ES2367620B1 - MANUFACTURING PROCEDURE OF POLYURETHANE FOAM PARTS WITH TEXTILE COATING AND MOLD FOR OBTAINING. - Google Patents

Abstract

Manufacturing process of polyurethane foam pieces with textile coating and mold to obtain them. # The procedure is of the type of which the polyurethane pieces with textile coating are manufactured by an open mold. # It is characterized because in an initial phase, prior to the pouring of the liquid polyurethane into the open mold, a main portion (4) of the textile laminar body (5) covers a front surface (3) of the bottom of the open mold (1), front surface (3) incorporated in a movable part (2) of the open mold (1), such moving part (2) being in this initial phase displaced with respect to the rest of the open mold (1). # Instead, in a later phase, the moving part (2) is mobilized to be placed in a definitive position in accordance with the rest of the open mold (1) and then proceed to the pouring of the liquid polyurethane, the rest of the textile laminar body (5) being located outside the inner space of the open mold ( one).

Description

one piece of polyurethane foam with textile cover

Manufacturing process of polyurethane foam pieces with textile coating and mold to obtain them. Object of the invention

The present invention, as expressed in the statement of this specification, refers to a process for manufacturing polyurethane foam pieces with textile coating and mold for obtaining them.

In principle, it is an open mold in which liquid polyurethane is poured into the bottom of such mold, having previously placed a textile laminar body in a part of such bottom, then closing the mold with a lid, creating a closed space where it will increase the volume of the polyurethane material as it heals completely occupying all that interior space of the mold.

The mold is then opened by removing the cover to extract the manufactured part with the inclusion of the textile laminar body attached to the polyurethane material by a surface part thereof previously provided.

Starting from this premise, the object of the invention is a new method in which a main portion of the textile laminar body is attached against a front surface of a movable part of the mold, the rest of that textile laminar body remaining outside the interior space of the mold. Background of the invention

At present, for the manufacture of cushions in the automotive sector, foaming on open mold of polyurethane foam is well known, subsequently closing it for the geometric conformation and adaptation of the foam to the interior con fi guration of the mold. The normally aluminum mold is composed of a bottom and its corresponding cover or covers, which together constitute the geometry that is to be achieved, the whole assembly being normally heated.

The process is the following.

With the mold open, liquid polyurethane is poured into the bottom thereof, so that when the polyurethane reacts in contact with the air and supported with the temperature of the mold, such polyurethane material begins to grow, increasing its volume, closing the lid or mold caps, whereby the polyurethane adapts to the internal geometry of the mold. After a while the polyurethane cures and solidifies, and then once the mold is opened, remove the manufactured part. This piece thus obtained is subsequently covered with a textile sheath.

Another of the processes, which is currently known, is the foaming of polyurethane directly on the textile cover, thus obtaining a set consisting of a piece of polyurethane formed and adhered to the textile cover. This process is commonly known as "foaming in situ."

This manufacturing process would be as follows.

First, on the bottom of an aluminum mold preferably, the textile cover is placed and adapted, by vacuum aspiration, to then pour the liquid polyurethane onto the textile. Next, the necessary covers are closed and the polyurethane grows and adapts by taking the mold geometry and, in turn, firmly joining the material attached to it.

In the current situation, when the requirement is a piece that in specific areas adheres to the sheath, to take advantage of the process known as “foaming in situ” and in the rest of the piece it is not desired that the sheath adheres to the same, taking advantage of traditional foaming, barriers that can be made of a plastic film are normally used, which prevents the foam in these areas from adhering to the sheath, thus obtaining a piece that is adhered in one of its areas to the case and in others not. This process is only feasible in installations and molds of "foaming in situ". Description of the invention

The invention consists in a process for manufacturing polyurethane foam pieces with textile coating and mold for obtaining them.

The process aims to obtain a piece of polyurethane foam, a part of which requires to be attached to a textile laminar body, without interposing barriers between the foam piece to be obtained and some parts of the textile laminar body, so that the new invention allows take advantage of the facilities and advantages of traditional formulations.

The tooling of the open mold developed adapts to the current foaming facilities, without these having to be modified and being able to coexist in the manufacture with traditional foaming molds.

To meet this requirement, the novelty presented, is that starting from a traditional foaming mold, it is modified to be able to perform in some areas of it a "foaming in situ", without these affecting the normal operation of the installation.

To undertake these functions, the area where it is intended to foam on top of the cover, must be independent of the rest, at least in functionality, during a series of steps in the process; to then fit the rest of the mold and form a unit with it. In turn, this area of the mold must have some system to fix and adapt a textile laminar body determining a cover to the corresponding surface, such as a vacuum suction system. When foaming on a single part of the cover, the rest of it has to be protected, either as it is currently done, by means of plastic, but which is only valid in “in situ” foaming molds, collecting the rest of the cover that you don't have to foam in a safe place, to foam the rest of the piece.

To meet all these requirements, an open mold has been developed, whose area where the cover is foam, has movement, either with linear displacement or angular displacement, to be able to separate it from the rest of the mold. This area is equipped with a double wall and small holes in the surface, in order to be able to perform vacuum aspiration. The aim of the movement is to be able to protect under it the parts of the case that are not going to be over-foamed. Once these areas are well protected, the area to be foamed by vacuum is fixed and coupled to the rest of the mold, a normal mold being formed, with an area covered by the sheath.

3 EN 2367620A1 4

Thus, as described, the procedural phases are basically the following:

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Movement of the area with aspiration, until it is separated from the mold assembly.

-

Placing the cover over this area, keeping under it areas that do not want to foam.

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Apply gaps over the area so that the cover is fixed to it.

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Coupling of the area that has moved to the rest of the mold, leaving the areas of the sheath protected, which do not want to over-foam.

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Foam with open mold above the area with cover, as well as in the rest of the mold.

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Close the mold caps.

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Curing of the closed mold piece.

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Opening of the mold covers.

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Movement or opening of the area with suction until the rest of the mold cover is released.

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Removal of the piece manufactured with this tooling.

The final result is that a polyurethane body is obtained with areas of the partially non-bonded textile sheath, but whose foam formulation is of the traditional type and can be manufactured in traditional molds and formulations facilities, without these having to be modified.

In order to facilitate a better understanding of this descriptive report and forming an integral part thereof, some figures are attached in which the object of the invention has been shown as an illustrative and non-limiting nature. Brief description of the drawings

Figure 1.- Shows a schematic view of an initial phase of the manufacturing process of polyurethane foam pieces with textile coating, object of the invention. The object of the invention is also an open mold for obtaining it.

Figures 2 and 3.-They show intermediate phases of the manufacturing process.

Figure 4.-Shows the piece obtained with the textile coating.

Figure 5.- Shows a schematic view of an open mold with another embodiment different from that shown in the previous figures.

Figure 6.- Shows a perspective view of the open mold shown in the previous figure. Description of the preferred embodiment

Considering the numbering adopted in the fi gures, the polyurethane foam pieces with textile coating are manufactured by means of an open mold, inside which liquid polyurethane is poured into the bottom of such mold, having previously placed in a part of such bottom a laminar body textile, then closing the mold with a lid, creating a closed space where the volume of polyurethane material will increase as it heals completely occupying the entire interior space of the mold.

The mold is then opened by removing the cover to extract the manufactured part with the inclusion of the textile laminar body attached to the polyurethane material by a surface part thereof previously provided.

Starting from this premise, the open mold 1 comprises at least one movable part 2 with a front surface 3 on which a main portion 4 of a textile laminar body 5 sits, ensuring that such main portion 4 is secured by vacuum, so that the rest of such textile laminar body 5 will be provisionally arranged by wrapping that movable part 2 of the open mold 1 as a skirt by outer areas that are not part of the bottom and inner space of the open mold assembly

one.

The previous placement of the textile laminar body 5 on the movable part 2 of the open mold 1 is carried out when said movable part 2 is displaced and disengaged with respect to the rest of such open mold 1, so that once the positioning and clamping by means of the vacuum is ensured of the textile laminar body 5 on the movable part 2 of the open mold 1, this movable part 2 is placed in the final position with respect to the rest of the mold 1 and then the liquid polyurethane is poured into the bottom of the open mold 1, bottom comprising the main portion 4 of the textile body 5 covering the front surface 3 of the movable part 2 of the open mold 1 and other surfaces of fixed parts of the open mold 1 that are not covered by the textile laminar body 5.

Then, as mentioned above, once the amount of polyurethane required has been poured on the bottom and inside of the open mold 1, it is closed with the lid 6, and then wait for the material to heal increasing in volume occupying the entire interior space of said open mold 1.

Once the polyurethane material has completely cured, the mold 1 is opened by removing the cover 6 and the manufactured part 7 comprising the polyurethane body 8 itself is removed with the incorporation of the textile laminar body 5 fixed by its main portion 4 to said polyurethane body 8 by an adhesion zone 9 of the outer surface of the polyurethane body 8.

On the other hand, it should be noted that the mold incorporates a perimeter space 10 around the movable part 2 of the open mold 1 to accommodate the part of the textile laminar body 5 arranged outside the interior space of the open mold 1.

The open mold 1 in a first embodiment as described above comprises a base formed by a single perimeter piece 11 that surrounds the movable part 2, perimeter piece 11 which together with the movable part 2 include the inner surface of the open mold 1.

On the other hand, in a second embodiment, the open mold 1 'comprises a base formed by a perimeter piece 11' that also surrounds the movable part 2 and a false frame 12 that superiorly limits the interior space of the open mold 1 '.

That false frame 12 can have linear or angular movement to move from an inactive position to an active one and vice versa, the active position corresponding to the preparation of the open mold 1 'to receive the polyurethane material.

5 EN 2367620A1 6

Claims (13)

one.

Manufacturing process of polyurethane foam pieces with textile coating, being the process of which the polyurethane pieces with textile coating are manufactured by an open mold, in whose interior space liquid polyurethane is poured having previously placed a textile laminar body (5 ) which will be joined by a main portion (4) thereof on an adhesion zone (9) of the outer surface of the polyurethane foam body (8); characterized in that in an initial phase, prior to the pouring of the liquid polyurethane into the open mold (1-1 '), the main portion (4) of the textile sheet body (5) covers only a front surface (3) of the bottom of the open mold (1-1 '), front surface (3) incorporated in a mobile part (2) of the open mobile (1-1'), said moving part (2) being in this initial phase displaced with respect to the rest of the mold open (1-1 '), while at a later stage, the movable part (2) is mobilized to place it in its final position in accordance with the rest of the open mold (1-1') and then proceed to the pouring of the polyurethane liquid, the rest of the textile laminar body (5) being located outside the inner space of the open mold (1-1 ').

2.

Method of manufacturing polyurethane foam pieces with textile coating according to claim 1, characterized in that the outer part of the textile laminar body (5) is housed in a perimeter space (10) around the movable part (2) of the open mold (1-1 ').

3.

Method of manufacturing polyurethane foam pieces with textile coating, according to any one of the preceding claims, characterized in that the main portion (4) of the textile laminar body (5) on the front surface (3) of the mobile part (2) The open mold (1-1 ') is secured by vacuum.

Four.

Mold for obtaining pieces of polyurethane foam with textile coating, comprising an open mold structure that is closed by at least one lid after having poured liquid polyurethane inside, having previously placed a textile laminar body (5); characterized in that it includes a movable part (2) independent of the rest of the open mold (1-1 '), movable part (2) that can adopt a displaced position with respect to the open mold assembly (1-1') and a corresponding position with the rest of the mold open (1-1 ') in which the polyurethane material is poured out

liquid, including such moving part (2) at least one front surface (3) that is part of the bottom of the open mold (1-1 ’) and on which a main portion (4) of the textile laminar body (5) sits.

5.

Mold for obtaining polyurethane foam pieces with textile coating according to claim 4, characterized in that the movable part (2) of the open mold (1-1 ’) has linear mobility.

6.

Mold for obtaining polyurethane foam pieces with textile coating, according to claim 4, characterized in that the movable part (2) of the open mold (1-1 ’) has angular mobility.

7.

Mold for obtaining polyurethane foam pieces with textile coating, according to any one of claims 4 to 6, characterized in that the movable part (2) of the open mold (1-1 ') incorporates a vacuum aspiration system to hold the main portion (4) of the textile laminar body (5).

8.

Mold for obtaining polyurethane foam pieces with textile coating, according to any one of claims 4 to 7, characterized in that it incorporates a perimeter space (10) around the sides of the mobile part (2) to accommodate the part of the laminar body textile (5) arranged outside the inner space of the open mold (1-1 ').

9.

Mold for obtaining polyurethane foam pieces with textile coating, according to any one of claims 4 to 8, characterized in that the open mold (1) incorporates a base formed by a single perimeter piece (11) that surrounds the mobile part ( 2), perimeter piece (11) which together with the moving part (2) include the internal surface of the open mold (1).

10.

Mold for obtaining polyurethane foam pieces with textile coating, according to any one of claims 4 to 8, characterized in that the open mold (1 ') incorporates a base formed by a perimeter piece (11') that surrounds the movable part (2) and a false frame (12) that superiorly limits the interior space of the open mold (1 ').

eleven.

Mold for obtaining polyurethane foam pieces with textile coating, according to claim 10, characterized in that the false frame

(12) is an independent element with linear mobility. 12. Mold for obtaining polyurethane foam pieces with textile coating, according to claim 10, characterized in that the false frame (12) is an independent element with angular mobility.  ES 2 367 620 A1    ES 2 367 620 A1   SPANISH OFFICE OF THE PATENTS AND BRAND Application no .: 201030580 SPAIN Date of submission of the application: 04.21.2010 Priority Date: REPORT ON THE STATE OF THE TECHNIQUE 51 Int. Cl.: B29C44 / 14 (01.01.2006) B29C44 / 58 (01.01.2006) RELEVANT DOCUMENTS

Category

Documents cited Claims Affected

X

EN 485195 A1 (FAURE BERTRAND IND) 16.05.1980, pages 8-14; figures. 1-12

TO

FR 2634687 A1 (ECIA EQUIP COMPOSANTS IND AUTO) 02.02.1990, the whole document. 1-12

TO

GB 2219964 A (IKEDA BUSSAN CO) 28.12.1989, the whole document. 1-12

TO

US 5096639 A (HUGHES IAN L) 17.03.1992, the whole document. 1-12

TO

GB 2114051 A (KAPTEX MOULDED PRODUCTS LIMITE) 17.08.1983, the whole document. 1-12

Category of the documents cited X: of particular relevance Y: of particular relevance combined with other / s of the same category A: reflects the state of the art O: refers to unwritten disclosure P: published between the priority date and the date of priority submission of the application E: previous document, but published after the date of submission of the application

This report has been prepared • for all claims • for claims no:

Date of realization of the report 03.02.2011

Examiner A. Pérez Igualador Page 1/5

REPORT OF THE STATE OF THE TECHNIQUE Minimum documentation sought (classification system followed by classification symbols) B29C Electronic databases consulted during the search (name of the database and, if possible, terms of search used) INVENES, EPODOC  WRITTEN OPINION Date of Completion of Written Opinion: 03.02.2011 Statement

Novelty (Art. 6.1 LP 11/1986)

Claims Claims 1-12 IF NOT

Inventive activity (Art. 8.1 LP11 / 1986)

Claims Claims 1-12 IF NOT

The application is considered to comply with the industrial application requirement. This requirement was evaluated during the formal and technical examination phase of the application (Article 31.2 Law 11/1986).  Opinion Base.- This opinion has been made on the basis of the patent application as published.  WRITTEN OPINION 1. Documents considered.- The documents belonging to the state of the art taken into consideration for the realization of this opinion are listed below.

Document

Publication or Identification Number publication date

D01

EN 485195 A1 (FAURE BERTRAND IND) 05/16/1980

2. Statement motivated according to articles 29.6 and 29.7 of the Regulations for the execution of Law 11/1986, of March 20, on Patents on novelty and inventive activity; quotes and explanations in support of this statement No inventive activity is appreciated (Articles 6 and 8 of Patent Law 11/1986) in any of claims 1 to 12 For the following reasons. Document D01 discloses an apparatus and a method for manufacturing cushions consisting of a foam block with a fabric cover or other similar material. The apparatus, which is represented in Figures 1 and 2, consists of the following parts: -a cuba, -a movable part of the mold (22) movable inside said tank (as seen when comparing drawing 1 with drawing 2), -a frame (13) that gives the block side shape -and a cover (15) The mold itself, that is, the set of elements that shape the foam block, is formed by the moving part (22), the frame (13) and the cover (15). The operation is as follows: With the movable bottom (the movable part of the mold) in its low position, the frame to place the sheet is separated from the tank of cloth (17) on the tank. Compressed air is introduced into the tank through the holes (24) so that the fabric bulges and stretches before placing it on the mobile part of the mold. The mobile mold is then raised until it is placed just below the domed fabric. Thus, finally a portion of the fabric remains on the surface of the movable part of the movable mold, the portion remaining protruding from the edges of said movable part of the mold being trapped between the edges of the frame and the tank. Finally, the lid is closed and the foaming material is poured. The technical characteristics claimed in claim 1 are: - "the main portion of the textile laminar body covers only a front surface of the open mold bottom" Drawing 2 of D01 shows what parts of the mold the fabric covers: the wall of the moving part (22), the walls of the frame and the lid wall. Therefore, it is clear that only a part of the mold is covered by the fabric. However, there is a difference, The claim does not only say that only a part of the mold is covered but that it is a part of the bottom of the mold. This difference, however, does not imply inventive activity since it is a mere design option; the upper wall (26) of Mold frame of D01 could obviously be configured in very different ways among which would be that of constitute part of the "bottom" of the mold. - "front surface incorporated in a movable part of the open mold" In the mold of D01 this is the same: the surface covered by the fabric is in the movable part of the mold. - "the moving part being, in the initial phase, displaced with respect to the rest of the open mold" This is also the same in D01. As seen in Figure 1, in the initial phase, part 22 is displaced with respect to the rest of the open mold. - "the moving part moves to position it in accordance with the rest of the mold" It has already been seen, in D01 before the spill, the mobile part (22) moves to place it in accordance with the rest of the mold. - "the rest of the textile laminar body being located outside the interior space" In D01, the rest of the fabric, that is, portions 16 and 18 of Figure 3, is outside the interior space, namely they remain between the edges of the tank and the frame (figure 2). Therefore, claim 1 lacks inventive activity. As for claim 2, as seen in Figure 2, the outer part of the fabric is in a perimeter space exterior: the one limited by the edges of the frame and the pool. With regard to claim 3, in D01, the fabric is also fixed by vacuum. In the last paragraph of page 14 It explains how to create a depression through the holes arranged in the pool. Therefore, claims 2 and 3 lack inventive activity. With regard to the independent claim 4 on the mold, as already seen, document D01 has a part of movable mold that can be in two positions (displaced and in accordance with the rest of the mold) and that has a surface that is part of the open mold: the reference piece 22 of the figures. This piece has in D01 linear movement, as claimed in the 5th claim.  WRITTEN OPINION For all the foregoing, claims 4 and 5 lack inventive activity. That the movement is angular instead of linear is a normal design option, then claim 6 is considered It lacks inventive activity. In D01 the fabric is fixed to the surface of the mobile mold by means of vacuum as already seen, therefore claim 7 It also lacks inventive activity. In the apparatus of D01, the fabric that does not remain inside the mold space is on the outside surrounding perimeter the mold. Therefore claim 8 also lacks inventive activity. The configuration claimed in claims 9 and 10, on the one hand, and on the other the different types of mobility of 11th and 12th, does not imply inventive activity because, although it is not identical to that disclosed in D01, it would be available to a expert in the field since these are normal design options.