JP2018502997A - 成形可能な天然繊維の不織布ワイヤハーネストラフ、およびその製造方法 - Google Patents
成形可能な天然繊維の不織布ワイヤハーネストラフ、およびその製造方法 Download PDFInfo
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- JP2018502997A JP2018502997A JP2017515136A JP2017515136A JP2018502997A JP 2018502997 A JP2018502997 A JP 2018502997A JP 2017515136 A JP2017515136 A JP 2017515136A JP 2017515136 A JP2017515136 A JP 2017515136A JP 2018502997 A JP2018502997 A JP 2018502997A
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Abstract
Description
本特許出願は、2014年9月19日に出願された米国仮特許出願第62/052798号、および2015年9月21日に出願された米国実用出願連続番号第14/859632号の利益を主張し、ここにその全体が引用により援用される。
1.技術分野
本発明は、一般に、細長い部材を束ね、引き回し、保護するためのトラフおよび溝に関する。
乗物で使用されるワイヤハーネスは、通常、正確にワイヤハーネスを導いてその意図された場所で維持し、ワイヤハーネスを望ましくない露出から防ぐために、トラフまたは溝内で引き回されている必要がある。一般に知られているトラフは、押し出されて射出成形されたプラスチックからできているため、比較的剛性で柔軟性に欠けている。加えて、トラフは押し出されるため一定の断面形状を有しており、そのため、隣接領域間のサイズおよび形には対応できない。そのため、異なる構成を有する複数のトラフが、たった1つのワイヤハーネスの支持および案内のために用いられることがある。特に乗物産業の場合、他の構造的なおよび半構造的な部品も、押し出しおよび射出成形プロセスを通じてプラスチックなどの石油系材料で形成される。これらの最終製品は、均一で剛性の断面を有しているだけでなく、高い重量対強度比を有している。重量の問題に加えて、およびこの問題の原因として、通常、射出成形プロセスには次のような固有の制限も内在している。主に、溶融した材料を金型の空隙にくまなく流す射出成形プロセスでゲートが必要になるため、完成部品をどれぐらい細くできるかということである。さらに、完成品が異なる領域において比較的剛性のプラスチックまたは金属材料で形成されている場合、完成品の物理的特性をカスタマイズする能力にも制限がある。これらのプラスチックまたは金属材料は、用途によっては求められることのある、製品の異なる領域で求められる剛性、柔らかさ、および柔軟性の組み合わせを、最終製品に持たせる能力を抑制し得る。特に乗物産業、航空機産業、および航空宇宙産業などの産業界は、部品の重量を減らして強度を高めることに常に関心を向けているため、強度対重量比が高い構造材料を探している。これは、主により軽量の乗物を生産する必要性によって押し進められており、その結果、燃料効率および能力効率の増加につながっている。さらに、産業界は環境に優しいおよび/または再生利用可能な構造材料を探し続けているため、それらの材料の寿命が尽きることによって環境に悪影響が及ぶことはない。
図面をより詳細に参照すると、図1は、以降ではトラフ12(図1および図2)と呼ばれる、不織布層を備える壁14から本発明の一実施形態に従って製造された(図3〜図5に図示されている、さまざまな壁の現在好ましい実施の形態)、改良された貫通溝を備える乗物シート10を示している。トラフ12は、乗物において、パッセンジャー・コンパートメントフロアの真下で、天井材およびトランクライナーなど多岐にわたる用途において、ワイヤおよび制御システム(電子、水圧、および空気システムなど)など、1つ以上の細長い部材を束ね、引き回し、および保護するための少なくとも1つの通路または溝13を有して構成される。ここでは、細長い部材は配線ハーネス16として図示されているが、これは例示であり本発明を限定するものではなく、シートへの応用は、多くの可能な用途のうちの1つにすぎない。不織布材料からなる壁14は、従来の射出成形されたプラスチック製の貫通溝および金属製の溝と比べて、壁14の重量を減らして柔軟性を強化するために、熱可塑性繊維と共に天然繊維を含む。トラフ12は、自動車量だけでなく、ボート、列車、オフロード車、飛行機、宇宙船など異なるタイプの乗物の範囲で使用可能だが、これは例示であり、本発明を限定するものではない。
Claims (29)
- 不織布トラフであって、
接着された天然セルロース繊維と熱可塑性繊維との混合物からなる少なくとも1つの不織布壁を備え、前記少なくとも1つの不織布壁は縦軸に沿って延在して中間部と両端部と有する基部を有しており、前記中間部は、前記基部から上方向に延在して、前記縦軸に対して略横断方向に略U字形状の断面を前記中間部に持たせる側壁の対を有し、前記不織布トラフはさらに、
前記基部から横方向に外向きに延在する少なくとも1つのフランジを備え、前記少なくとも1つのフランジは乗物部材に取り付けられるように構成されている、不織布トラフ。 - 前記少なくとも1つのフランジに接着されたファスナをさらに含む、請求項1に記載の不織布トラフ。
- 前記少なくとも1つのフランジと前記基部との間で延在するリビングヒンジをさらに含む、請求項2に記載の不織布トラフ。
- 前記リビングヒンジは前記フランジおよび前記基部の厚さよりも小さい厚さを有する、請求項3に記載の不織布トラフ。
- 前記天然セルロース繊維はケナフ麻を含み、前記熱可塑性繊維はポリプロピレンまたはポリエチレンのうち少なくとも一方を含む、請求項1に記載の不織布トラフ。
- 前記少なくとも1つの不織布壁は厚さが異なる領域を有している、請求項1に記載の不織布トラフ。
- スクリム層をさらに含み、前記スクリム層は前記少なくとも1つの不織布壁の外面に接着され、少なくとも部分的に前記不織布壁に拡散して前記少なくとも1つの不織布壁および前記スクリム層の両方の材料を含む混合領域を形成する、請求項1に記載の不織布トラフ。
- 前記スクリム層は前記少なくとも1つの不織布壁の外面を形成する、請求項7に記載の不織布トラフ。
- 前記スクリム層は前記少なくとも1つの不織布壁の対の間に挟まれ、少なくとも部分的に前記不織布壁の各々に拡散して前記スクリム層の両側に混合領域の対を形成し、前記混合領域は別々の前記不織布壁および前記スクリム層からの材料を含む、請求項7に記載の不織布トラフ。
- 前記側壁の1つに取り付けられ、前記基部の上方で延在して前記側壁のうち反対側の側壁に当接するように構成されているカバーをさらに含む、請求項1に記載の不織布トラフ。
- 前記カバーはリビングヒンジを介して前記1つの側壁に取り付けられている、請求項10に記載の不織布トラフ。
- 前記カバーに固定されたファスナをさらに含む、請求項10に記載の不織布トラフ。
- 前記ファスナは、前記不織布壁との材料の一体片として形成された雄ファスナ部と、前記不織布壁との材料の一体片として形成された雌ファスナ部とを含む、請求項12に記載の不織布トラフ。
- 前記側壁から外方向に延在する縁をさらに含む、請求項1に記載の不織布トラフ。
- 前記少なくとも1つのフランジのうち少なくとも1つは熱可塑性材料で構成されており、前記少なくとも1つの不織布壁の少なくとも1つに接着されている、請求項1に記載の不織布トラフ。
- 不織布トラフを製造する方法であって、
天然セルロース繊維と熱可塑性繊維とを混ぜて混合物を形成する工程と、
前記混合物から少なくとも1つの不織布ウェブを形成する工程と、
前記少なくとも1つの不織布ウェブを圧縮成形して縦軸に沿って延在する少なくとも1つの不織布壁を形成する工程であって、前記少なくとも1つの不織布壁は中間部と両端部とを有し、基部と、前記基部から上方向に延在して前記縦軸に対して略横断方向に略U字形状の断面を前記中間部に持たせる壁の対とを有している工程と、
前記基部から横方向に外側に向かって延在する少なくとも1つのフランジを形成し、前記少なくとも1つのフランジを乗物部材への取付用に構成する工程とを備える方法。 - 前記圧縮成形中に、ファスナを前記少なくとも1つの横方向に延在するフランジに接着する工程をさらに含む、請求項16に記載の方法。
- 前記少なくとも1つのフランジと前記基部との間で延在するリビングヒンジを形成する工程をさらに含む、請求項16に記載の方法。
- 前記フランジおよび前記基部の厚さよりも小さい厚さを有する前記リビングヒンジを形成する工程をさらに含む、請求項18に記載の方法。
- ケナフ麻を含む前記天然セルロース繊維と、ポリプロピレンまたはポリエチレンのうち少なくとも一方を含む前記熱可塑性繊維とを提供する工程をさらに備える、請求項16に記載の方法。
- 厚さが異なる領域を有している前記少なくとも1つの不織布壁を形成する工程をさらに含む、請求項16に記載の方法。
- スクリム層を前記少なくとも1つの不織布壁の外面に接着し、前記スクリム層を前記少なくとも1つの不織布壁に拡散して前記少なくとも1つの不織布壁および前記スクリム層の両方の材料を含む混合領域を形成する工程をさらに備える、請求項16に記載の方法。
- 前記少なくとも1つの不織布壁の対の間に前記スクリム層を挟み、前記スクリム層を前記不織布壁の各々に拡散して前記スクリム層の両側に混合領域の対を形成する工程をさらに含み、前記混合領域は前記不織布壁および前記スクリム層からの別々の材料を含む、請求項22に記載の方法。
- 前記側壁の1つに取り付けられるカバーを形成し、前記基部の上方で延在して前記側壁のうち反対側の側壁に当接するようにカバーを構成する工程をさらに備える、請求項16に記載の方法。
- 前記カバーと前記カバーが取り付けられる前記1つの側壁との間でリビングヒンジを形成する工程をさらに含む、請求項24に記載の方法。
- 前記カバーおよび前記カバーが当接する前記側壁のうち少なくとも一方との材料の一体片として形成された部分を少なくとも有するファスナを形成し、前記ファスナの前記部分を、前記カバーまたは前記カバーが当接する前記側壁のうちの他方に固定されるように構成する工程をさらに備える、請求項24に記載の方法。
- 前記カバーおよび前記カバーが当接する前記側壁のうちの一方と材料の一体片として形成された雄ファスナ部を有する前記ファスナを形成し、前記カバーおよび前記カバーが当接する前記側壁のうちの他方と材料の一体片として形成された雌ファスナ部を有する前記ファスナを形成する工程をさらに含む、請求項26に記載の方法。
- 前記側壁の少なくとも1つから外方向に延在する縁を形成する工程をさらに含む、請求項16に記載の方法。
- 前記圧縮成形中に、前記少なくとも1つのフランジのうち少なくとも1つを前記基部に接着する工程をさらに含む、請求項16に記載の方法。
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