CN1452545A

CN1452545A - Method for making gelatinous cushion with reduced membrane effect

Info

Publication number: CN1452545A
Application number: CN00819394A
Authority: CN
Inventors: J·-L·马丁
Original assignee: Finasse (sa)
Current assignee: Foster's Group; COMOTEC SA
Priority date: 2000-03-30
Filing date: 2000-03-30
Publication date: 2003-10-29
Anticipated expiration: 2020-03-30
Also published as: WO2001074566A1; CN100343040C; AU2000236633A1; JP4638112B2; JP2003531742A; HK1058646A1

Abstract

The invention concerns a method for making a gelatious cushion comprising a gelatinous material enclosed at least partly in a membrane, comprising steps which consist in: thermoforming the membrane in a mould; filling up the cushion with a liquid preparation, closing the cushion by sealing or bonding a cushion support at the periphery of the membrane; and polymerising the liquid preparation. The invention is characterized in that the method comprises a step which consists in deforming the cushion membrane performed after the step thermoforming the membrane, by applying a deforming force at least in one point of the thermoformed membrane, so that the membrane surface has permanently, at the end of the manufacturing process, at least a hollow or undulating part.

Description

A kind of production method with the mat that contains gel that reduces film effect

The present invention relates to produce the mat of in the EP96400277 application, describing with the type that reduces film effect.

In order to recall prior art, Figure 1A, 1B and 1C are illustrated in the EP96400277 application a disclosed technical problem and are solved by described the present invention here.Figure 1A represents the mat that contains gel 1 of a traditional structure, and here it has adopted the shape of the nose pad that is used for the eyes frame.This mat 1 comprises a flexible film 2 of thermal finalization, its edge welding or sticking and on a tabular support 3.This film 2 forms a sealing bag with these tabular support 3 front surfaces, and constraint has a kind of gel rubber material in the sealing bag, is generally a kind of silicones.

Under the spreading effect, particularly when this mat 1 support was on nose, gel rubber material 4 should absorb spreading power, makes damping of shocks, and a kind of good comfort level is provided.If yet more attentively observe the reaction of the spreading of this mat 1, shown in Figure 1B, to see reinforcement along with the pressure on this mat 1, because the buoyancy effect that the stretching of this film 2 that produces by the compression gel rubber material causes, and this gel effect is disappeared.This buoyancy effect is called " film effect " in the EP96400277 application.Therefore, when this pad holder was on nose, shown in Fig. 1 C, this spreading that is produced by the weight of this shelf was such, and promptly this film effect overwhelms gel effect and occupies an leading position.Caused lacking reliable comfort level.

Fig. 2 A be type described in a kind of EP9640027 application reduction the cross sectional view of an embodiment of mat 5 of film effect, this embodiment does not have this shortcoming.This mat 5 comprises the pliable and tough film 6 of an a kind of gel rubber material 7 of parcel as described above, and the edge joint weld of this film 6 is connected on the supporting plate 8.This film 6 has at least one pleat, has two pleats 9,9 ' towards this mat inner orientation here so that form multiple slit on the surface of this mat, the shape of this colloid and these pleats paste and.Shown in Fig. 2 B, when this mat 5 was subjected to rolling, extruded colloid 7 was pressed on the film 6 that is unfolded.Because the expansion of this film launches additional film size under pressure and can postpone the time that this film 6 reaches the elastic stress state.Basically guaranteed this mat 5 for the reaction that rolls by this colloid 7 like this, as shown by arrows, so that remove because the elasticity sensation that film effect causes perhaps postpones the appearance of this elasticity sensation at least.Therefore the comfort level that is provided by this mat is obviously improved.

The production method of such mat of describing in above-mentioned European application is summarised among Fig. 3.This method need be scheduled to a hot forming tool 10, and its bottom has one or more Zhe, for example with Zhe 9,9 ' corresponding two Zhe 11,11 ' of the mat 5 of Fig. 2 A.This film 6 deliquescing and be close to the bottom of this mould 10 by a suction system 12 by thermal source.Fill the mat cavity of such enforcement then by the flowing product 7 that is used for after polymerization, being transformed into colloid, apply above-mentioned bracket webs 8 then and when the polymerization of this flowing product 7 does not finish, on this thin plate 8, this film is carried out the edge welding to seal this cavity.The production of this mat is proceeded and can be finished in this polymerization after this mat 5 of sealing.

A target of the present invention is a kind of production method with the mat that reduces film effect of design, and this method can be constructed a kind of refill of the mat of just having described.

In fact, although conventional method itself does not have any shortcoming and has brought satisfaction completely, but can the production similar products like according to diverse ways, so that can select such method, the most suitable obtainable tool of production group of this method, staff's technical ability and required productivity ratio etc., this is useful always in enterprise.

Another target of the present invention is the various embodiments that design has the mat of the film effect that reduces prior art.

Can realize this target by the production method that designs a kind of gel mat.This production method comprises: wrap up a kind of gel rubber material at least in part in a film, comprise the steps: the thermoforming step of this film in a mould; Fill the step of this mat by a kind of flowing product; By with pad holder welding or step sticking and this mat of sealing on this film edge; Polymerization procedure with this flowing product, this flowing product is transformed into a kind of gel rubber material during this step, by at least one point of this thermoforming film, applying after method that deformation force will include the deforming step of this mat film is inserted into the thermoforming step of this film, the surface of this film has groove or ripple at least all the time in process of production, simultaneously the shape of this colloid and this film paste and.

According to an embodiment, the deforming step of this film was implemented inject flowing product in the moulding mat before, when this thermoforming film is also in this mould, by at least one point of this film, applying a deformation force from this mould so that the part of this film is roughly thrown off, remainder is kept by suction system, decontrols this deformation force in filling with after sealing this mat and before the complete polymerization of this flowing product.

According to an embodiment, deforming step comprises that by one the mould of at least one moving member implements, and this moving member moves towards the inside of this mould so that apply this deformation force on this film.

According to an embodiment, the deforming step of this film was implemented before injecting flowing product to the moulding mat, when the thermoforming film is also in this mould, by at least one point of this film, applying a deformation force so that mould roughly is out of shape, this mould is pliable and tough or elastomeric material, the Deformation control of this mould the distortion of film, decontrols this deformation force in filling with after sealing this mat and before the complete polymerization of this flowing product.

According to an embodiment, the deforming step of this film is implemented in mat sealing back, applying a deformation force on by at least one point at this film between the flowing product polymerization period, the distortion by the film after this flowing product polymerization of memory effect of this gel rubber material is conclusive.

According to an embodiment, obtain this deformation force by on this mat surface, applying an object, this object surfaces has at least one projection, and the impression of this projection is stayed on the surface of this mat in polymerization process.

According to an embodiment, this pad holder has the thickness greater than this film thickness, and this film edge becomes 1-90 ° welded corner joint on pad holder along the side surface with respect to the gel rubber material of pad holder.

The invention still further relates to the gel mat of implementing according to above-mentioned method, it is included in and wraps up a kind of gel rubber material in the film at least in part, the edge of this film welding or sticking and on pad holder, this film has at least one groove or ripple, this gel rubber material and film shape paste with.

According to an embodiment, this film has the impression of a qualification shape.

According to an embodiment, the edge of this film becomes 1-90 ° welded corner joint on pad holder along the side surface with respect to the gel rubber material of pad holder.

According to an embodiment, this film is the film of polyurethane.

According to an embodiment, this film comprises two flexible film of placement arranged side by side.

According to an embodiment, this gel rubber material is a silicone resin film.

According to an embodiment, this mat is included on the side surface of colloid of pad holder and implements a mark, has amplified this mark by the magnifying glass effect that is enclosed in the colloid between this film and pad holder.

These targets of the present invention and other features and advantage according to two embodiments of method of the present invention with of the invention processly have a mat that reduces film effect, specifically describe with reference to the accompanying drawings in the following description.Accompanying drawing comprises:

-Figure 1A, 1B, 1C described the front, and traditional softening mat is shown;

-Fig. 2 A and 2B are the cross sectional view of mat of the reduced film effect of traditional type;

-Fig. 3 illustrates the production method of the mat of traditional reduction film effect;

-Fig. 4 A-4D illustrates first embodiment of the mat that can reduce film effect in accordance with the present production process;

-Fig. 5 A-5C illustrates second embodiment of the mat that can reduce film effect in accordance with the present production process;

-Fig. 6 illustrates the distortion of the method according to this invention second embodiment;

-Fig. 7 illustrates the embodiment according to gel mat of the present invention; With

-Fig. 8 A and 8B illustrate the characteristic according to mat of the present invention.

Fig. 4 A-4D illustrates the basic step of the production method of the gel mat that can reduce film effect according to the present invention.

In first production stage, flexible film 20 thermoforming in traditionally shaped porous mold 30,20 one-tenth common arcs of this flexible film and here it does not have Zhe.This film 30 for example is the polyurethane film, and its thickness is more than tens microns.In a distortion, this film 30 is configured with two stacked little thickness polyurethane film (not shown).This mould 30 is connected with a underframe 31, and this underframe 31 comprises an induction chamber 32 that is connected with pumping system 33.This thermoforming is implemented by introducing a thermal source such as infrared radiation IR.When this pumping system 33 is activated, film 20 be attracted paste and in the bottom of this mould 30 and form paste with this mold shape and mat cavity 40.

According to the present invention, this film 20 then at least in the point deformation on its surface so that reduce the volume of this mat cavity 40.This mould 30 comprises that at least one is used for the deformed region of this effect.Shown in Fig. 4 B, here this deformed region is the form of a moving member 34 of slidably installing in this underframe 31, and the upper surface of this moving member 34 leads in this mould 30.

Therefore in step shown in Fig. 4 B, keep air-breathing and push away this sliding part 34 at the center position of this mould.The top of this part 34 forms a projection, and this projection pushes away this film 20 and makes that this film 20 is local throws off with this mould 30, the remainder of this film by air-breathing maintenance and 30 subsides of this mould with.When in mat cavity 40, filling a kind of flowing product 21 that can polymerization two or three component when being preferably silicones, keep being applied to the deformation force on this film 20 for the goods of base.

In the step of Fig. 4 C,, keep being applied to the deformation force on this film 20, so that form the bracket webs of following mat 40 at mat cavity 40 usefulness plastic material thin plate closed periods always.These thin plate 22 supports are on the limit of this thermoforming cavity, and here this thin plate 22 keeps touching with the side edge of this film 20.Guarantee the welding of edge on this thin plate 22 of this film 20 in a conventional manner, promptly place a flat ring resistor disc 35 by this thermoforming cavity edge in this mould 30.This resistor disc 35 is connected on the power supply 36 that electric current I is provided and this resistor disc 35 has a temperature that can reach 200 ° at short notice.During welding operation, on supporting plate 22, apply sizable pressure, so that embed flowing product 21, this flowing product 21 can be between this film 20 and this thin plate 22.

According to the present invention, be applied to deformation force on this film 20 by moving member 34, this mat 40 close and after, and before these flowing product 21 complete polymerizations, unclamp.Unclamp shape of cushion 40 that constraint back occurs in Fig. 4 D not specify or infinite mode demonstrates.This shape has stochastic behaviour and can not describe clear, because it is the result of the depression of a plurality of equilibrium of forces between the surface tension that is applied on this film 20 and these mat 40 inside, this balance tends to return its initial shape of being given by thermoforming.In fact this flowing product 21 can not expand and air can not enter into this mat 40, and this mat is sealed to seal.The shape of this mat 40 has at least one groove or ripple and subsequently at ambient temperature, perhaps in that this mat is fixed in the drying box of net shape, fixes shaping by the polymerization of flowing product.

At least one mat that forms the pleat in crack that is equipped with described in having such mat 40 of at least one groove or ripple and applying at EP96400277 has been finished same function.In fact, the unfolded surface of this film and the appearance of retardation films effect simultaneously under the effect that this mat rolls.

For affiliated technical field those of ordinary skill, the method for just having described can be carried out multiple modification and enforcement.Particularly this mould 30 can comprise the sliding part of a plurality of formation projections, for example two moving members that are arranged on the edge proximity of thermoforming cavity.According to another modification, this mould 30 is implemented by pliable and tough or elastomeric material.In this case, deformation force is applied directly to the bottom of mould itself, and this mould can modification and made deformation of thin membrane simultaneously.When unclamping this deformation force, this mould recovers its original shapes.At last,, apply on film by means of at least one nozzle that is arranged in this mould so, perhaps apply compressed-air actuated injection on one's body certainly, also can obtain deformation force at this mould if this mould is deformable.

Fig. 5 A-5C illustrates second kind of embodiment according to the inventive method., realize a kind of mat 50 in a conventional manner here, it comprises: an also unpolymerized flowing product 52 of a thermoforming film 51, one and a bracket webs 53.Before these flowing product 52 complete polymerizations,, on this profiled member 55, apply the surface of this mat 55, shown in Fig. 5 A by relative motion towards this mat 50 of profiled member 55.This structural member 55 comprises the part of a generally flat surface and at least one formation projection 56.

In Fig. 5 B, can see that the part that forms projection 56 makes film 51 distortion of mat.Between flowing product 52 polymerization periods, this part 55 remains against on this mat 50.After this polymerization was finished, shown in Fig. 5 C, this film 51 had groove or the ripple that at least one part that is adapted to pass through this formation projection 56 is reserved impression.Because the memory effect of this colloid 52, this is shaped as final, and this shape always will be recovered this shape after rolling for a long time subsequently.Guaranteed to reduce the film effect that the expansion by under the effect of rolling this film 51 causes as above-mentioned shape.

Different with first embodiment of method of the present invention, here, this film is with the constant dimensions modification, because this deformation force is implemented after this mat 50 of sealing.Because flowing product 52 is incompressible, so can not reduce the size of this mat.Therefore two kinds of methods just having described have such common trait, promptly after this mat thermoforming and before the complete polymerization of this flowing product, comprise a strain step; These two kinds of methods also have such difference simultaneously, promptly in first kind of situation are to guarantee distortion before injecting flowing product, in second kind of situation are to guarantee distortion after injecting flowing product and this mat of sealing.

Second kind of form of implementation according to the inventive method can also be carried out different modification.For example this mat can be implemented the distortion of this mat by the moving member 34 of aforesaid mould 30.In this case, deforming step occurs in the step that Fig. 4 C shows, but this moving member 34 only just applies after sealing this mat by supporting plate and leans against on this film.In this case, in mould inside generation polymerization.Fig. 5 A in addition, this part 5 that 5B shows can comprise the projection of a plurality of greater or lesser sizes, and has for example crenation external form.As shown in Figure 6, comprise that the distortion of film 61 of a mat 60 of unpolymerized flowing product 62 can also be implemented by mesh 65, this mesh is staying its impression on mat 60 after the polymerization.This mat has the shape of a plurality of ripples then.

On the whole, the people notices that satisfactorily this production method of just having described is very suitable for producing in batches mat in addition, particularly owing to designed the mould that comprises a plurality of thermoforming cavitys.In this case, by this mat of large-sized supporting plate production in groups, this large scale supporting plate cuts into single supporting plate then, for example by punching press.

Fig. 7 shows the particular embodiment according to a mat 70 of the present invention.This mat 70 is different from the mat of front, because along becoming the different angle " A " of 0 ° angle to keep this supporting plate 71 with colloid surface with respect to this support plate 71.Therefore, this film 72 is welded on the edge of supporting plate 71, and this supporting plate 71 is cut sth. askew along angle " A ".This angle " A " in fact can be included in 1-90 ° (being welded on the right side).Equal that 0 ° angle " A " for example describes in the prior art corresponding to a downhand weld with shown in the prior figures.

There is another perfect idea of applicant to relate to the mark of gel mat again.Such mark is used for demonstrating a series of numbers on this mat, and one produces mark, an ornamental acronym or every other mark, desirable sign or picture.One such mark can be implemented on the film of this mat by a kind of nondestructive method such as inkjet printing methods.Yet such method is proved to be implements the expensive difficulty of adjusting.

The method according to this invention shown in Fig. 8 A is implemented such mark like this, promptly goes forward embodiment such as alphabetic flag " XYZ " on the inner surface of the supporting plate 79 of a mat to this film at this supporting plate 79 of welding.This supporting plate 79 is in most of the cases bigger than the thinner intensity of this film, during particularly a kind of nose template, uses a kind of abrasion method, for example a kind of mark of laser system.In case finish this mat 80, shown in Fig. 8 B, this mark is exaggerated by the colloid 81 that is trapped between supporting plate 79 and the film by the magnifying glass effect, and this colloid is translucent.This initial mark seems to become big, as seeing among Fig. 8 B.

Claims

1. gel mat (40,50,60,70) production method, this gel mat comprise that one is wrapped in a film (20,51 to small part, 61) gel rubber material in (21,52,62,72), this production method comprises: one in mould (30) the thermoforming step of this film, a usefulness flowing product (21,52,62) fill the step of this mat, by welding or sticking and pad holder (22,53,62,71) to this film (20,51,65,72) thereby edge seals the step of this mat, the polymerization procedure of flowing product, this flowing product converts gel rubber material between polymerization period, the method is characterized in that, it comprises this mat (Fig. 4 B, Fig. 5 B, the deforming step of film Fig. 6) is by applying at least one point of this thermoforming film after a deformation force is inserted in the thermoforming step of this film with this deforming step, so that this film surface in process of production has at least one groove or ripple (Fig. 4 D all the time, Fig. 5 C, Fig. 6), the shape of this colloid and this film paste and.

2. method according to claim 1, it is characterized in that, the deforming step of this film (20) was implemented before this flowing product (21) being inserted in the moulding mat (40), when this thermoforming film is also in this mould (30), by at least one point of this film, applying a deformation force, the effect of roughly from this mould, throwing off with a part that produces this film, the remainder of this film is held by air-breathing, fully before the polymerization, unclamp this deformation force afterwards and at this flowing product (21) filling and seal this mat (40).

3. method according to claim 2, it is characterized in that, this deforming step is implemented by the mould (30) that at least one comprises at least one moving member (34), and this moving member (34) moves so that apply deformation force on this film (20) towards the inside of this mould.

4. method according to claim 1, it is characterized in that, the deforming step of this film was implemented before this flowing product being injected in this moulding mat, when this thermoforming film is also in mould, by at least one point of this mould, applying a deformation force, so that this mould roughly is out of shape, this mould is pliability and the flexible material of tool, the Deformation control of this mould the distortion of this film, this deformation force is after filling and sealing this mat and unclamped before the complete polymerization of this flowing product.

5. method according to claim 1, it is characterized in that, the deforming step of this film (51,61) at this mat of sealing (50,60) afterwards, by at flowing product (52,62) at least one point of this film, apply deformation force between polymerization period, implement, after this flowing product polymerization, pass through this gel rubber material (52,62) memory effect, the distortion of this film is final.

6. method according to claim 5, it is characterized in that this deformation force obtains by apply an object (55,65) at mat surface, this object surfaces has at least one protrusion (56,65) makes that its impression is stayed on the surface of this mat in polymerization process.

7. according to each described method of claim 1-6, it is characterized in that, this pad holder (71) has the thickness greater than this film thickness, the edge of this film (72) is welded on the pad holder along angle (" A "), and this angle (" A ") is to become between 1 °-90 ° the angle with respect to the surface of the gel rubber material of pad holder.

8. the gel mat (40,50,60,70,80), it is implemented according to each described method of claim 1-7, comprise that one is wrapped in a film (20,51,61 to small part, 72) gel rubber material in (21,52,62), the welding of this film or sticking and its edge are on pad holder, it is characterized in that this film has at least one groove or ripple, the shape of this gel rubber material and this film paste and.

9. mat according to claim 8 (60) is characterized in that, this film (61) has the impression that limits shape.

10. according to Claim 8 or 9 described mats (70), it is characterized in that, the edge of this film (72) is welded on the edge of pad holder along angle (" A "), and this angle (" A ") is with respect to the angle between 1 ° of-90 ° of angle of surface one-tenth of the gel rubber material of pad holder.

11. each described mat is characterized in that according to Claim 8-10, this film is the polyurethane film.

12. each described mat is characterized in that according to Claim 8-11, this film comprises two juxtaposed flexible film.

13. each described mat is characterized in that according to Claim 8-12, this gel rubber material is the silicones colloid

14. each described mat (80) according to Claim 8-13, it is characterized in that, it comprises a mark of implementing (" XYZ ") on the colloid surface of pad holder (79), this mark is exaggerated by the colloid that is trapped between pad holder (79) and this film by the magnifying glass effect.