FR2567067A1 - Process for manufacturing furniture covers having an irregular surface, with a ultrasonic welding machine, and cover obtained thereby - Google Patents

Process for manufacturing furniture covers having an irregular surface, with a ultrasonic welding machine, and cover obtained thereby Download PDF

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Publication number
FR2567067A1
FR2567067A1 FR8410871A FR8410871A FR2567067A1 FR 2567067 A1 FR2567067 A1 FR 2567067A1 FR 8410871 A FR8410871 A FR 8410871A FR 8410871 A FR8410871 A FR 8410871A FR 2567067 A1 FR2567067 A1 FR 2567067A1
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FR
France
Prior art keywords
surface layer
welded
layer
weld
horns
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
FR8410871A
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French (fr)
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FR2567067B1 (en
Inventor
Muneharu Urai
Tadafumi Abe
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Tachi S Co Ltd
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Tachikawa Spring Co Ltd
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Publication date
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Priority to FR8410871A priority Critical patent/FR2567067B1/en
Publication of FR2567067A1 publication Critical patent/FR2567067A1/en
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Publication of FR2567067B1 publication Critical patent/FR2567067B1/en
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45Joining of substantially the whole surface of the articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • B29C66/436Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832Reciprocating joining or pressing tools
    • B29C66/8322Joining or pressing tools reciprocating along one axis

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

The invention relates to a method for manufacturing furniture covers. According to the invention, ultrasonic welding horns 4A and opposing protuberances are arranged in order to conform to a final shape to which the cover is to correspond; a surface layer 1, upholstery padding 2 and a support layer 3 are sandwiched between the arrangement of horns and the arrangement of protuberances; the three-layer body is compressed between these arrangements and the body is subjected to an ultrasonic wave in order to heat and weld the body in its selected zones. The invention applies especially to the covering of car interiors or of furniture.

Description

La préserve invention se rapporte à un procédé de fabrication de ousses de garniture pour divers usages, comme par exemple des coussins de siège ou-bien des garnitures décoratives appliquées à l'intérieur d'une automobile ou à un meuble. The invention relates to a method of manufacturing trim pads for various uses, such as, for example, seat cushions or decorative trim applied to the interior of an automobile or to a piece of furniture.

Les figures 1 à 5 montrent des housses de garniture selon l'art antérieur. Plus particulièrement, la figure 1 montre, en coupe, un coussin de siège comme comprenant une couche de surface 1, un capitonnage en polyuréthane mousse 2 et une couche d'appui 3 dans l'ordre nommé. Comme on peut le voir, la couche de surface 1 est soudée à la chaleur au capitonnage sousjacent 2 le long de lignes de soudure A, tandis que la couche d'appui 3 est soudée à la chaleur au capitonnage 2 qui la recouvre, le long de lignes de soudure 2a. Figures 1 to 5 show lining covers according to the prior art. More particularly, Figure 1 shows, in section, a seat cushion as comprising a surface layer 1, a polyurethane foam padding 2 and a support layer 3 in the order named. As can be seen, the surface layer 1 is heat welded to the underlying padding 2 along weld lines A, while the backing layer 3 is heat welded to the padding 2 which covers it along weld lines 2a.

Comme on peut le voir sur la figure 2, la couche de surface a des rainures ou gorges parallèles et obliques qui y sont formées en relief. Ces rainures parallèles et obliques a et b croisent les lignes de soudure 8 comme cela est indiqué, par exemple, en Aa et Ab. La figure 3 montre une partie de la couche de surface où deux rainures parallèles et obliques "a" et "b" croisent une seule ligne de soudure A.à échelle agrandie La figure 4 est une vue en coupe agrandie de la couche de surface faite suivant la ligne IV-iV de la figure 3. As can be seen in Figure 2, the surface layer has parallel and oblique grooves or grooves formed therein in relief. These parallel and oblique grooves a and b intersect the weld lines 8 as indicated, for example, in Aa and Ab. FIG. 3 shows a part of the surface layer where two parallel and oblique grooves "a" and "b "cross a single weld line A. on an enlarged scale FIG. 4 is an enlarged sectional view of the surface layer made along line IV-iV of FIG. 3.

Quelquefois, ces rainures peuvent être courbées. Le problème d'une housse de garniture selon l'art antérieur réside dans le fait que la soudure est~incomplète dans les zones de croisement Aa, Ab où les rainures parallèles et obliques croisent les lignes de soudure, pour les raisons qui suivent
(a) Lorsqu'un chauffage diélectrique ou autre dispositif de chauffage et de soudage est appliqué à une zone de croisement, l'espace vide empêche autant la production de chaleur qu'ailleurs dans la couche de surface 1. Plus particulièrement, dans le cas d'un chauffage diélectrique, la production de chaleur due au frottement intermoléculaire dans l'épaisseur du matériau diélectrique est insuffisante pour assurer un soudage complet en une zone de croisement.Même si l'espace vide dans la zone de croisement est comprimé pour réduire son volume, la densité apparente du matériau diélectrique reste encore à une faible valeur en comparaison à la partie solide de la couche de surface et en conséquence la quantité de chaleur produite dans la zone de croisement est inadéquate pour produire une soudure aussi bonne à la zone de croisement qu'ailleurs dans la couche de surface. Une méthode de chauffage et de soudage autre que le chauffage diélectrique ne permet pas non plus la formation d'une soudure complète en une zone de croisement. Plus particulièrement, on ne peut obtenir de soudure dans la zone de croisement ou bien l'on ne peut obtenir une soudure aussi forte et fiable qu'ailleurs dans la couche de surface.
Sometimes these grooves can be curved. The problem of a lining cover according to the prior art resides in the fact that the weld is ~ incomplete in the crossing zones Aa, Ab where the parallel and oblique grooves cross the weld lines, for the following reasons
(a) When a dielectric heating or other heating and welding device is applied to a crossing zone, the empty space prevents the production of heat as much as elsewhere in the surface layer 1. More particularly, in the case of dielectric heating, the production of heat due to intermolecular friction in the thickness of the dielectric material is insufficient to ensure complete welding in a crossing zone. Even if the empty space in the crossing zone is compressed to reduce its volume, the bulk density of the dielectric material still remains at a low value compared to the solid part of the surface layer and therefore the amount of heat produced in the crossing zone is inadequate to produce such a good weld in the crossing than elsewhere in the surface layer. A heating and welding method other than dielectric heating also does not allow the formation of a complete weld in a crossing zone. More particularly, one cannot obtain a weld in the crossing zone or else one cannot obtain a weld as strong and reliable as elsewhere in the surface layer.

(b) Dans le cas où les lignes parallèles et obliques croisent les lignes de soudure à un angle relativement petit, il en résulte des zones allongées de croisement, et en conséquence le défaut ci-dessus mentionné est accru. (b) In the case where the parallel and oblique lines cross the weld lines at a relatively small angle, this results in elongated crossing zones, and as a result the above-mentioned defect is increased.

(c) Un polyuréthane ordinaire, tel que celui utilisé dans un coussin en tissu cousu est moins motteux et a une meilleure élasticité ainsi que de meilleures autres caractéristiques physiques qu'un polyuréthane mousse à faible température de fusion ou un polyuréthane mousse imprégné d'un agent de soudage. Cependant, le polyuréthane ordinaire a une température de soudage relativement élevée et en conséquence une soudure parfaite aux zones de croisement est presqu'impossible. Par conséquent, un polyuréthane ordinaire, bien que souhaitable à utiliser, ne peut en réalité être utilisé. (c) An ordinary polyurethane, such as that used in a sewn fabric cushion, is less lumpy and has better elasticity and better physical properties than a low melting polyurethane foam or a foam polyurethane impregnated with a welding agent. However, ordinary polyurethane has a relatively high welding temperature and therefore perfect welding at the crossing areas is almost impossible. Therefore, ordinary polyurethane, although desirable to use, cannot in reality be used.

C'est la même chose avec l'article (e) ci-dessous. It's the same with the article (e) below.

(d) Le polypropylène et d'autres matériaux qui ont uneperte diélectrique relativement faible, ou qui peuvent produire des étincelles lorsqu'ils sont soumis à un champ électrique à haute fréquence, ne peuvent être utilisés comme matériau de la couche de surface; des soudures incomplètes peuvent résulter dans les zones de croisement Aa, Ab dans une couche de surface à raies, ou bien dans les zones en creux dans une couche de surface en relief E voir article (e) ci-dessousj , et l'aspect plaisant de la couche de surface peut être abîmé par les étincelles. Quelquefois, les étincelles apparaissent sur une couche de surface enduite d'un revêtement ignifuge et analogue bien que l'aspect des étincelles dépende de la sorte du matériau de revêtement utilisé. (d) Polypropylene and other materials which have a relatively low dielectric loss, or which can produce sparks when subjected to a high frequency electric field, cannot be used as the material of the surface layer; incomplete welds may result in the crossing areas Aa, Ab in a striped surface layer, or in the hollow areas in a raised surface layer E see article (e) belowj, and the pleasant appearance of the surface layer can be damaged by sparks. Sometimes sparks appear on a surface layer coated with a flame retardant coating and the like although the appearance of the sparks depends on the kind of coating material used.

(e) La figure 5 montre une couche de surface I en relief qui porte des zones en creux C. La soudure est presqutimpossible dans toute zone de croisement où une ligne de soudure croise un creux. Même si chaque zone de creux dans une couche de surface est très faible comme dans le cas d'espaces entre des points dans une étoffe tricotée ou en fil grossier, une soudure au rembourrage sous-jacent est presqu'impossible. On rencontre la même difficulté pour souder une couche de surface ayant un motif en relief à son dos. (e) FIG. 5 shows a surface layer I in relief which carries hollow zones C. Welding is almost impossible in any crossing zone where a weld line crosses a hollow. Even if each hollow area in a surface layer is very small as in the case of spaces between stitches in knitted fabric or coarse yarn, welding to the underlying padding is almost impossible. We encounter the same difficulty in welding a surface layer having an embossed pattern on its back.

Une étoffe ordinaire, une étoffe tricotée ou une étoffe non tissée a une surface irrégulière et par conséquent cette étoffe ne peut être fermement soudée au capitonnage sous-jacent. De même, on ne peut obtenir aucune soudure parfaite en un point de croisement où une ligne de soudure croise des couches qui se chevauchent. Ordinary fabric, knitted fabric or non-woven fabric has an irregular surface and therefore this fabric cannot be firmly welded to the underlying upholstery. Likewise, no perfect weld can be obtained at a crossing point where a weld line crosses overlapping layers.

(f) Dans le cas où l'on utilise une étoffe teinte comme couche de surface 1 et dans le cas où la teinture utilisée contient un métal, la partie teinte de l'étoffe quand elle est soumise au chauffage diélectrique, peut avoir son aspect gEté.  (f) In the case where a dyed fabric is used as surface layer 1 and in the case where the dye used contains a metal, the dyed part of the fabric when it is subjected to dielectric heating, may have its appearance gEté.

(g) Dans le cas ou le chauffage diélectrique ou toute autre technique conventionnelle de chauffage et de soudage ne peut produire une soudure ferme d'une couche de surface au rembourrage sous-jacent, la couche de surface et le rembourrage sous-jacent doivent être cousus ensemble. (g) In the event that dielectric heating or any other conventional heating and welding technique cannot produce a firm weld of a surface layer to the underlying padding, the surface layer and the underlying padding must be sewn together.

C'est un travail fastidieux. It is tedious work.

La présente invention a pour objet un procédé de soudage d'une couche de surface, d'un capitonnage et d'une couche d'appui, sans présenter les inconvénients décrits ci-dessus. The present invention relates to a method of welding a surface layer, a padding and a support layer, without having the drawbacks described above.

Pour atteindre cet objectif, dans un procédé de fabrication de housses de garniture selon l'invention, on utilise un soudage par ultrasons pour ainsi souder une couche de surface, un capitonnage et une couche d'appui quel que soit le matériau utilisé pour former ces trois couches ou quelle que soit la condition de surface de ces couches. To achieve this objective, in a method of manufacturing lining covers according to the invention, ultrasonic welding is used to thereby weld a surface layer, a padding and a support layer whatever the material used to form these three layers or whatever the surface condition of these layers.

L'invention sera mieux comprise, et d'autres buts, caractéristiques, détails et avantages de celle-ci apparaitront plus clairement au cours de la descriprion explicative qui va suivre faite en référence aux dessins schématiques annexés donnés uniquement à titre d'exemple illustrant plusieurs modes de réalisation de l'invention et dans lesquels
- la figure 1 est une vue en coupe schématique d'une housse de garniture;
- la figure 2 montre, en plan, un fragment de la housse de garniture;
- la figure 3 montre des zones de croisement Aa et Ab où une ligne de soudure "A" coupe deux gorges "a" et "b" à échelle agrandie;
- la figure 4 est une vue en coupe schématique d'une partie de la housse de garniture faite suivant la ligne IV-IV de la figure 3; ;
- la figure 5 montre, en plan, un fragment d'une housse de garniture en relief;
- la figure 6 est une vue en coupe schématique d'un corps en trois couches pris en sandwich entre des plaques opposées de support de cornes à souder par ultrasons;
- la figure 7 est une vue en coupe du corps à trois couches pris en sandwich entre des supports opposés; et
- la figure 8 est une vue en coupe schématique de l'une des cornes à souder par ultrasons, faite suivant la ligne VIII-VIII de la figure 7.
The invention will be better understood, and other objects, characteristics, details and advantages thereof will appear more clearly during the explanatory description which follows, made with reference to the appended schematic drawings given solely by way of example illustrating several embodiments of the invention and in which
- Figure 1 is a schematic sectional view of a trim cover;
- Figure 2 shows, in plan, a fragment of the trim cover;
- Figure 3 shows crossing areas Aa and Ab where a weld line "A" cuts two grooves "a" and "b" on an enlarged scale;
- Figure 4 is a schematic sectional view of a portion of the trim cover made along the line IV-IV of Figure 3; ;
- Figure 5 shows, in plan, a fragment of a trim cover in relief;
- Figure 6 is a schematic sectional view of a three-layer body sandwiched between opposite support plates of horns to be welded by ultrasound;
- Figure 7 is a sectional view of the three-layer body sandwiched between opposite supports; and
FIG. 8 is a schematic sectional view of one of the horns to be welded by ultrasound, taken along line VIII-VIII of FIG. 7.

Sur la figure 6, une couche de surface 1, un capitonnage 2 et une couche d'appui 3 sont disposés dans l'ordre nommé, et le corps à trois couches ainsi formé est pris en sandwich entre deux plaques opposées de support 4 et 5. Plus particulièrement, le support inférieur 5 est poussé contre la couche de surface 7 avec des protubérances associées Sa (largeur "t") appliquées le long des lignes de soudure n, qui s'étendent à travers des gorges "a", "b tl comme le montre la figure 3.Le support supérieur 4 est poussé contre la couche d'appui 3 avec les cornes associées 4A (largeur 11T'!) appliquées à la couche d'appui en relation face aux protubérances Sa. Comme on l'a précé demment mentionné, il apparat un espace vide à chaque zone de croisement où la ligne de soudure croise des gorges. In FIG. 6, a surface layer 1, a padding 2 and a support layer 3 are arranged in the named order, and the three-layer body thus formed is sandwiched between two opposite support plates 4 and 5 More particularly, the lower support 5 is pushed against the surface layer 7 with associated protuberances Sa (width "t") applied along the weld lines n, which extend through grooves "a", "b tl as shown in Figure 3. The upper support 4 is pushed against the support layer 3 with the associated horns 4A (width 11T '!) applied to the support layer in relation to the protrusions Sa. As is aforementioned, there is an empty space at each crossing area where the weld line crosses grooves.

Une force est appliquée à la plaque supérieure de support 4 pour comprimer le corps à trois couches , et ensuite une vibration ultrasonique est transmise par chaque corne de la plaque supérieure 4 à la contreprotubérance de la plaque inférieure 5 à travers la couche d'appui 3, le capitonnage 2 et la couche de surface I.  A force is applied to the upper support plate 4 to compress the body in three layers, and then an ultrasonic vibration is transmitted by each horn of the upper plate 4 to the protuberance of the lower plate 5 through the support layer 3 , the upholstery 2 and the surface layer I.

La couche de surface 1 est comprimée de façon que les espaces vides aux zones de croisement ka, Ab se réduisent de volume et l'onde ultrasonique traverse ces espaces vides diminués. Alors, de la chaleur est produite en particulier autour des zones de la couche d'appui 3 juste en dessous des cornes à souder par ultrasons 4A (largeur 'Te') et autour des zones de la couche de surface 1 juste au-dessus des protubérances (largeur 't3 et par suite, la couche de surface I se trouve soudée au capitonnage 2 qui la recouvre le long des lignes de soudure comme indiqué en 2a sur la figure 1.Comme on peut le voir, la corne à souder par ultrasons a une largeur PPT relativement importante en comparaison à la largeur 19t de la protubérance opposée et par conséquent l'onde ultrasonique de la corne converge vers la contre-projection, pour ainsi chauffer efficacement et souder la couche de surface 1 au capitonnage la recouvrant 2 le long de chaque ligne de soudure. De même, la couche d'appui 3 est chauffée et soudée au capitonnage sous-jacent dans les zones choisies de la couche d'appui juste en dessous des cornes à souder par ultrasons.The surface layer 1 is compressed so that the empty spaces at the crossing zones ka, Ab are reduced in volume and the ultrasonic wave passes through these reduced empty spaces. Then, heat is produced in particular around the areas of the support layer 3 just below the horns to be welded by ultrasound 4A (width 'Te') and around the areas of the surface layer 1 just above the protrusions (width 't3 and therefore the surface layer I is welded to the padding 2 which covers it along the weld lines as shown in 2a in Figure 1. As can be seen, the horn to be welded by ultrasound has a relatively large PPT width compared to the width 19t of the opposite protuberance and therefore the ultrasonic wave of the horn converges towards the counter-projection, thereby effectively heating and welding the surface layer 1 to the padding covering it 2 along each weld line Similarly, the support layer 3 is heated and welded to the underlying padding in the selected areas of the support layer just below the horns to be welded by ultrasound.

La méthode de chauffage diélectrique nécessite une feuille d'isolement. Usuellement, la méthode de chauffage ultrasonique ne nécessite pas de feuille d'isolement. il y a cependant certaines occasions où l'utilisation d'une feuille d'isolement est efficace pour améliorer la production de chaleur, bien que cela dépende de la sorte de matériau qui est utilisé . Alors, une feuille d'isolement est disposée entre-la plaque supe- rieure 4 et la couche d'appui 3 pour améliorer l'effet de soudure. Une feuille de tissu haute fréquence a été disposée sur la couche d'appui 3 et ensuite une feuille de tissu Empire a été disposée sur la feuille de tissu haute fréquence. Ces tissus ont été soumis à la chaleur produite par l'onde ultrasonique, pour ainsi accélérer le chauffage du corps à trois couches sous-jacent.Le tissu Empire, quand il est chauffé, peut s'amollir, mais le tissu haute fréquence ou un tissu enduit de silicone ne peut s'amollir à une température élevée, et il est facile à séparer d'un moule. Une feuille de fibre de verre enduite de résine de tétrafluorure d'éthylène, supérieure par sa résistance à la chaleur et facile à séparer d'un moule, peut être utilisée dans le même but. The dielectric heating method requires an insulation sheet. Usually, the ultrasonic heating method does not require an insulation sheet. there are, however, some occasions when the use of an insulation sheet is effective in improving heat production, although this depends on the kind of material that is used. Then, an insulation sheet is placed between the upper plate 4 and the support layer 3 to improve the weld effect. A sheet of high frequency fabric was placed on the backing layer 3 and then a sheet of Empire fabric was placed on the sheet of high frequency fabric. These fabrics have been subjected to the heat produced by the ultrasonic wave, thereby accelerating the heating of the underlying three-layer body. Empire fabric, when heated, may soften, but high frequency fabric or a silicone coated fabric cannot soften at a high temperature, and is easy to separate from a mold. A sheet of glass fiber coated with ethylene tetrafluoride resin, which is superior in heat resistance and easy to separate from a mold, can be used for the same purpose.

Dans un exemple de soudure à ultrasons en utilisant une feuille d'une fibre de verre enduite de résine de tétrafluorure d'éthylène, la machine à souder par ultrasons fonctionnait à 22 kHz.In one example of ultrasonic welding using a sheet of glass fiber coated with ethylene tetrafluoride resin, the ultrasonic welding machine operated at 22 kHz.

La figure 8 montre une vue en coupe schématique faite suivant la ligne Vili-Vili de la figure 7 et en regardant comme cela est indiqué par les flèches. Comme on peut le voir, la corne 4 se compose de sections 4A, 4B, 4C ... et ces sections peuvent fonctionner indépendamment. Figure 8 shows a schematic sectional view taken along the line Vili-Vili of Figure 7 and looking as indicated by the arrows. As can be seen, the horn 4 is made up of sections 4A, 4B, 4C ... and these sections can operate independently.

Cependant, dans le cas d'une ligne de soudure relativement courte, la corne ne doit pas être sectionnée. Lorsque 1ton entreprend en réalité un soudage par ultrasons, la relation de position de la corne, du corps à trois couches et des protubérances montrée sur les figures 6 et 7 peut être retournée.However, in the case of a relatively short weld line, the horn should not be cut. When 1ton actually undertakes ultrasonic welding, the positional relationship of the horn, the three-layer body and the protrusions shown in Figures 6 and 7 can be returned.

Comme on l'a déjà mentionné ci-dessus aux articles (b), (c), (d) et (e), les espaces vides dans les zones de croisement Aa, Ab empêchent des soudures complètes de la couche de surface et de la couche d'appui au capitonnage intermédiaire dans les zones de croisement lorsqu'un chauffage diélectrique ou tout autre chauffage conventionnel est appliqué.De même,comme on l'a déjà décrit ci-dessus aux articles (c), (d), (f) et (g), une soudure complète ne se produit pas dans un matériau dont la perte diélectrique reste à une faible valeur et lion ne peut obtenir une soudure satisfaisante dans un capitonnage de polyuréthane ordinaire ou un matériau pouvant provoquer des étincelles lorsqu'il est soumis à un champ électrique à haute fréquence Cependant, la soudure ultrasonique assure le soudage complet de tels matériaux ainsi que de matériaux à surface irrégulière ou en relief. As already mentioned above in articles (b), (c), (d) and (e), the voids in the crossing zones Aa, Ab prevent complete welds of the surface layer and of the intermediate upholstery support layer in the crossing zones when dielectric heating or any other conventional heating is applied. Likewise, as already described above in articles (c), (d), ( f) and (g), a complete weld does not occur in a material whose dielectric loss remains at a low value and lion cannot obtain a satisfactory weld in an ordinary polyurethane upholstery or a material which can cause sparks when is subjected to a high frequency electric field However, ultrasonic welding ensures the complete welding of such materials as well as materials with irregular or raised surface.

La technique de soudure par ultrasons ne nécessite pas de feuille d'isolement. i#ême si cette feuille d'isolement est utilisée dans la soudure par ultrasons, elle n'est pas consommée comme elle-le serait avec un chauffage diélectrique. On n'obtint que quelques produits défectueux en comparaison à d'autres méthodes de chauffage et de soudage, et le prix de production est relativement bas. The ultrasonic welding technique does not require an insulation sheet. Even if this insulation sheet is used in ultrasonic welding, it is not consumed as it would be with dielectric heating. Only a few defective products were obtained compared to other heating and welding methods, and the production price was relatively low.

La résistance de la soudure est accrue, et un aspect plaisant est garanti. The resistance of the weld is increased, and a pleasant appearance is guaranteed.

Le procédé selon l'invention ne doit pas être limité à des housses de garniture comprenant chacune une couche de surface, un capitonnage et une couche appui.  The method according to the invention should not be limited to lining covers each comprising a surface layer, a padding and a support layer.

Le procédé selon l'invention peut également s'appliquer à des housses de garniture comprenant chacune une couche de surface, un capitonnage et un panneau dur à la place de la couche d'appui. Alors, une telle housse de garniture peut être utilisée comme garniture d'ornement à appliquer à ltintérieur d'une portière d'automobile ou à un meuble dans des buts d'ornement ou de décoration. The method according to the invention can also be applied to lining covers each comprising a surface layer, padding and a hard panel in place of the support layer. Then, such a trim cover can be used as an ornamental trim to be applied inside an automobile door or to a piece of furniture for ornamental or decorative purposes.

Claims (3)

R E X E N D I C A T I O N SR E X E N D I C A T I O N S 1.- Procédé de fabrication d'une housse de garniture, caractérisé en ce qu'il consiste à 1.- Method of manufacturing a lining cover, characterized in that it consists of agencer des cornes à souder par ultrasons (4A) et des protubérances opposées (5a) de façon à être en conformité avec une forme finale donnée à laquelle doit correspondre ladite housse; arranging horns to be welded by ultrasound (4A) and opposite protuberances (5a) so as to be in conformity with a given final shape to which said cover must correspond; mettre en sandwich une couche de surface (1), un capitonnage (2) et une-couche d'appui (3) ou un panneau dur entre l'agencement des cornes à souder par ultrasons et l'agencement des protubérances opposées; sandwiching a surface layer (1), a padding (2) and a backing layer (3) or a hard panel between the arrangement of the horns to be welded by ultrasound and the arrangement of the opposite protuberances; comprimer le corps en trois couches entre ces agencements; et compress the body in three layers between these arrangements; and soumettre le corps en trois couches à une onde ultrasonique pour chauffer et souder le corps en trois couches dans ses zones choisies. subject the body in three layers to an ultrasonic wave to heat and weld the body in three layers in its selected areas. 2. Procédé selon la revendication 1, caractérisé en ce que l'étape précitée de préparer un agencement de cornes à souder par ultrasons consiste à agencer un certain nombre de sections de corne pour qu'elles soient en conformité avec une forme finale donnée à laquelle ladite housse doit correspondre. 2. Method according to claim 1, characterized in that the aforementioned step of preparing an arrangement of horns to be welded by ultrasound consists in arranging a certain number of horn sections so that they are in conformity with a given final shape to which said cover must match. 3. Housse de garniture, caractérisée en ce qu'elle comprend une structure à trois couches composée d'une couche de surface (î) avec des ondulations, d'un capitonnage (2) en mousse de polyuréthane ordinaire et d'un matériau d'appui (3), qui sont soudés ensemble en des parties données par la chaleur produite par une vibration à ultrasons, les ondulations de ladite couche de surface étant aplaties et soudées auxdites parties données par application de la pression d'un moyen formant corne à ultrasons (4A)  3. Upholstery cover, characterized in that it comprises a three-layer structure composed of a surface layer (î) with undulations, of a padding (2) made of ordinary polyurethane foam and of a material d 'support (3), which are welded together in parts given by the heat produced by an ultrasonic vibration, the undulations of said surface layer being flattened and welded to said given parts by application of the pressure of a horn means ultrasound (4A)
FR8410871A 1984-07-09 1984-07-09 METHOD FOR MANUFACTURING COVER COVERS WITH IRREGULAR SURFACE WITH AN ULTRASONIC WELDING MACHINE AND COVER OBTAINED Expired FR2567067B1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2676387A1 (en) * 1991-05-17 1992-11-20 Noirault Massol Lionel Method for producing thermoformed buttoning or quilting using ultrasound, and products obtained thereby

Citations (8)

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Publication number Priority date Publication date Assignee Title
US3075862A (en) * 1956-09-25 1963-01-29 Volkswagenwerk Ag Cover panels and method of manufacture
US3483073A (en) * 1965-07-24 1969-12-09 Dunlop Rubber Co Joined sheets of cross-linked polyurethane and method of joining
GB1252940A (en) * 1967-11-20 1971-11-10
DE2543047A1 (en) * 1975-09-26 1977-04-07 Ludwig Seidl Waterproof polyurethane-coated textile clothing - with watertight seams and resistance to chemical cleaning agents
GB1493477A (en) * 1974-10-10 1977-11-30 Eurane Europ Polyurethan Polyurethane foam composite
GB1497332A (en) * 1974-09-17 1978-01-05 Saito T Method and apparatus for rendering a foamed material weldable to a facing material to form cushioning material
US4237181A (en) * 1977-07-04 1980-12-02 Kurashiki Boseki Kabushiki Kaisha Method of manufacturing a flexible polyurethane foam product
GB2057959A (en) * 1979-07-24 1981-04-08 Fastbac Res Shaping soft permeable material

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3075862A (en) * 1956-09-25 1963-01-29 Volkswagenwerk Ag Cover panels and method of manufacture
US3483073A (en) * 1965-07-24 1969-12-09 Dunlop Rubber Co Joined sheets of cross-linked polyurethane and method of joining
GB1252940A (en) * 1967-11-20 1971-11-10
GB1497332A (en) * 1974-09-17 1978-01-05 Saito T Method and apparatus for rendering a foamed material weldable to a facing material to form cushioning material
GB1493477A (en) * 1974-10-10 1977-11-30 Eurane Europ Polyurethan Polyurethane foam composite
DE2543047A1 (en) * 1975-09-26 1977-04-07 Ludwig Seidl Waterproof polyurethane-coated textile clothing - with watertight seams and resistance to chemical cleaning agents
US4237181A (en) * 1977-07-04 1980-12-02 Kurashiki Boseki Kabushiki Kaisha Method of manufacturing a flexible polyurethane foam product
GB2057959A (en) * 1979-07-24 1981-04-08 Fastbac Res Shaping soft permeable material

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2676387A1 (en) * 1991-05-17 1992-11-20 Noirault Massol Lionel Method for producing thermoformed buttoning or quilting using ultrasound, and products obtained thereby

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