CN113580461A - Multi-hardness one-step forming automobile seat foam mold and method - Google Patents

Multi-hardness one-step forming automobile seat foam mold and method Download PDF

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Publication number
CN113580461A
CN113580461A CN202110942886.1A CN202110942886A CN113580461A CN 113580461 A CN113580461 A CN 113580461A CN 202110942886 A CN202110942886 A CN 202110942886A CN 113580461 A CN113580461 A CN 113580461A
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China
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area
hardness
male die
foam
cushion
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王艳飞
黄玉强
刘帅
魏凯
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Changchun Faway Adient Automotive Systems Co Ltd
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Changchun Faway Adient Automotive Systems Co Ltd
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Priority to CN202110942886.1A priority Critical patent/CN113580461A/en
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    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—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
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/582—Moulds for making undercut articles

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  • Moulds For Moulding Plastics Or The Like (AREA)
  • Mattresses And Other Support Structures For Chairs And Beds (AREA)

Abstract

The invention belongs to the technical field of automobile seat foam molding, and particularly relates to a multi-hardness one-step molding automobile seat foam mold and a method; the male die comprises a male die body, a plurality of micro elements of the same kind are arranged on the male die body, and the micro elements of the same kind are sequentially arranged on the male die body from top to bottom; wherein the microelements are divided into a bulge and a groove, and the shape of the bulge and the groove is semicircular, 1/4 circular or irregular arc; the shape of the male die for foam molding is controlled through the infinitesimal design on the male die, so that the foam molding of multi-hardness foam is realized, the foam of a plurality of macro-hardness subareas can be molded by only adopting one filling material, and the foam hardness required by different areas is easy to control.

Description

Multi-hardness one-step forming automobile seat foam mold and method
Technical Field
The invention belongs to the technical field of automobile seat foam molding, and particularly relates to a multi-hardness one-step molding automobile seat foam mold and a method.
Background
At present, vehicle seat mainly comprises skeleton, foam and mask (face guard), on current foam molding process basis, in order to very big limit to satisfy the demand of user to the seat travelling comfort, what most of seats adopted is that double hardness foam is two foam hardness of flank and main face (core face), can not satisfy the urgent demand of driver and passenger in the aspect of the seat travelling comfort promotion far away. From the perspective of comfort of human perception engineering, a driver feels soft at the initial stage of sitting and needs different hardness for supporting after sitting, and at present, a seat manufacturer adopts a mode of sticking a layer of soft foam with the thickness of 10-20 mm to meet the first soft requirement of the driver on the surface layer of the seat. In order to meet the modeling requirements of customers and complete the assembly of the protective surface and the foam, most of seats need to cut the softer foam into 2-4 pieces and then paste the foam one by one, so that the production procedures of the seats are greatly increased. In addition, the requirements of the upper back, the lower back, the lumbar vertebra (part), the sacrum, the hip bone, the thigh and other parts of the human body on the hardness of the foam of the seat are different, and the commonly used double-hardness foam forming method is that the double-cavity is respectively added with isocyanate polyester polyether and other chemical components to carry out crosslinking reaction to form the double-hardness foam, but the conventional chemical foam forming method meets the bottleneck of a multi-hardness control technology and can only reach the level of the double-hardness foam.
The conventional chemical foaming forming method is to change the chemical composition distribution ratio of isocyanate, polyester, polyether and the like to interfere the size of foam pores in the internal structure of polyurethane foam so as to obtain foam bodies with different hardness or different partition hardness, belongs to the field of micro interference foam microstructure, but cannot realize more than two hardness forming of the foam in the aspect of hardness process control.
The conventional physical method is to fill a molding material of the side wing foam in one cavity of the side wing; the main surface of the core is filled with another molding material in another cavity, but the materials in the two cavities are often mixed together in the actual operation process, so that uneven foam hardness influences the riding comfort perception of an occupant.
Disclosure of Invention
In order to overcome the problems, the invention provides a multi-hardness one-step forming automobile seat foam mold and a method, wherein the shape of a male mold for foam forming is controlled through a micro-element design on the male mold, so that the foam forming of multi-hardness foam is realized, the foam of a plurality of macro-hardness partitions can be formed by only adopting one filling material, and the foam hardness required by different partitions is easy to control.
A multi-hardness one-step forming automobile seat foam die comprises a male die 1 and a female die 2, wherein the female die 2 and a bearing body thereof are arranged along with the shape of the male die, the male die 1 comprises a male die body, a plurality of micro elements of the same kind are arranged on the male die body, and the micro elements of the same kind are sequentially arranged on the male die body from top to bottom; wherein the micro-element is divided into a bulge 11 and a groove 12, and the shape of the bulge 11 and the groove 12 is semicircular, 1/4 circular or irregular arc.
The diameter or width of the bulge 11 is 5-20 mm, and the depth is 1/6-1/2 times of the thickness of the foam to be manufactured.
The distance between the adjacent edges of the adjacent protrusions 11 is 5-50 mm.
The diameter or width of the groove 12 is 10-50 mm, and the depth is 1/12-1/2 times of the thickness of the foam to be manufactured.
The distance between the adjacent edges of the adjacent grooves 12 is 5-30 mm.
A method for multi-hardness one-step forming automobile seat foam comprises the following steps:
firstly, designing a infinitesimal on a male die 1 of a seat cushion as follows:
when the foam hardness of the cushion supporting area is 5kPa, the corresponding relation between the surface area s of the cushion A and the design infinitesimal number x is as follows: (Π a)2(d2)x)/4s＝40％；
When the foam hardness of the required supporting area is 6kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝50％；
When the foam hardness of the required supporting area is 7kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝65％；
When the desired support area foam hardness isWhen 8kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design elements is as follows: (Π a)2(d2)x)/4s＝80％；
The diameter and the shape of a infinitesimal element on a male die 1 for manufacturing the cushion are designed by combining the modeling characteristics of each seat, so that the hardness of a touch area of the cushion is controlled to reach a hardness balance point required by the design of the touch area and a support area;
wherein a is the diameter or width of the microelements on the male die 1, and d is the distance between adjacent microelements on the male die 1, namely the distance between two opposite side edges of the adjacent microelements;
step two, designing the micro elements on the male die 1 of the seat back tactile area as follows:
when the required foam hardness of the backrest support area is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝45％；
When the required foam hardness of the support area is 4.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝60％；
When the required foam hardness of the support area is 5.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝80％；
Designing the shape and size of a micro element of a male die 1 for manufacturing the backrest by combining the modeling characteristics and requirements of each seat, and further controlling the hardness of a tactile area of the backrest to reach a hardness balance point required by the design of the tactile area and a supporting area;
step three, the foam hardness of the 3 rd to 5 th areas of the lumbar vertebra of the seat back is greater than that of the 1 st to 7 th areas of the thoracic vertebra, so that:
the micro-element design of the supporting area of the male die 1 of the backrest in the 1 st to 7 th regions of the thoracic vertebra and the tactile area of the male die 1 of the backrest in the 3 rd to 5 th regions of the lumbar vertebra is as follows:
when the required foam hardness of the backrest support area is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2)x)/4s＝50％；
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2)x)/4s＝35％；
When the required foam hardness of the backrest support area is 4.5kPa, the corresponding relation between the A surface area s of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2)x)/4s＝65％；
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2)x)/4s＝45～55％；
When the required foam hardness of the backrest support area is 5.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2)x)/4s＝85％；
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2)x)/4s＝55～75％；
Designing a male die 1 infinitesimal according to the step two in the region except the regions of 1 st to 7 thoracic vertebrae and 3 rd to 5 lumbar vertebrae on the male die 1 of the seat back;
step four, designing the micro elements on the male die 1 at the front end area of the cushion as follows:
when the foam hardness of the required cushion supporting area is 5kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design microelements on the male die 1 of the cushion is as follows: Π a2(d2)x)/4s＝45～55％；
When the foam hardness of the required cushion supporting area is 6kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝55～65％；
When the foam hardness of the required cushion supporting area is 7kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝65～75％；
When the foam hardness of the required cushion supporting area is 8kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝85～95％；
In the area outside the front end area of the cushion, male die 1 infinitesimal is designed according to the first step;
buckling a male die 1 and a female die 2 which are designed for manufacturing the seat backrest together, and simultaneously injecting the same filling material into two parts of a side wing and a core part in a backrest die consisting of the female die 2 and the male die 1 to form the seat backrest, or respectively injecting different filling materials into two parts of the side wing and the core part in the backrest die consisting of the female die 2 and the male die 1 to form the seat backrest;
the designed male die 1 and the female die 2 for manufacturing the seat cushion are buckled together, and the same filling material is simultaneously injected into the two parts of the side wing and the core part of the cushion mold consisting of the female die 2 and the male die 1 to form the seat cushion, or different filling materials are simultaneously injected into the two parts of the side wing and the core part of the cushion mold consisting of the female die 2 and the male die 1 to form the seat cushion.
The invention has the beneficial effects that:
the invention not only solves the problem that the soft area with multi-hardness touch feeling and the supporting area which are required by the comfort and the safety of a driver can be simultaneously formed in one step. The certain number of the bulges and the grooves designed on the male die also reduce the contact area between the male die and the foam, so that the forming and demoulding of the foam are easier, and meanwhile, the certain number of the bulges and the grooves designed on the male die adopt a circular or shell-shaped design with gentle curvature change, so that the probability of foam tearing caused by demoulding difficulty is reduced.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the contents of the embodiments of the present invention and the drawings without creative efforts.
FIG. 1 is a schematic view of the convex configuration of the male mold of the present invention.
FIG. 2 is a schematic diagram of the structure of the male mold of the present invention in which the microelements are grooves.
FIG. 3 is a schematic view of the configuration of the male mold of the present invention in which the microelements are semicircular.
FIG. 4 is a schematic view of the configuration of the microcell 1/4 circle on the male mold of the present invention.
FIG. 5 is a schematic view of the irregular arc-shaped configuration of the microelements on the male mold of the present invention.
FIG. 6 is a schematic view of the present invention in use.
Wherein: 1-a male mold; 11-a bump; 12-a groove; 2-female die; 3-backrest foam.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
In the description of the present invention, unless expressly stated or limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, e.g., as meaning permanently connected, removably connected, or integral to one another; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.
In the description of the present embodiment, the terms "upper", "lower", "left", "right", and the like are used based on the orientations and positional relationships shown in the drawings only for convenience of description and simplification of operation, and do not indicate or imply that the referred device or element must have a specific orientation, be configured and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used only for descriptive purposes and are not intended to have a special meaning.
Example 1
As shown in fig. 1-5, a multi-hardness one-step molding automobile seat foam mold comprises a male mold 1 and a female mold 2, wherein the female mold 2 is arranged along with a bearing body thereof, a seat part manufactured by the male mold 1 in the foam mold can be directly assembled with a protective surface (mask) in a buckling or magic adhesive strip mode, and the bearing body of the seat part manufactured by the female mold 2 in the foam mold is a framework steel wire (curtain) or a framework steel plate or a framework plastic plate. The female die 2 related to the invention has a free structure design, and generally can be matched with a bearing body of the female die to form a structure with a reduced weight.
The male die 1 comprises a male die body, wherein a plurality of micro elements of the same type are arranged on the male die body, and the micro elements of the same type are sequentially arranged on the male die body from top to bottom; wherein the micro-element is divided into a bulge 11 and a groove 12, and the shape of the bulge 11 and the groove 12 is semicircular, 1/4 circular or irregular arc.
The diameter or width of the bulge 11 is 5-20 mm, and the depth is 1/6-1/2 times of the thickness of the foam to be manufactured.
The distance between the adjacent edges of the adjacent protrusions 11 is 5-50 mm.
The diameter or width of the groove 12 is 10-50 mm, and the depth is 1/12-1/2 times of the thickness of the foam to be manufactured.
The distance between the adjacent edges of the adjacent grooves 12 is 5-30 mm.
A method for multi-hardness one-step forming automobile seat foam comprises the following steps:
the soft feeling and the supporting feeling at the initial driving stage are divided into two types, namely car models similar to cars and sports off-road vehicles, wherein the cars drive on urban roads, the soft feeling (touch areas) is emphasized by people who drive cars, the off-road vehicles are emphasized by people who drive cars, and the supporting feeling (supporting areas) and the vibration reduction effect of the supporting areas are needed for long-term driving. In view of this, the mold provided by the invention can flexibly meet the hardness requirements of different vehicle types on the foam or the foam layer. The foam hardness required by different positions of the seat according to different parts of a human body is controlled by the type, the number, the shape, the diameter or the width of the micro elements designed on the male die 1 body and the distance between the adjacent micro elements;
step one, satisfying the cushions in various foam hardness support areas, realizing the micro-element design on the male die 1 of the seat cushion in the touch area (soft area) as follows:
when the foam hardness of the cushion supporting area is 5kPa, the corresponding relation between the area s of the surface A (namely the upper surface of the cushion) of the cushion and the number x of the design infinitesimal elements is as follows:
(Πa2(d2) x)/4s is 40%, in which case the depth e or b of the infinitesimal element can be a value between 10 and 20mm, and the resulting touch area (soft area) corresponds to a value between about 1.5 and 2Kpa of macro-hardness;
when the foam hardness of the required supporting area is 6kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows:
(Πa2(d2) x)/4s is 50%, in which case the depth e or b of the micro element may be a value between 10 and 20mm, and the resulting tactile area (soft area) corresponds to a value between about 1.5 and 2Kpa for macro hardness.
When the foam hardness of the required supporting area is 7kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows:
(Πa2(d2) x)/4s is 65%, in which case the depth e or b of the micro element may be a value between 10 and 25mm, and the resulting tactile area (soft area) corresponds to a value between about 1.5 and 3kPa for macro hardness.
When the foam hardness of the required supporting area is 8kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows:
(Πa2(d2) x)/4s of 80%, in which case the depth e or b of the micro-elements may be a value between 10 and 25mm, and the resulting tactile area (soft area) may correspond to a value between about 1.5 and 3kPa for macro-hardness. The area with larger coverage area of the micro element is mostly designed by adopting shell-shaped micro elements.
According to the coverage rate rule of the design infinitesimal elements, the diameter and the shape of the infinitesimal elements on the male die 1 for manufacturing the cushion are designed by combining the modeling characteristics of each seat, and further the hardness of the touch area of the cushion is controlled to reach the hardness balance point required by the design of the touch area and the support area;
wherein a is the diameter or width of the microelements on the male die 1, and d is the distance between adjacent microelements on the male die 1, namely the distance between two opposite side edges of the adjacent microelements;
step two, satisfying the backrest of various foam hardness support areas, and realizing the micro-element design on the male die 1 of the seat backrest touch area as follows:
when the required foam hardness of the support area of the backrest is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
(Πa2(d2) x)/4s is 45%, in which case the depth e or b of the micro-elements may be 10 to 15mm and the resulting tactile area may have a macro-hardness of about 1.5 to 2kPa
When the foam hardness of the required support area is 4.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
(Πa2(d2) x)/4s is 60%, in which case the depth e or b of the micro-elements may be a value between 10 and 20mm and the resulting tactile area may have a macro-hardness of about 1.5 to 2kPa
When the required foam hardness of the support area is 5.5kPa, the corresponding relation between the A surface area s of the backrest and the designed infinitesimal number x is as follows:
(Πa2(d2) x)/4s of 80%, in which case the depth e or b of the micro-elements may be a value between 10 and 20, and the resulting tactile area may correspond to a macro-hardness of between about 1.5 and 3 kPa. The area with larger coverage area of the micro element is mostly designed by adopting shell-shaped micro elements.
According to the coverage rate law of the design infinitesimal elements and the modeling characteristics of each seat, designers design the shape and the size of the male die 1 infinitesimal element for manufacturing the backrest according to the macroscopic hardness of the support area and the touch area required by customers or according to the comfortable perception requirement, and further control the hardness macroscopically perceived by the human body in the touch area of the backrest to reach the hardness balance point required by the design of the touch area and the support area;
and step three, meeting the requirement that the micro-element design of the male die 1 of the touch area and the support area of the seat cushion in the step one and the backrest in the step two is the basic requirement of the comfort of the seat. Deeper designs are closely related to the depth and breadth of ergonomic understanding by seat developers or vehicle manufacturers. More specialized comfort designs require consideration of the micro-element design of the foam touch zones required at different parts of the human body to control the hardness of the different zones.
More specialized back comfort designs are as follows: in order to better keep the healthy and physiological sitting posture of the spine in an S shape during driving, the foam hardness of the 3 rd to 5 th root areas of the lumbar vertebra of the seat back is greater than that of the 1 st to 7 th root areas of the thoracic vertebra, so that:
the micro-element design of the supporting area of the male die 1 of the backrest in the 1 st to 7 th regions of the thoracic vertebra and the tactile area of the male die 1 of the backrest in the 3 rd to 5 th regions of the lumbar vertebra is as follows:
when the required foam hardness of the support area of the backrest is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2) x)/4s of 50%, wherein the depth e or d of the micro-elements may be a value between 15 and 20mm, and the resulting tactile area may have a macro-hardness of about 1.0 to 1.5kPa
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2) x)/4s of 35%, wherein the depth e or d of the infinitesimal element may be a value between 5 and 10mm, and the resulting touch area has a macro-hardness of about 2.5 to 3.5kPa
When the required foam hardness of the backrest support area is 4.5kPa, the corresponding relation between the A surface area s of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2) x)/4s of 65%, wherein the depth e or d of the micro-elements may be a value between 15 and 20mm, and the resulting tactile area may have a macro-hardness of about 1.0 to 1.5kPa
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2) x)/4s is 45-55%, in which case the depth e or d of the micro element may be 10-15 mm, and the obtained touch area has a macro hardness of about 2.5-4.5 kPa
When the required foam hardness of the support area of the backrest is 5.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1 infinitesimal design of male die in the 1 st to 7 th thoracic regions: (Π a)2(d2) x)/4s is 85%, in which case the depth e or d of the micro-elements may be a value between 15 and 20mm, and the resulting tactile area may have a macro-hardness of about 1.0 to 1.5kPa
1 infinitesimal design of a male die in the 3 rd to 5 th lumbar vertebra areas: (Π a)2(d2) x)/4s is 55 to 75%, and in this case, the depth e or d of the micro element may be a value between 10 and 15mm, and the obtained touch area corresponds to a value between 2.5 and 5.5kPa for macro hardness. The area with larger coverage area of the micro element is mostly designed by adopting shell-shaped micro elements.
Designing a male die 1 infinitesimal according to the step two in the region except the regions of 1 st to 7 thoracic vertebrae and 3 rd to 5 lumbar vertebrae on the male die 1 of the seat back;
step four, after the male die 1 of the seat back is designed in the step three, a more specialized cushion comfort is taken into consideration, and the balance point of the touch sense area of the support area is designed in order to obtain good touch sense of the contact between the front end of the cushion (about 30-35% of the length of the cushion) and the biceps femoris and semi-musculus femoris in the driving process, the foam of the support area at the position has almost no support effect on the thighs of a driver, and the ideal male die 1 micro matching technical design scheme is as follows: the micro-element on the male die 1 at the front end area of the cushion is designed as follows
When the required foam hardness of the cushion support area is 5kPa, the area s of the surface A (namely the upper surface of the cushion) of the cushion and the area s of the cushionThe corresponding relation among the number x of the designed microelements on the male die 1 is as follows: Π a2(d2) x)/4s is 45-55%, in which case the depth e or b of the infinitesimal element may be a value between 15-20 mm, and the resulting tactile area (soft area) corresponds to a value between about 1.0-2.0 Kpa of macro-hardness.
When the foam hardness of the required cushion supporting area is 6kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2) x)/4s is 55-65%, in which case the depth e or b of the infinitesimal element may be a value between 15-20 mm, and the resulting tactile area (soft area) corresponds to a value between about 1.0-2.0 Kpa of macro-hardness.
When the foam hardness of the required cushion supporting area is 7kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2) x)/4s of 65 to 75%, wherein the depth e or b of the micro element may be set to a value of 15 to 25mm, and the resultant tactile area (soft area) corresponds to a value of about 1.0 to 2.5kPa in terms of macro hardness. The area with larger coverage area of the micro element is mostly designed by adopting shell-shaped micro elements.
When the foam hardness of the required cushion supporting area is 8kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2) x)/4s is 85 to 95%, in which case the depth e or b of the micro element may be a value between 15 to 25mm, and the resultant tactile area (soft area) corresponds to a value between about 1.0 to 2.5kPa for macro hardness. The area with larger coverage area of the micro element is mostly designed by adopting shell-shaped micro elements.
Designing a male die 1 infinitesimal according to the step one in the region except the front end region of the seat cushion;
the area covered by the micro element of the male die 1 is more than 70 percent and is regarded as a micro element covering surface with a larger area, and the design at the moment mostly adopts shell-shaped micro elements;
as shown in fig. 6, step five, after designing the upper infinitesimal part of the male mold 1 and the female mold 2 of the seat and the backrest according to the touch area and the support area balance point required by the comfort of the seat, the emphasis points of the touch area and the support area of different vehicle types and the macroscopic perception points of human bodies, buckling the male mold 1 and the female mold 2 which are designed for manufacturing the backrest of the seat together, and simultaneously injecting the same filling material into two parts of the side wing and the core part in the backrest mold composed of the female mold 2 and the male mold 1 to form the backrest of the seat, or respectively injecting different filling materials into two parts of the side wing and the core part in the backrest mold composed of the female mold 2 and the male mold 1 to form the backrest of the seat;
the designed male die 1 and the female die 2 for manufacturing the seat cushion are buckled together, and the same filling material is simultaneously injected into the two parts of the side wing and the core part of the cushion mold consisting of the female die 2 and the male die 1 to form the seat cushion, or different filling materials are simultaneously injected into the two parts of the side wing and the core part of the cushion mold consisting of the female die 2 and the male die 1 to form the seat cushion.
Example 2
The male die 1 body is provided with a plurality of forms of microelements, so that the macro control of the foaming hardness of the foam of one cavity of the isocyanate polyester polyether filling material is realized. The related infinitesimal elements refer to a plurality of arc-shaped bulges 11 or grooves 12 arranged on the male die 1 from top to bottom, multi-hardness zoning foam is realized by designing and arranging the areas and the depths of the arc-shaped bulges 11 or the grooves 12 with different arrangement, only one isocyanate polyester polyether filling material enters a cavity of the male die 1 from a filling port of the male die 1 in the foam molding process, and the problems of uneven hardness and difficulty in debugging and controlling the hardness of a foam body obtained by a double-hardness conventional chemical foaming molding method are solved. The foam obtained by the mould forms a surface contact supporting protective surface between every two arc bulges or grooves and the protective surface.
The shape of the protrusion and the groove can be arc-shaped imitating the surface of the shell.
Described in more detail below:
from the aspect of occupant sitting perception, the foam hardness of the invention comprises the first touch-sensing area hardness during the sitting process of the occupant and the support area hardness after the sitting process, and the side wings and the main surface are flexibly designed with touch-sensing areas and support areas with various hardness according to the human body perception requirement.
The foam hardness of the invention comprises an upper back touch area and a support area of a backrest part of the automobile seat, a lower back touch area and a support area, a posture maintaining area during turning, a lumbar vertebra touch area and a support area, a hip bone and sacrum touch area and a support area, a hip bone and caudal vertebra touch area and a support area of a cushion part of the automobile seat, a thigh touch area and a support area, and a thigh front end touch area and a support area. The key part (lower back part) of the driving posture maintaining area maintained by the driver is arranged between the 7 th thoracic vertebra and the 12 th thoracic vertebra of the human spinal column of the backrest part of the automobile seat, whether a touch area is added or not can be selected according to the driving road conditions of different automobile types such as cars, off-road vehicles, trucks and the like, and in contrast, the driving posture maintaining performance can be reduced by adding the touch area.
The convex die 1 for foam molding is provided with the bulge 11, the shape is 1/2 circular, 1/4 circular or shell-shaped, the diameter or width a of the bulge 11 ranges from 5mm to 20mm, the depth b of the bulge 11 ranges from 1/6m to 1/2m times of the thickness m of foam, for example, the upper back touch area can be 1/2m times, and the lumbar spine touch area can be 1/3m times. The distance d between every two adjacent bulges 11 is a planar transition area with the range of 5-50 mm, and the transition area supports the forming surface and the surface of the protective surface to prevent the protective surface from collapsing.
The other foam forming male die 1 related to the invention is provided with a groove 12, the shape is 1/2 circular, 1/4 circular or shell-shaped, the diameter or width a of the groove 12 ranges from 10mm to 50mm, the depth e of the groove 12 ranges from 1/12m to 1/2m times of the thickness m of the foam, for example, the upper back touch area can be 1/8m times, and the lumbar spine touch area can be 1/2m times. The distance d of the transition area between the adjacent grooves 12 ranges from 5mm to 30 mm. The hardness of comfortable touch areas and the hardness of supporting areas required by different parts of a human body are flexibly designed and obtained through the shape selection of the bulges 11 and the grooves 12 on the foam forming male die 1, the diameter or the width and the depth of the selected shape, the arrangement number and other parameters. The design mode of the surface contact supporting protective surface is more suitable for soft protective surfaces such as cloth seats, the design mode of the point contact supporting protective surface is suitable for protective surfaces made of all materials, and the requirement of the comfort performance of the seats is met according to reasonable design such as the diameter, the width, the depth, the arrangement quantity and the like of a concave shape on the foam forming male die 1.
The shell-shaped design has the advantage that the end with the smaller depth is designed near the tightening line where the facing and the foam are connected.
Example 3
Taking the semicircular groove 12 designed on the male die 1 as an example as a infinitesimal, the diameter of the infinitesimal of the upper back tactile area is 40mm, the depth is 30mm, the diameter of the infinitesimal of the lower back tactile area is 40mm, the depth is 20mm, the diameter of the infinitesimal of the posture maintaining area during turning does not relate to the tactile area and the lumbar (part) tactile area is 30mm, the depth is 10mm, the diameters of the infinitesimal of the hip and sacrum tactile areas are 20mm and 20mm, the diameters of the infinitesimal of the hip and caudal vertebra tactile areas of the cushion part of the automobile seat are 10mm, the depths are 10mm, the diameters of the infinitesimal of the thigh tactile area are 20mm, the depths are 15mm, the diameters of the infinitesimal of the calf tactile area are 40mm and the depths are 20 mm;
the invention improves the mode of interfering foam micropore control hardness by a conventional chemical method into a mode of macroscopically controlling the body infinitesimal of the male die 1 by isocyanate polyester polyether filling material to realize multi-hardness foam. On the basis of an ergonomic theory, the male die 1 is provided with the projections and the grooves, so that the density among foam cells is changed macroscopically, multi-hardness foams in different areas and different layers are obtained through one-step forming, only one chemical component for foam forming is needed in the foam forming process, and the hardness control process is easier to realize.
Although the preferred embodiments of the present invention have been described in detail with reference to the accompanying drawings, the scope of the present invention is not limited to the specific details of the above embodiments, and any person skilled in the art can substitute or change the technical solution of the present invention and its inventive concept within the technical scope of the present invention, and these simple modifications belong to the scope of the present invention.
It should be noted that the various technical features described in the above embodiments can be combined in any suitable manner without contradiction, and the invention is not described in any way for the possible combinations in order to avoid unnecessary repetition.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as the disclosure of the present invention as long as it does not depart from the spirit of the present invention.

Claims (6)

1. A multi-hardness one-step forming automobile seat foam die comprises a male die (1) and a female die (2), wherein the female die (2) and a bearing body thereof are arranged along with the shape of the male die, and the multi-hardness one-step forming automobile seat foam die is characterized in that the male die (1) comprises a male die body, a plurality of microelements of the same kind are arranged on the male die body, and the microelements of the same kind are sequentially arranged on the male die body from top to bottom; wherein the micro elements are divided into two types of bulges (11) and grooves (12), and the shapes of the bulges (11) and the grooves (12) are semicircular, 1/4 circular or irregular arcs.
2. The multi-hardness one-shot forming automobile seat foam mold according to claim 1, wherein the protrusions (11) have a diameter or width of 5-20 mm and a depth of 1/6-1/2 times of the thickness of the foam to be made.
3. A multi-hardness one-shot forming automobile seat foam mold according to claim 2, wherein the distance between the adjacent edges of the adjacent protrusions (11) is 5-50 mm.
4. The multi-hardness one-shot forming automobile seat foam mold according to claim 1, wherein the groove (12) has a diameter or width of 10-50 mm and a depth of 1/12-1/2 times of the thickness of the foam to be made.
5. A multi-hardness one-shot forming automobile seat foam mold according to claim 4, wherein the distance between the adjacent edges of the adjacent grooves (12) is 5-30 mm.
6. A method for forming automobile seat foam at one time through multiple hardnesses is characterized by comprising the following steps:
firstly, designing a infinitesimal on a male die (1) of a seat cushion as follows:
when the foam hardness of the cushion supporting area is 5kPa, the corresponding relation between the surface area s of the cushion A and the design infinitesimal number x is as follows: (Π a)2(d2)x)/4s＝40％；
When the required foam hardness of the support area is 6kPaThe corresponding relation between the surface area s of the cushion A and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝50％；
When the foam hardness of the required supporting area is 7kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝65％；
When the foam hardness of the required supporting area is 8kPa, the corresponding relation between the surface area s of the cushion A and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝80％；
The diameter and the shape of a infinitesimal element on a male die (1) for manufacturing the cushion are designed by combining the modeling characteristics of each seat, so that the hardness of a touch area of the cushion is controlled to reach a hardness balance point required by the design of the touch area and a support area;
wherein a is the diameter or width of the microelements on the male die (1), and d is the distance between adjacent microelements on the male die (1), namely the distance between two opposite side edges of the adjacent microelements;
step two, designing the micro elements on the male die (1) of the seat back tactile area as follows:
when the required foam hardness of the backrest support area is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝45％；
When the required foam hardness of the support area is 4.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝60％；
When the required foam hardness of the support area is 5.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows: (Π a)2(d2)x)/4s＝80％；
The shape and the size of a micro element of a male die (1) for manufacturing the backrest are designed by combining the modeling characteristics and the requirements of each seat, and the hardness of a tactile area of the backrest is further controlled to reach a hardness balance point required by the design of the tactile area and a supporting area;
step three, the foam hardness of the 3 rd to 5 th areas of the lumbar vertebra of the seat back is greater than that of the 1 st to 7 th areas of the thoracic vertebra, so that:
the micro-element design of the supporting area of the male die (1) of the backrest in the 1 st to 7 th regions of the thoracic vertebra and the tactile area of the male die (1) of the backrest in the 3 rd to 5 th regions of the lumbar vertebra is as follows:
when the required foam hardness of the backrest support area is 3.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1, designing microelements of male molds (1) in the 1 st to 7 th regions of the thoracic vertebrae: (Π a)2(d2)x)/4s＝50％；
Designing the micro elements of the male die (1) in the 3 rd to 5 th areas of the lumbar vertebra: (Π a)2(d2)x)/4s＝35％；
When the required foam hardness of the backrest support area is 4.5kPa, the corresponding relation between the A surface area s of the backrest and the number x of the design microelements is as follows:
1, designing microelements of male molds (1) in the 1 st to 7 th regions of the thoracic vertebrae: (Π a)2(d2)x)/4s＝65％；
Designing the micro elements of the male die (1) in the 3 rd to 5 th areas of the lumbar vertebra: (Π a)2(d2)x)/4s＝45～55％；
When the required foam hardness of the backrest support area is 5.5kPa, the corresponding relation between the area s of the A surface of the backrest and the number x of the design microelements is as follows:
1, designing microelements of male molds (1) in the 1 st to 7 th regions of the thoracic vertebrae: (Π a)2(d2)x)/4s＝85％；
Designing the micro elements of the male die (1) in the 3 rd to 5 th areas of the lumbar vertebra: (Π a)2(d2)x)/4s＝55～75％；
Designing the micro element of the male die (1) according to the second step in the area except the areas of the 1 st to 7 th thoracic vertebrae and the 3 rd to 5 th lumbar vertebrae on the male die (1) of the seat back;
step four, designing the micro elements on the male die (1) at the front end area of the cushion as follows:
when the foam hardness of the required cushion supporting area is 5kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design microelements on the male die (1) of the cushion is as follows: Π a2(d2)x)/4s＝45～55％；
When the foam hardness of the required cushion supporting area is 6kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝55～65％；
When the foam hardness of the required cushion supporting area is 7kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝65～75％；
When the foam hardness of the required cushion supporting area is 8kPa, the corresponding relation between the area s of the surface A of the cushion and the number x of the design infinitesimal elements is as follows: (Π a)2(d2)x)/4s＝85～95％；
Designing the micro elements of the male die (1) according to the first step in the area outside the front end area of the cushion;
buckling a male die (1) and a female die (2) which are designed for manufacturing the seat backrest together, and simultaneously injecting the same filling material into two parts of a side wing and a core part in a backrest die consisting of the female die (2) and the male die (1) to form the seat backrest, or respectively injecting different filling materials into two parts of the side wing and the core part in the backrest die consisting of the female die (2) and the male die (1) to form the seat backrest;
the designed male die (1) and the female die (2) for manufacturing the seat cushion are buckled together, and the same filling material is simultaneously injected into two parts of the side wing and the core part of the cushion mold consisting of the female die (2) and the male die (1) to form the seat cushion, or different filling materials are simultaneously injected into two parts of the side wing and the core part of the cushion mold consisting of the female die (2) and the male die (1) to form the seat cushion.
CN202110942886.1A 2021-08-17 2021-08-17 Multi-hardness one-step forming automobile seat foam mold and method Pending CN113580461A (en)

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