GB2202435A

GB2202435A - Apparatus for manufacturing a seat

Info

Publication number: GB2202435A
Application number: GB08707164A
Authority: GB
Inventors: Hiroyuki Makino
Original assignee: Tachi S Co Ltd
Current assignee: Tachi S Co Ltd
Priority date: 1987-03-25
Filing date: 1987-03-25
Publication date: 1988-09-28
Anticipated expiration: 2007-03-25
Also published as: AU589504B2; GB2202435B; AU7007887A; DE3709656A1; FR2612908A1; GB8707164D0

Description

1 APPARATUS FOR MANUFACTURING A SEAT 2202435 The present invention relates

to an apparatus for manufacturing an automotive seat, and in particular to a mechanism for placing a cushion member to an upper die of a seat manufacturing apparatus in which a seat is assembled by bonding a top cover member to the surface of a cushion member which has been foamed by a mold into a shape of the outer configuration of the seat.

AS shown in Fig 1, in a conventional seat manufacturing apparatus, the bonding of a top cover member (a) to a foam cushion member (b) (e.g. made of urethane foam material) requires firstly the application of adhesive to the outer surface of the cushion member (b) foamed into an outer configuration of the seat or to the back surface of the top cover member (a) formed by sewing into a predetermined shape, and secondly treating those two members, so as to bond them together. Now, Fig 2 illustrates a finished seat in which the cushion member (b) with the top cover member (a) bonded thereto is mounted to a frame forming a part of the seat, and the ends of the top cover member (a) are secured to the f rame (c) by means of hog ring (d) or the like. In the Fig 2, a reference character (e) denotes a spring member extended in the frame (c) to support the cushion member (b).

In such kind of conventionaal apparatus, there are provided a pair of upper a nd lower dies so arranged that the upper die is adapted to mount the cushion member (b) thereon with such securing means as clamps and the lower die is adapted to place the top cover member (a) thereon. and, lowering and pressing of the upper die against the lower die causes the bonding of the top cover and cushion members together.

However, in the apparatus, a mechanical clamp means have been employed for securing the cushion member (b) to 2 f the upper die in order that the lateral walls of the cushion member (b) are retained between the clamps and by being so retained the cushion member (b) is kept secured on the upper die, and consequently the undermentioned 5 disadvantages are found:1. When it is desired to mechanically cause the clamps to hold the walls of the cushion member therebetween, there is need to equip a mechanism for opening and-closing the clamps relative to the cushion member, resulting in a greater complication of mechanical structure of the apparatus.

2. The securing of the cushion member to the upper die requires a number of assembling steps and workers, which deteriorates the operationability.

3. The pressure given by the clamps to the lateral walls of cushion member creates a deformation of the surfaces of the walls, which prevents a close contact between the cushion member and top cover member.

4. In the case where a small number of clamps are provided on the upper die, the cushion member is not secured positively to the die and dangles therefrom, with the result that the cushion member is displaced from its correct position relative to the top cover member.

It is a primary purpose of the present invention to provide an apparatus for manufacturing a seat which is simple in structure, permits an easy securing of a cushion member to an upper die, improve the operation for mounting the cushion member to the upper die, and avoids deformation of the cushion member. 30 According to the present invention there is provided apparatus for manufacturing an automotive seat by bonding a top cover member to a foam cushion member, said apparatus comprising: at least one lower die adapted for placing said top cover member thereon; 1 t 3 at least one upper die adapted for securing said cushion member on said upper die, said upper die being vertically movable relative to said lower die so as to press said cushion member against said top cover member; vacuum suction means for securely drawing and removing said cushion member to and from said upper die, said vacuum suction means being provided in said upper die.

Thus, in apparatus according to the present invention, there are provided vacuum suction means which effect vacuum suction of air so as to draw the cushion member and secure it to the upper die. in operation, while operating the vacuum suction means, the cushion member secured on the upper die is pressed against the top cover member placed on an oppositely disposed lower die, to thereby bond those two members together, and thereafter, by stopping the air discharge or suction of the vacuum suction means, the upper die is removed from the cushion member with the top cover member bonded thereto.

Accordingly, in the present invention, the upper die functions to act as a drawing-securing plate for drawing and fixedly securing the cushion member thereto.

In one aspect of the present inventionj there are plurality of upper dies and a cross-shaped turret on which the upper dies are fixed. The upper dies are fixed to the respective ends of the cross-shaped turret and the turret is rotatably provided in the apparatus of the present invention so that each of the upper dies may be selectively rotated. Further, the corresponding number of lower dies are mounted on carriages movable on a rail so that the lower dies may be selectively displaced. By being so constructed, a number of top cover and cushion members can be bonded together effectively to provide a number of seats at one time.

According to the present invention, there is further provided a method of manufacturing an automotive seat by i 4 k W5U5 a tU UM ititi U a f gal untion 1EME1 t A method comprising:

placing the top cover member on a lower die; securing the cushion member to an upper die which is vertically movable relative to said lower die so as to press said cushion member against said top cover member by vacuum suction means provided in said upper die.

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:- Fig 1 is a sectional view showing the state in which a top cover member is not bonded to c. ushion member; Fig 2 is a sectional view showing the state in which the top cover member is bonded to the cushion member, and those two members are secured to a frame; Fig 3 is a partially sectional view of an apparatus according to the present invention, showing the state in which an upper die is positioned a distance above a lower die before being lowered; Fig 4 is a partially sectional view of the apparatus in conjunction with the Fig 3, showing the state in which the upper die is lowered and pressed against the lower die for bonding a top cover member and a cushion member together; Fig 5 is an elevational perspective view of upper die; Fig 6 is a front view showing the state in which the cushion member is drawn and secured to the upper die; Fig 7 is a sectional view of the upper die; Fig 8 is a sectional view of an up per die which is different in structure from the abovementioned upper die; and Fig 9 is a sectional view showing a connecting portion of vacuum suction means which is connected with the upper die.

1 v Referring to Fig 3, there is illustrated the state in which a cushion member (b) is secured to an upper die, and a top cover member (a) is turned inside out and placed on a lower die (3).

In this figurei reference numerals (10) and (11) designate an upper frame and a ring-shaped (endless) base respectively. To the base (11), arranged are a pair of spaced-apart rails (lla)(lla) on which carriages (17) are mounted movably. The lower die (3) is fixedly mounted on each of the carriages (17).

The lower die (3) is so adapted that the top cover member is placed thereupon, and the surface of the die is formed in a shape corresponding to the surface shape of the cushion member (b). Further, the fashion in which the lower die (3) is mounted on the carriages (7) is such that there are four lower dies fixedly arranged on the respective four carriages in such a manner as to correspond to respective upper dies (21)(22)(23)(24) which will be described later. An elevating cylinder (12) is provided on the upper frame (10) such that the cylinder (12) is disposed right above the lower die (3).

A turret mounting member (13) is connected to a rod of the elevating cylinder (12) so that operating the cylinder (12) causes vertical movement of the turret mounting member (13).

Rotatably mounted on the turret mounting member (13) is a turret (14) in such a manner that the turret (14) may be rotated intermittently at 90 degrees about a shaft (15). The turret (14) is of a cross-shaped configuration and has four ends to which upper dies (21)j,(22)i(23) and (24) are respectively provided. A cylinder (18).is provided on the turret mounting member (13). By operating the cylinder (18), the turret (14) is caused to rotate in the direction of arrow, intermittently at 90 degrees, as mentioned above.

To specifically describe this mechanism, an arm (19) is 6 rotatably provided on the shaft (15), one end of the arm (11) being connected to a rod (18a) of the cylinder (18) and the other end thereof being removably connected with the turret (14), and thus, operation of the cyliner (18) causes the rod (18a) to retract, whereby the arm (19) is caused to rotate so as to rotate the turret (14) 90 degrees.

Each of the abovementioned upper dies (21),(22),(23) and (24) is so adapted that the cushion member (4) is secured thereupon, and each surface of the upper dies is formed in a shape corresponding to that of the bottom surface of the cushion member (b). Rotation of the turret (14) in the arrow directions causes downward movement of one of the upper dies (21) with the cushion member (b) secured thereon. Then, operation of the elevating cylinder (12) causes the upper die (21) to move down towards the lower die (3).

Vacuum suction means are provided on the upper dies (21),(22),(23) and (24), and are adapted to retain the cushion member (b) on each of the upper dies (21),(22),(23) and (24) upon operation.

In Fig 3, reference numeral (16) represents a foot switch, by which an onof electric switching operation is effected to actuate the aforementioned vacuum suction means.

Referring now to Fig 9, there is shown one embodiment of the vacuum suction means, which comprise a vacuum pump (not shown), a vacuum tank (not shown) and a vacuum tube (4) connected to those vacuum pump and tank. one free end of the vacuum tube (4) is connected with the arm (19) which has a protrudent tube (19a) extending therefrom in a direction toward the central portion of one of the upper dies (21),(22),(23) and (24). On the protrudent tube (19a), there is arranged a connecting member (5) in a manner slidable coaxially thereof. The connecting member 7 (5) is movable by operation of the foot switch (16) in the arrow direction as shown in the two-dot chain line. Thus, when operating the foot switch (16), the connecting member (5) is moved in such direction, and brought to connection with the connecting tube (7) provided on the side of the upper dies (21), (22),(23) and (24). When once again operating the foot switch (16), the connecting member (15) is moved in an opposite direction and removed out of the connecting tube (7). In such operation manner, when the connecting member (5) is brought to connection with the connecting tube (7), establishing a communication between the protrudent tube (19a) of the arm (19) and the connecting tube (7) o the side of the upper dies (21),(22),(23) and (24), then air suction is effected in one of those upper dies. and at the same time there is established a joined connection between the arm (19) and such one of the upper dies, whereupon a linear force given by the aforementioned cylinder (18) is transformed into a rotation force, which is in turn transmitted to the turret (14) for its rotation. on the other hand, when the connecting member (5) is removed out of the connecting tube (7), the air suction is ceased and the arm (19) is disconnected from the one of those upper dies.

Another arm same with the abovementioned arm (19) is provided on the opposite side of the illustrated turret mounting member (13), and also equipped with identical vacuum suction means to the abovementioned ones.

Such another arm is so arranged on the turret (14) that it is positioned at a point distant 90 degrees with respect to the illustrated arm (9). Thus, as shown in Fig 4, while one cushion member (b) on the upper die (21) is being subjected to a bonding process, air is sucked from the other upper die (24) on which the other. cushion member (bl) is placed, by means of another vacuum suction means provided on said another arm.

1 8 Fig 5 illustrates one embodiment of the upper die (21), in which the securing surface (21a) thereof, which comprise an engagement surface for the cushion member (b), is formed in an uneven shape corresponding to the bottom surface of the cushion member (b), and further the securing surface (21a) is formed with a plurality of suction holes (1).

Fig 6 shows the state in which the cushion member (b) is drawn and secured to the upper die (21).

In Fig 7,, one exemplary embodiment of the upper die (21) is illustrated, wherein a plurality of suction tubes (6) are respectively connected to the suction holes (1) and also all of the suction tubes (6) are collectively connected to the abovementioned connecting tube (7), to thereby communicate with a vacuum pump (not shown).

In Fig 8, there is represented another form of upper die, as referred in the numeral (25). The upper die (25) is of a closed box shape with a vacuum room (61) formed therein. TO the vacuum room (61), connected is a vacuum tube (V) in a fluid communication manner, the vacuum tube (V) being further in the same communication with the vacuum pump (not shown).

Now, the operation of the apparatus in the present invention will be described with reference to Figs 3 and 4.

At first, the top cover member (a) is placed on the lower die (3) and the cushion member (b) is drawn and secured to the upper die (21) corresponding to the lower die (3). In this state, it is observed that the connecting member (5) on the one end of the arm (19) is brought to connection with the connecting tube (7)-on the side of the upper die (21), and an air suction force is exerted through those connecting elements (5) and (7) to the securing surface (21a) of the upper die (21) so as to draw the cushion member (b).

During the above-described step, an adhesive is ^1 9 applied to either the surface of the cushion member (b) being secured on the upper die (21), or that of the top cover member (a) on the lower die (3).

Thereafter, when the foot switch (16a) is operated, the rod (18a) of the cylinder (1) is retracted, causing the arm (19) to rotate about the shaft (15),, and as the connecting member (5) is in connection with the connecting tube (7); in other words, one end of the arm (19) is, by virtue of the connecting member (5), in a joined connection with the upper die (21), the turret (14) is then caused to rotate 90 degrees in the arrow direction (see Fig 3). Accordingly. the cushion member (b) on the upper die (21) is positioned in an opposed relation. with the top cover member (a) on the lower die (3).

Next, the upper die (21) is lowered by operating the cylinder (12) so as to give a pressure to both top cover member (a) and cushion member (b), and as shown in Fig 4, those members are bonded together.

After the bonding, the foot switch (16) is operated again, and then the connecting member (5) is disconnected from the connecting tube (7), thut from the upper die (21). At that time, air suction force is not exerted on the upper die (21). The cushion member (b) is then released from the vacuum securing on the upper die (21), and by operating the cylinder (12), the upper die (21) is raised. And, the resultant seat so formed is removed out of the lower die (3) and mounted to the frame (c), whereby a complete automotive seat is obtained.

In succession, with the cylinder (18) in operation, the arm (19) is returned to the initial position, as in Fig 3, so that the following upper die (24) is rendered ready for the vacuum suction securing of another cushion member (b') thereto.

Alternatively, as mentioned above, in the case where another arm is provided on the opposite side of the arm (19) relative to the turret mounting member (13), such another cushion member (bl) may be brought to another upper die (24) for the vacuum suction securing purpose during the process wherein the cushion member (b) is being secured to 5 the upper die (21).

Continuous operations of the present apparatus in the above-described manner produce a number of seats.

The present invention is, therefore, endowed with the undermentioned effects:- (1) The conventional clamp operation mechanisms for opening and closing the clamps are no longer required and thus the structure of the apparatus is simplified.

(2) Since the cushion member is retained on the die by virtue of an air suction force being exerted to the cushion member through the suction holes of the die, there is no need to use any pressure retaining means to secure the cushion member to the die, and as such almost no deformation of the cushion member due to the pressure is eliminated, which allows a positive bonding of the top cover member to the cushion member and improves the quality of the resultant seat to a greater extent in comparison with the conventional ones.

(3) The cushion member is prevented from dangling from the die, thereby assuring a correct position of the cushion member relative to the top cover member. It is therefore possible to bond the cushion member to a predetermined point in the top cover member precisely.

(4) Mounting and demounting of the cushion member 10 to and from the die is based upon air suction and air release mechanisms. The operationability in such process is greatly improved as compared with the conventional seat manufacturing apparatuses.

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Claims

CLAIMS '.

1. Apparatus for manufacturing an automotive seat by bonding a top cover member to a foam cushion member, said apparatus comprising:

at least one lower die adapted for placing said top cover member thereon; at least one upper die adapted for securing said cushion member on said upper die, said upper die being vertically movable relative to said lower die so as to press said cushion member against said top cover member; vacuum suction means for securely drawing and removing said cushion member to and from said upper die, said vacuum suction means being provided in said upper die.

2. Apparatus according to Claim 1, wherein said vacuum suction means are so arranged that air suction or air discharge is ceased subsequent to such process wherein said cushion member is drawn and secured to said upper die by said vacuum suction means and then said upper die with said cushion member is lowered and pressed against said top cover member placed on said lower die, completing the bonding of both said cushion and top cover members.

3. Apparatus according to Claim 1 or Claim 2 in which there is provided a plurality of upper dies each fixed on a respective end of a turret rotatably mounted on a vertically movable turret mounting member.

4. Apparatus according to any of the preceding Claims, wherein said turret is rotated by means of an arm which forms rotationmeans and wherein said arm is connected with a tube of said vacuum suction means.

5. Apparatus according to any of the preceding Claims, wherein said upper die has a securing surface formed in a shape corresponding to a bottom surface of said cushion member and wherein in said securing surface, there are perforated a plurality of suction holes.

6. Apparatus according to any of the preceding v 12 Claims, wherein said lower die is provided on at least one carriage which is movably arranged on a rail.

7. A method of manufacturing an automotive seat by bonding a top cover member to a foam cushion member, the method comprising:

placing the top cover member on a lower die; securing the cushion member to an upper die which is vertically movable relative to said lower die so as to press said cushion member against said top cover member by 10 vacuum suction means provided in said upper die.

8. Apparatus according to Claim 1 and substantially as herein described.

9. Apparatus for manufacturing an automotive seat substantially as herein described with reference to Figs 3 15 to 9 of the accompanying drawings.

10. A method according to Claim 7 and substantially as herein described.

11. A method of manufacturing an automotive seat, the method being substantially as herein described with 20 reference to Figs 3 to 9 of accompanying drawings.

Published 19M at The Patent Office, State House, 68171 High Holbora, London WC1R 4TP. Further copies may be obtained from The Patent Office, Sales Brancli St Maxy Cray, Orpington, Kent BR5 3RD. Printed by Multiplex techniques ltd, St Mary Cray, Kent, Con. 1187.

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