹簧钢丝。
在涂覆所述颜色指示剂之后,对弯曲的弹簧钢丝进行热处理,其中将弯曲的弹簧钢丝加热到280℃至320℃之间的温度。通过加热到该温度来激活所述颜色指示剂,因此中间区域的颜色变化视觉可见。
在所示的示例性实施例中,仅软垫弹簧的中间区域涂覆有颜色指示剂,其中也可以将颜色指示剂完全涂覆于所述软垫弹簧。然而,通过在某些区域涂覆颜色指示剂,可以使从视觉上看到的由于热处理引起的颜色变化变得更为简单。此外,可以仅在所述软垫弹簧负载变形的区域内涂覆所述涂层,即特别是两个端环之间的区域。
所述软垫弹簧可弯曲成不同的弹簧类型。因此,所述软垫弹簧可成形为邦尼尔弹簧、袋装弹簧、开放式线圈或其它的弹簧类型。所述软垫弹簧也可以组装成由多个软垫弹簧制成的单元,然后加工成床垫或软垫家具。
为了使最终客户能够检查床垫或软垫家具中是否使用了高质量的软垫弹簧,可以在垫套中设置至少一个透明或由开口形成的观察窗,因此可以通过肉眼检查所述软垫弹簧是否进行了热处理。
在涂覆所述颜色指示剂之后,可以卷绕和/或弯曲所述弹簧钢丝以成形所述软垫弹簧。
所述软垫弹簧成品可以选择性地封装在例如床垫或软垫家具的材料袋中。
最后,可以将所述软垫弹簧或材料袋连接到弹簧芯,并且这些弹簧芯可以安装在床或软垫家具中。
也预期通过添加钛会对弹簧钢丝的热轧弹簧钢体的微观结构和最终产品的微观结构产生影响,因为这样通常会形成更细晶粒的微观结构。
这种被称为晶粒细化的效果可以对所述软垫弹簧的弹簧钢丝的韧性和延展性产生积极影响,从而与更好的变形性能相关联。
此外,还常常保留对强度的影响,并且通过氮与钛的牢固结合可以提高拉伸性能,因此可以提高在冷成形期间制造所述弹簧钢丝的加工能力。
在这种情况下,特别是钛微合金对弹簧钢丝的材料性能有积极的影响。
因此,对氮的高亲和力促进了其的结合,这增强了所述弹簧钢的抗老化性。因此也可以减少软垫弹簧的设置损失。
此外,细钛沉淀具有晶粒细化作用,这对所述钢的延展性具有积极影响,反过来在制造所述软垫弹簧方面具有优势。
Claims (14)
1.一种软垫弹簧,包括由微合金钢制成的弹簧钢丝和至少设置在其上某些区域内的颜色指示剂,其中微合金钢含有重量比为0.004-0.015%的一种或多种合金元素。
2.根据权利要求1所述的软垫弹簧,其特征在于,所述弹簧钢由钛微合金钢构成,所述钛微合金钢的钛的重量比为0.004-0.01%。
3.根据权利要求1或2所述的软垫弹簧,其特征在于,所述弹簧钢由钛微合金钢构成,所述钛微合金钢的钛的重量比为0.005-0.008%。
4.根据前述权利要求中任一项所述的软垫弹簧,其特征在于,所述颜色指示剂作为含铜涂层涂覆在所述弹簧钢丝上,特别是作为由铜构成的涂层涂覆在所述弹簧钢丝上。
5.根据前述权利要求中任一项所述的软垫弹簧,其特征在于,所述钢是基于C38(D)至C70(D)类型的钢,并且以钛作为合金元素。
6.一种用于制造软垫弹簧的方法,特别是用于制造软垫家具或床垫的方法,至少包括以下步骤:
-制造由微合金钢制成的弯曲或未弯曲的弹簧钢丝,其中所述微合金钢含有重量比为0.001-0.015%的一种或多种合金元素;
-在弹簧钢丝弯曲之前、之中或之后,在弹簧钢丝的至少某些区域内涂覆热敏颜色指示剂;
-将弹簧钢丝加热到颜色指示剂的最低转换温度;
-软垫弹簧制造完成。
7.根据权利要求6所述的方法,其特征在于,制造所述弹簧钢丝包括在热轧过程中对弹簧钢与钛和/或钛化合物进行微合金化,以便在随后的冷却过程中,由于添加的钛和/或添加的钛化合物的数量,改变所述钢的晶粒细化而形成弹簧钢体。
8.根据权利要求6或7所述的方法,其特征在于,制造所述弹簧钢丝包括优选在低于50℃的温度下通过拉伸所述弹簧钢体来形成所述弹簧钢丝。
9.根据前述权利要求6至8中任一项所述的方法,其特征在于,在制造弯曲或未弯曲的弹簧钢丝以及在至少某些区域内涂覆热敏颜色指示剂后,加热所述弹簧钢丝至高于250℃的温度,优选加热至280℃至320℃之间的温度,以进行热处理和颜色指示剂的活化。
10.根据前述权利要求6至9中任一项所述的方法,其特征在于,所述颜色指示剂的涂覆厚度在0.05μm至1.5μm之间,特别是在0.10μm至0.80μm之间。
11.根据前述权利要求6至10中任一项所述的方法,其特征在于,所述颜色指示剂仅涂覆在所述弹簧钢丝的某些区域内,特别是在所述软垫弹簧的中间区域。
12.根据前述权利要求1至5中任一项所述的软垫弹簧,其特征在于,所述软垫弹簧通过前述权利要求6至11中任一项所述的方法制造。
13.一种具有根据权利要求1至5中任一项所述的软垫弹簧的软垫家具或床垫。
14.根据权利要求13所述的软垫家具或床垫,其特征在于,观察窗设置在用于软垫弹簧的垫套上或设置在由多个软垫弹簧制成的单元上。
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PL3448207T3 (pl) | 2023-03-20 |
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CN109152485B (zh) | 2021-08-03 |
BR112018072000A2 (pt) | 2019-02-12 |
HRP20230041T1 (hr) | 2023-03-03 |
AU2017256502B2 (en) | 2023-03-16 |
ES2935642T3 (es) | 2023-03-08 |
US20210222749A1 (en) | 2021-07-22 |
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